Payload Interfaces

Turbopump Assembly Rotation Fixture

The 61700 is designed to support a complex geometry payload. The Rotational Holding Fixture has the footprint of an off-the-shelf Flotron Model XD747 with twice the load capacity. The load rating of this fixture was doubled by increasing end frame component cross sections and wall thicknesses in addition to incorporating Flotron’s 800 series hardware and coupling system. Flotron also designed and manufactured the precision tooling that supports the payload. A stainless steel base plate mounts between the fixture interfaces. This heat treated base plate was water-jet cut to match payload geometry and then machined. A set of precision machined brackets mount to the top face of the base plate and a set of precision machined tooling pins interface the payload through these brackets. Two of the bracket assemblies incorporate spherical bearings that are used to assist with angular alignment.

Manual Composite Operations Rotation Fixture

The 45000 is a custom rotational holding fixture that utilizes a gearbox similar in size to that used on our 900 series fixtures. The fixture is designed to support a curved wing skin in a large perimeter frame that was also designed and manufactured by Flotron. Precision mounting of the wing skin to the perimeter frame at the correct angle and true position was accomplished by utilizing a CMM during the welding process and during assembly by incorporating custom designed interface clamps. Precision adjustment capability allows the customer to perform multiple operations at different stations without changing fixtures.

Clean Room Rotation Fixture with CG Offset Cradle

This unit is designed to be similar to the 800 series while meeting custom specifications. It retains the low backlash, stair step resistant gearbox design of the 800 series as well as its stiff high load capacity frame. However, the frame is highly modified in order to meet the customer's requirements. It also includes a special mount for holding and counter balancing the customer's load. The unit is supplied with the clean room option that includes electroless nickel plating on all steel parts, stainless steel hardware, including the caster frames, and high gloss epoxy white paint on the gearbox housing.

Large Swing

Large Swing Radius with Mechanical Height Adjustment

In addition to offering the traditional axis of rotation with a large 100” swing radius, this Spacecraft Positioner has synchronized mechanical lifting capability with a single input hand crank. The risers can be raised and lowered with the payload integrated. The design intent of this tool is to position the spacecraft at an ergonomic height for the technicians during assembly, integration and test operations and then provide vertical lifting capability to raise the spacecraft payload and provide swing clearance for ergonomic rotation. This effectively provides technicians access to all sides of the spacecraft during processing. The load capacity of this mechanical ground support equipment is 4,000 lbs considering SFy = 3 and SFu = 5 in addition to a simultaneous dynamic loading condition of 0.5G horizontal (worst case direction) and 1.0G vertical for both stress and stability. The leveling jacks allow the operator to level the Rotation Fixture on uneven floor terrain. The lock rods are rigidly attached between the frame weldment and the rotation axis index plate to eliminate radial backlash.

Integration Fixtures

Precision Alignment

Cantilevered Precision Tip / Tilt / Rotate with Height Adjustment

Integrating boxes on the underside of a spacecraft without the use of overhead material handling equipment requires precision positioning and lifting capability of a Flotron Assembly Fixture. The lift mechanism, dual stage slide and tip/tilt/rotate stage on this Cantilevered Precision Alignment Fixture provide six degrees of freedom to accomplish this feat. Finishes and lubricants are compatible in an ISO 14644-1, (Class ISO 7) / FED STD 209E (Class 10,000) clean room spacecraft manufacturing environment.

Precision Alignment with Motorized Height Adjustment

The vertical axis of this RF Testing Fixture / Precision Alignment Fixture is powered by an electromechanical lift system with variable speed drive operating through a self- locking (for safety) ACME screw and a worm-gearbox. A spring-set back-up safety-brake is also used for redundancy to ensure no drift occurs from vibration or other outside loads. This Aerospace Tool can be lowered via its caster-jacks onto 3 adjustable tooling balls/pads. The precision tooling ball system can rotate the fixture and load around 3 perpendicular axes until the load is accurately aligned according to the customer supplied laser alignment system. At the rear of the fixture is an electronics rack for supporting the customer's electronics test equipment. The payload interface arm was designed considering the customers unique payload geometry without interfering with the test setup.

Modular Precision Alignment Base Fixture

This RF Test Cart / Precision Alignment Fixture base fixture is intended to be used with a customer provided payload interface. A large lift jack at the rear of the unit allows the technician to orient the customer’s payload interface so that it is perpendicular to the floor during payload integration. The caster jacks lower the Aerospace Tool so that a series of three precision alignment tooling features seat in their respective floor mounted receptacles. A precision slide is than translated at the back to pivot this Pointing Fixture (with payload integrated) and align for an RF testing application.

Precision Alignment, Rotation, Translation and Height Adjustment

This Precision Alignment Fixture / Cantilevered RF Test Fixture incorporates lifting and horizontal translation features to align a payload while it is mounted to a test plane. The rotation gearbox, lift jacks, and translation cross slide are non-back-driving. Tooling rods mounted to the base of the fixture locate the fixture between angle mounts that are bolted to the floor during docking. The mechanical inputs to the rotation, lift, and translation hardware all have locking features to eliminate undesired operator input.

Split Ring Rotation and Precision Alignment

Rotating a large cylindrical payload when interfaces are not available at its ends can in some cases be accomplished with split ring interface hardware. The top two halves of the rings are lifted off with a spreader bar, attached to the payload, and reattached to the bottom two ring halves. The spreader bar is removed, and the cylindrical payload is free to rotate. The Test Fixture is capable of rotating the payload 360 degrees with an angular velocity ranging from 1/10th RPM up to 1 RPM using a UL approved motor and control system via a pendant. A drive shaft drives the base of both rings and four idler wheels on the frames support ring rotation. A tow bar and motorized mover were provided to tow/transport the testing fixture. A leveling jack on the front of the fixture seats in a precision receptacle on the floor for repeatability and the motorized mover can pivot the fixture in an arc around this point.

Single Axis of Rotation for Precision Optical Alignment

This Spacecraft Optical Test Fixture has a single axis of rotation and a load rating of 600 lbs. Similar to the Dual Axis Rotate and Precision Alignment Fixture, this Aerospace Tool is designed to support assembly, integration and test operations in addition to optical alignment. Clearance lockout features, including lock rods, index locking screws, removable leveling feet (not shown), ensure that, when a 10 gram load is applied, the resulting angular deflection is less than 5 arc-seconds. Shock absorbing casters offer payload protection during transportation. Removable forklift tubes are constructed from aluminum material. Push bars provide an ergonomic interface for the technician to transport and navigate the Aerospace Tool (with payload integrated) through hallways and over varying terrains.

Multi Axis Rotate

Dual Axis Rotate and Precision Alignment

This Spacecraft Optical Test Fixture has two axes of rotation and a 2,000 lbs capacity. The rotational functionality of this two axis gimbal can be utilized for assembly, integration and test applications. Testing involves pointing an optical spaceflight hardware payload while maintaining optical stability. The optical stability requirement was verified by applying a three gram load to the most extreme corner of a payload test simulator and ensuring that the tool did not deflect more than 5 arc-seconds. Flotron was able to achieve this optical stability by eliminating the adjustment capability that is typically offered in our Off-The-Shelf product line (i.e. interface distance and height adjustment) and essentially fabricate a single weldment structure. Caster jacks lower this Pointing Fixture onto a set of leveling feet to provide a stable working plane. Lock rods and index locking features are rigidly attached between the frame weldment and the rotation axes to eliminate radial backlash and axial translation. Finishes and lubricants are compatible in an ISO 14644-1, (Class ISO 7) / FED STD 209E (Class 10,000) clean room spacecraft manufacturing environment.

Dual Axis Rotate with Hydraulic Height Adjustment

In addition to serving as a Cantilevered Rotation Fixture, this Custom Solution has lifting capability and a custom end effector that can tilt the payload to orient for testing. Stiffness and natural frequency requirements were considered in the design to prevent payload vibration during testing given the potential vibration loads imposed by the environment. The caster jacks lower the RF Test Cart / Precision Alignment Fixture so that a series of three precision alignment tooling features seat in their respective floor mounted receptacles. A precision slide is then translated at the back to pivot this now Pointing Fixture (with payload integrated) and align for an RF testing application. The footprint of this Aerospace Tool had to fit into both the elevator and the lab environment located on an upper floor. The large dual wheel casters keep the floor contact pressure to a minimum to meet the floor loading requirement.

SC2000-TR Spacecraft Tilt / Rotate Fixture

The SC2000-TR is designed to support small to mid-sized spacecraft in a cantilevered orientation. This spacecraft positioner tilts the payload from 0 – 90 degrees and rotates 360 degrees along the longitudinal axis. The SC2000-TR supports spacecraft assembly, integration, and testing operations. The tilt system utilizes redundant electro-mechanical actuators that are each capable of supporting the entire load. Rotation is accomplished through the use of a geared bearing and motorized non-back-driving gearbox assembly and both tilt and rotate functions utilize UL approved controls. Safety is considered first with multiple accessible safety stops, various operator presence sensing device options, limit switches, redundant braking, and audible / visual alerts, among others. Finishes and lubricants are compatible in an ISO 14644-1, (Class ISO 7) / FED STD 209E (Class 10,000) clean room spacecraft manufacturing environment.

Sensor Test Fixture

This motorized two axis rotation fixture with custom designed payload interface is designed to support an RF payload during assembly, integration and testing operations. We were able to utilize quite a few Off-The-Shelf components. In addition to providing mechanical rotate systems that are actuated using an input hand crank, Flotron offers Aerospace Tools with electro-mechanical rotate systems that are actuated with a pendant or control panel and have push button operation. Flotron incorporates UL approved controls and safety is considered first. There are multiple accessible safety stops, various operator presence sensing device options, limit switches, redundant braking, and audible / visual alerts among others.

Cantilevered

Cantilevered Satellite Integration Fixture

There are cases where spacecraft integration requires an access hole thru the payload mounting interface. This access may be required for instrument integration, propulsion integration, spacecraft wiring ... etc. To provide a scale of the size of the Flotron represented in the image below, the available payload swing diameter (as measured from the rotation centerline) is Ø110" and the ID of the slew ring is approximately Ø54". This cantilevered satellite integration fixture can support high moment and radial loads considering SFy = 3 and SFu = 5 in addition to a simultaneous (horizontal and vertical) dynamic loading condition. The resultant stability (with payload integrated) is 0.75G. The payload can be rotated 360° either by hand crank or by interfacing with a socket and electric hand drill. The gear drive is self-locking and non-back-driving with minimal backlash and the index plate on the input shaft can be physically pinned. The payload mounting interface dimensions and tolerances were specified by our customer. The finishes are compatible in a CLASS 10K clean room spacecraft manufacturing environment (no zinc, tin, or cadmium) and the lubricants were selected for compatibility. Covers were added over the geared slew ring and pinion gear to eliminate pinch points and to mitigate lubricant migration. The operator can maneuver the Rotation Fixture by the push bar or the tow bar. Forklift tube pockets have been incorporated at the rear to lift the Flotron (with the payload integrated) as well as at the side to handle the empty Flotron. The caster wheel material and geometry were specified to optimize rollability. Additional features include leg bumpers, relevant caution labels, angular indicator labels, and a storage container. Flotron fabricated a 2X proof load test simulator that represents 200% payload weight, 200% resultant moment and 100% torque. Flotron performed a proof load test with the payload simulator integrated when supported by the casters as wells as when lifted with a forklift. Weld inspection of critical welds (as defined by Flotron Engineering) was performed using an Eddy Current inspection method through the powder coat finish.

Customer Review:

The spacecraft mated to the Flotron fixture, all features were exercised to the delight of our customer and it is working excellent! Thank you again for the fine craftsmanship that your team delivered on.

High Moment Capacity Cantilevered Rotation

Flotron’s customers typically interface their payload at both ends. However, there are cases where the payload has only a single mounting interface and in these cases the payload needs to be supported in a cantilevered configuration. Flotron’s Cantilevered Rotation Fixtures have been utilized for a myriad of applications including spacecraft positioning, small satellite AI&T, radar system RF testing, among others. This Aerospace Tool is designed considering that the payload CG will be located at a significant distance from the mounting interface and that there will be a high resultant moment load. The geared bearing that Flotron has selected to accommodate these high moment loads can also accommodate higher radial loads and therefore the CG of the payload can be further off of the rotational centerline and still offer ergonomic rotation for the technician. Flotron also has the capability to design and manufacture custom end effectors and tooling interface hardware to adapt to complex payload geometry.

Motorized Height Adjustment with Working Platform

In the example below, a work station provides ergonomic access for technicians to offload a solar array wing from an overhead linear guide rail system, then pivot the work station (with wing attached) 90 degrees about a floor anchor and finally offload and deploy the solar array wing onto another overhead linear guide rail system. Finishes and lubricants are compatible in an ISO 14644-1, (Class ISO 7) / FED STD 209E (Class 10,000) clean room spacecraft manufacturing environment. In addition to providing mechanical lift systems that are actuated using an input hand crank, Flotron offers Aerospace Tools with electro-mechanical lift systems that are actuated with a pendant or control panel and have push button operation. Flotron incorporates UL approved controls and safety is considered first. There are multiple accessible safety stops, various operator presence sensing device options, limit switches, redundant braking, and audible / visual alerts among others.

Cantilevered, Motorized Rotation and Height Adjustment

The Aerospace Tool above has both electro-mechanical lift and rotation functionality. This up-ender is used to offload individual rigid solar array panels from Flotron Rotation Fixtures one at a time into a stack. The panel stack is fastened together, lifted for clearance, tilted 90 degrees and then offloaded onto an overhead linear guide rail system. Finishes and lubricants are compatible in an ISO 14644-1, (Class ISO 7) / FED STD 209E (Class 10,000) clean room spacecraft manufacturing environment. In addition to providing mechanical lift and rotation systems that are actuated using an input hand crank, Flotron offers Aerospace Tools with electro-mechanical lift systems that are actuated with a pendant or control panel and have push button operation. Flotron incorporates UL approved controls and safety is considered first. There are multiple accessible safety stops, various operator presence sensing device options, limit switches, redundant braking, and audible / visual alerts among others.

Cantilevered, Motorized Height Adjustment with Scissor Lift

In almost all cases, Flotron's Cantilevered Aerospace Tool Designs incorporate a tower structure that the payload cantilevers from. In the example below however, we utilized an electromechanical scissor lift to fulfill a vertical lifting requirement and then sized the scissor lift appropriately to accommodate an overhung cantilevered moment load. The scissor lift has a redundant belt driven lift mechanism and does not bleed down like a hydraulic system would. A tubular aluminum weldment / payload interface structure is fastened to a pair of precision linear guide bearing rails that in turn mount to the top of the scissor lift via an adapter plate. The tubular weldment (with payload cantilevered off of one end) can be translated horizontally with a ball screw and then locked into position. The caster jacks lower the RF Test Cart / Precision Alignment Fixture so that a series of three precision alignment tooling features seat in their respective floor mounted receptacles. A precision slide is then translated at the back to pivot this Pointing Fixture (with payload integrated) and align for an RF testing application. In addition to providing mechanical lift systems that are actuated using an input hand crank, Flotron offers Aerospace Tools with electro-mechanical lift systems that are actuated with a pendant or control panel and have push button operation. Flotron incorporates UL approved controls and safety is considered first. There are multiple accessible safety stops, various operator presence sensing device options, limit switches, redundant braking, and audible / visual alerts among others.

Thermal Cycle Compatible

This aluminum Cantilevered Fixture also functions as an RF Test Fixture, Thermal Test Fixture and Transportation Fixture. It is compatible in both RF testing and thermal environments. The entire structure is bolted together and Flotron had to consider both mean and fatigue stresses resulting from both mechanical and thermal loads. The base frame is counter-weighted to maintain 0.5G horizontally stability. At a later stage of processing, this Cantilevered Fixture is bolted to the top of a Flotron designed Alignment Fixture to position and orient a payload for RF testing.

Engineered Lift

Asynchronous Lift

A Flotron Engineered Manual Composite Layup Lift and Rotation fixture was implemented to support the upper and lower fuselage halves that were originally resting on the floor in this application. Operators were bending over and were literally on their hands and knees reaching to perform their daily process. This Flotron Custom Solution was designed to lift and rotate the long composite payload to minimize workplace injuries and potential damage to high value flight hardware, provide access through ergonomic rotation, and maximize production throughput. A low backlash gearbox provides the rotational functionality and two independent end frames support the payload and lift it with unsynchronized hand-crank rack and pinion lift jacks. The couplings allow for angular misalignment. One of the end frames of this turnover fixture is bolted to the floor and the opposing end frame rolls on tracks that are bolted to the floor, providing flexibility to accommodate varying payload lengths. Custom cradles support the trunnion shafts in their lowest position during the payload loading and unloading process on this Flotron Lift Fixture.

Synchronized Mechanical Lift

Flotron designed and implemented a mechanically synchronized lift system on this lift fixture. With a single input hand crank, an operator can ergonomically raise and lower a 2,000 lbs payload two feet. This 24” height change range is accomplished safely and without back-driving by incorporating redundant brakes in conjunction with ball screw lift jacks. Two carriage plates are guides vertically using precision linear guide bearing rails. In addition to lifting functionality, this aerospace tool is a rollover dolly that provides 360 degrees of ergonomic rotation. Flotron’s mechanically synchronized lift / rotate holding fixture is used to position various aircraft control surfaces at the appropriate height and orientation as the payloads travel through a series of automated drilling processes down a production line on air pallets.

Long-Stroke Leveling Jack Lift

Flotron’s vertical lifting capability has served multiple purposes for our customers ground support equipment needs. In addition to accommodating various operator heights or positioning payloads at critical heights to perform various processes, Flotron’s engineered lift systems are used for vertical integration applications. In this particular case, Flotron incorporated high capacity, long-stroke lift jacks at the four corners of the rotation fixture end frames to lift the fixture (plus 4,000 lbs payload) 15 inches vertically to attach the payload to an overhead platform. Additionally, this Aerospace Tool offers ergonomic rotation to the technician for assembly, integration and test applications. An air pallet system has been incorporated under each of the four lift jacks and transforms this tool into a transportation fixture to maneuver the fixture (with payload integrated) over sealed floor surfaces.