Automated Satellite Reflector Tuning via Photogrammetry

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Solution Overview

Problem

The manual, time-consuming, and error-prone process of tuning satellite antenna reflector dishes for precise shape accuracy is costly and inefficient, requiring extensive human intervention and taking approximately 10 to 15 days to complete.

Innovation Solution

An automated reflector tuning system using high precision photogrammetry and micro actuators, driven by an optimizing control loop, measures and adjusts the reflector surface to achieve specified accuracy, significantly reducing cycle time and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual tuning process is used, then tuning accuracy can be achieved, but production time and cost increase significantly

Engineering Contradiction:

Improvereflector shape accuracyVSAvoidproduction rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical tuning system with an automated system using motorized actuators and computer control. The manual touch labor is substituted by an automated feedback control system that uses measurement data to drive actuator adjustments, thereby increasing productivity while maintaining precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a feedback control system where the reflector surface is measured, the measurements are processed to determine required adjustments, and actuators are commanded to make those adjustments. This closed-loop feedback mechanism maintains tuning accuracy while automating the process to increase production rate.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If manual tuning process is used, then tuning can be performed, but cycle time and variability increase

Engineering Contradiction:

Improvetuning accuracyVSAvoidtuning cycle time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces manual measurement and adjustment operations with automated systems. The photogrammetry system automatically captures surface geometry, computer algorithms automatically process the data to determine adjustments, and motorized actuators automatically execute the adjustments, dramatically reducing cycle time while maintaining accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent enables continuous automated operation where measurement, processing, and adjustment occur in an integrated feedback loop without manual intervention between steps. This continuous automation eliminates the discontinuous nature of manual tuning operations, reducing both cycle time and variability.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If manual tuning process is used, then adjustments can be made, but human error and variability increase

Engineering Contradiction:

Improveshape conformityVSAvoidprocess consistency

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent replaces manual operations with automated measurement and control systems. The photogrammetry system provides objective digital measurements, computer algorithms consistently process data according to fixed criteria, and motorized actuators execute adjustments with precise repeatability, eliminating human error and improving process consistency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a self-regulating feedback system where the measurement system automatically detects shape deviations and the control system automatically commands the appropriate corrections without human intervention. This self-service capability ensures consistent application of tuning criteria and eliminates variability introduced by human operators.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The automated system reduces the tuning cycle time by 90% and costs by 95%, while maintaining or improving product quality, completing the process in less than a day.

Implementation Method 1

automated reflector tuning for a radio frequency (RF) dish antenna may be accomplished using a high precision measurement system employing photogrammetry coupled with data analysis processing for measuring position of the reflector surface

Methodology Applied

Scientific EffectPhotogrammetry: Photogrammetry

Data Source

PatentUS9774093B2Automated reflector tuning systems and methdos

Publication Date: 2017.09.26 THE BOEING CO

AI summary

Methods, apparatus, and systems for automated reflector tuning include combining high precision automated photogrammetric measurement with high precision servo actuator positioning control of a reflector surface using custom optimizing control software to produce a novel, fully automated satellite reflector alignment tuning system. Precise adjustment to the shape of the reflecting surface of an antenna reflector (reflector tuning) can be essential for a satellite reflector antenna to meet electrical performance requirements, usually requiring a shape accurate to within 0.004 inches RMS. The automated reflector tuning may include determining a set of characterization coefficients by precisely measuring the response of the reflector shape to actuator movements, and using the characterization coefficients in a mathematical analysis to determine optimal actuator movements to achieve a required shape of the reflector surface.