Category Archives: News

Small Satellite Cantilevered Rotation Fixture Application

MIT / Lincoln Labs developed, built and prepared for launch the 113 kg, 1.5 meter long ORS-5 SensorSat Space Situational Awareness Small Satellite.  A Flotron CTL-36 Small Satellite Cantilevered Rotation Fixture, part of Flotron’s CTL series, provided the MIT/LL team with ergonomic access during Assembly, Integration and Test operations.  ORS-5 (Sensorsat) is a Low Earth Orbit satellite with optical imaging payload that will monitor potential threats to space assets in the geostationary (GEO) belt.  All of the satellite components (minus the optical imaging payload) were attained from commercial spaceflight hardware suppliers to keep cost down.  ORS-5 utilizes the GeOST (Geometry Optimized Space Telescope) concept, established at MIT Lincoln Labs.  GeOST allows a small detector in low earth orbit to achieve greater imaging sensitivity and discern between celestial objects and resident space objects by pointing the spacecraft’s imager at the GEO Belt at an angle perpendicular to its velocity vector while ensuring that the velocity vectors of both the imager and the space asset are aligned.

Flotron CTL-36 Load Capacity and Design Considerations:
The Flotron CTL-36 load capacity is 3,000 lbs considering a payload CG located at up to 30” out from the interface mounting plate.  Flotron considers a simultaneous dynamic loading condition of 0.5G horizontal (worst case direction) and 1.0G vertical for both stress and stability in addition to SFy = 3 and SFu =5.

Flotron CTL-36 Rotation:
The rotation axis is 36” above the floor and the swing radius is approximately 27.25”.  The gear ratio is 217:1 meaning that 217 turns on the input hand-wheel will result in one 360° rotation of the payload.  This system consists of a geared bearing that is secured to the vertical tower.  The Easy Crank torque of the gear system is approximately 7,200 in-lbs.   “Easy Crank” is a term defined by Flotron and specifies that the input load on the hand-crank is 12 lb or less for ergonomic operation.

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Flotron CTL-36 Interface:
The standard interface plate is 24”DIAM and has x20 Ø.531 thru holes on a 22” bolt circle.

Flotron CTL-36 Material, Finish and Lubricant: 
The frame is constructed from carbon steel material.  The frame and tow bar are powder coated gloss white and the gearbox is painted gloss white.  The steel interface plate is electro-less nickel plated.  The caster bodies are finished with satin e-nickel.  All of the fasteners/hardware are stainless steel, e-nickel plated or black oxide.  The caster swivel bearings are lubricated with Braycote 601EF.

Flotron CTL-36 Push Handle, Casters & Other Features:
A push handle is been integrated in the base frame and located at an ergonomic height for an operator to effectively maneuver the Flotron.  The casters have 6”dia phenolic wheels, tread lock brakes & bolt-on swivel locks that allow for safe and ergonomic transport.  A storage box has been integrated on the base frame to store customer tools, fasteners … etc.

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Ball Aerospace Delivers the JPSS-1 Weather Satellite to Launch Site

A Flotron Satellite Positioner transports the Ball Aerospace and Technologies Corp. (BATC) designed, manufactured and tested JPSS-1 NASA/NOAA next generation Weather Satellite to the launch site at Vandenberg AFB this week. The Flotron will upend the satellite vertically where it will be fueled and integrated with the launch vehicle. BATC will support launch operations and on-orbit checkout. JPSS-1 is currently scheduled to launch in November.

BOULDER, Colorado, September 5, 2017 — Ball Aerospace successfully delivered the Joint Polar Satellite System-1 (JPSS-1), NOAA’s next-generation polar orbiting weather satellite, to Vandenberg Air Force Base in California on Aug. 31, where it is scheduled to launch Nov. 10, 2017. This follows a successful pre-ship review with NASA at Ball’s Boulder, Colorado, manufacturing complex.

“The arrival of the spacecraft at Vandenberg is a tremendous milestone for the program and the culmination of excellent collaboration and hard work by the JPSS-1 team – NOAA, NASA, Ball, Harris, Raytheon and Northrop Grumman,” said Rob Strain, president, Ball Aerospace. “This advanced weather satellite will play a significant role in providing actionable environmental intelligence to decision makers in government and business, and to the general public.”

The JPSS series of polar-orbiting weather satellites will work as the foundation of NOAA’s operational environmental forecasting system for the next 20 years. The JPSS missions are funded by NOAA to provide global environmental data in low-Earth polar orbit. NASA is the acquisition agent for the flight systems, launch services and components of the ground segment.

JPSS data increases the timeliness and accuracy of numerical forecast models three to seven days in advance of severe weather events. These forecasts allow for early warnings and enable agency managers to make informed decisions to protect American lives and property.

The JPSS-1 satellite will host a suite of state-of-the-art instruments: Advanced Technology Microwave Sounder (ATMS – Northrop Grumman), Cross-track Infrared Sounder (CrIS – Harris), Visible Infrared Imaging Radiometer Suite (VIIRS – Raytheon), Ozone Mapping and Profiler Suite (OMPS – Ball), and Clouds and the Earth’s Radiant Energy System (CERES – Northrop Grumman).

Ball designed and built the JPSS-1 spacecraft, the Ozone Mapping and Profiler Suite-Nadir instrument (OMPS), integrated all five of the satellite’s instruments, and is performing satellite-level testing and launch support. JPSS-1 will launch aboard a United Launch Alliance Delta II rocket from Vandenberg Air Force Base.

Following launch, JPSS-1 will join the Ball-built NOAA/NASA Suomi NPP satellite which has served as NOAA’s primary operational satellite for global weather observations since May 2014. Together, the two satellites, each circling the Earth 14 times per day, will provide global observations for U.S. weather and environmental predictions.

Engineered Lift Can Reduce Injuries in the Workplace

engFor many workers, accessing machinery and hardware during their daily activities can literally put them in a tight spot.   There are several reasons to add Engineered Lift to your rotation device.

Reduction in Overuse injuries – When workers must access equipment at awkward angles and bend their bodies into tight spots just to perform daily duties, they are at greater risk for overuse injuries.  Allowing employees to work ergonomically can increase productivity and decrease worker’s compensation claims.  By adding Engineered Lift to your rotation device you will gain access and cut down on these costs.

Greater Access – You will gain greater access to specific parts of the equipment that you are working on, and allow improved ergonomics in the process.  With ease of access comes more freedom to create and be productive.

Better Vantage point – By enabling technicians the ability to view the entire surface of the equipment or machine, they will have a greater ability to diagnose and repair, run diagnostics and improve assembly.

Reduce risk of damage to high value hardware – As workers strain and struggle to access areas of hardware that are working on, there is a risk that they will inadvertently damage it.  With the ability to lift the hardware and gain access, this will reduce these risks.

Flotron offers 3 Types of Ergonomic lift-

Asynchronous – Independent end frames support the payload, each carriage can be independently lifted or lowered and the spherical bearings allow for angular misalignment.  Of course, this solution can be customized to allow for different length payloads or to accommodate a different height change range by modifying the rack lengths.  It can be bolted to the floor, roll on tracks or be modified to be mobile on casters.

Synchronized – If there is a concern that asynchronous lifting will induce undesired loads into sensitive hardware, synchronized engineered lift is the better option.  This allows the user to operate a single crank to raise and lower both carriages simultaneously and within a fine resolution of one another.  Flotron will work with the customer to engineer a solution that can accommodate the specific envelope, geometry and CG location of the payload as well as design custom interface hardware if required.

Long-Stroke Lift Jacks – Lift Jacks are the simplest vertical lift solution where the lift range is limited to about 13” and there multiple operators available to raise and lower simultaneously.  Applications can range from vertically integrating a payload to gaining access for testing.   

The Boeing 777X Is Innovating the Way We Travel and Is Creating American Jobs Along the Way.

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The success of the Boeing 777 has prompted Boeing to expand on this line with the addition of the 777X.  This line will include the 777-8X and 777-9X. 

In August Boeing announced the 777-9X – Capable of seating up to 400 passengers, the Boeing 777-9x will offer passengers extra room and more space for carry-ons, as well as 15% larger windows, new lighting and enhanced architecture.  It’s GE9x jet engines are both fuel efficient and incredibly powerful.  Fuel efficiency will also be improved with the extra-large wingspan.  The wingspan is so large that the wings will actually have hinges for taxiing.  When fully expanded they will span an incredible 235 feet.  Fuel Efficiency is further improved with lighter materials.  The use of carbon fiber composite in the body and wings, make this airliner as unencumbered as possible.   

BOEING 777-9X Specs

Engines: Two

Aisles: Two

Typical seating: 400 passengers

Cabin width: 5.97 meters (236 inches)

Wingspan (extended): 71.8 meters (235 feet, 5 inches)

Wingspan (on ground): 64.8 meters (212 feet, 8 inches)

Length: 76.7 meters (251 feet, 9 inches)

Range: 14,075 kilometers (8,746 miles)

Expected to begin service: 2020

List price: $400 million

Source: Boeing Co.

Boeing has already received hundreds of orders for the 777-9X, and production will begin early next year.  Wing and tail portions of the aircraft will be manufactured in St Louis, MO.  That alone is expected to generate around 700 new jobs in the area.