S 6 th h o I n r t t

e C r o n u a r t i s o e n

a o l n

P

E l a x n t r e e t

High Temperature Mechanisms m High Temperature Mechanisms a r e y

E P n A Breakthrough Development r o v b i r e o

n W m o e r n k t s s h

T o p e , c

h A n Jerri Ji t l o a l n o t g a

Honeybee Robotics Spacecraft Mechanisms Corporation i , e

G s e

New York, NY o r g i a 0 6 / 2 2 1 0 - 2 0 2 8

Page 1 Overview S • Introduction 6 th h o I n r t t

e C

• High Temperature Mechanisms r o n u a r t i s o e

– High Temperature Switched Reluctance Motor n

a o l n

P

E l

– High Temperature Drill a x n t r e e t m – High Temperature Brushless DC Motor & Resolver a r e y

E P n r o v b • Summary & Conclusions i r e o

n W m o e r n k t s s h

T o p e , c

h A n t l o a l n o t g a i , e

G s e o r g i a 0 6 / 2 2 1 0 - 2 0 2 8

Page 2 Introduction

• The extreme high temperature /high pressure environments on S 6 th h o I

Venus are unique compare with other NASA Solar System n r t t

e C r o exploration mission, environment condition is 460C, 90 bar, 97% n u a r t i s CO2 at the surface, sulphuric acid clouds at 50 km o e n

a o l n

P • No exist off-the-shelf motors or known R&D prototype motors are E l a x n t r

capable of operating under Venus surface conditions for any e e t m a r e appreciable amount of time y

E P n r o v

• Two types of high temperature motor have been developed by b i r e o

n W

Honeybee Robotics: m o e r n k t s

– HT Switched Reluctance Motor s h

T o p e , • Completed Phase I & II study (2.5 years) c

h A n t l o a l n

• Final prototype was used to actuate a high temperature drill o t g a i , e

G – HT DC Brushless Motor and Resolver s e o r

• Completed 6 month study (Phase I) g i a • Next generation BLDC motor along with high temperate 0

sample acquisition scoop and high temperature joint are 6 / 2 2 1 0

under development in Phase II study - 2 0 2 8

Page 3 Switched Reluctance Motor

• The switched reluctance motor is a direct current, brushless electric S 6 th motor. h o I n r t t

e • It has salient poles on both the rotor and stator, but only the stator C r o n u carries windings. The rotor has no windings, magnets, or cage a r t i s o e n

winding. a o l n

P

• Both the rotor and the stator are built up from a stack of magnetic- E l a x n t

alloy, salient-pole laminations. r e e t m a r e

• The operating principle of SRMs is based on the tendency of a rotor y

E P n

pole pair to align with the energized stator pole pair. r o v b i r e o

n W m o e r n k t s s h

T o p e , c

h A n t l o a l n o t g Rotor a i , e

G s e

Stator o r g i a

Stator 0

Windings The four current phases 6 / 2 2 1

are listed as A, B, C and 0 - 2 0 2 D, with A-A’, etc., being a 8 pole pair.

Page 4 Switched Reluctance Motor

• The SRM design uses materials and components selected based on S 6 th the requirement to survive above 460°C, at earth atmosphere. h o I n r t t

e C r o n u a r t i s o e n

a o l n

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E l a x n t r e e t m a r e y

E P n r o v b i r e o

n W m o e r n k t s s h

T o p e , c

h A n t l o a l n o t g a i , e

G s e o r g i a 0 6 / 2 2 1 0 - 2 0 2 8

Page 5 Switched Reluctance Motor

• The prototype motor performance is mainly driven by the S 6 th requirements of future Venus drilling and sampling systems (weight- h o I n r t t

on-bit, auger rotation speed, etc.) and robotic arms (payload mass, e C r o reaction loads, positioning requirements, etc.) n u a r t i s o e

• It has been operated non-continuously for over 20 hours at Venus- n

a o l n like conditions (460°C temperature, mostly CO2 gas environment) P

E l a and is still functioning properly. x n t r e e t m a r e y

E P n r o v b i r e Speed/Torque Gradiant at 48V Torque/Current Gradiant48V o

n W m o

6.00 e

9000 r n k t s s

8000 h

5.00 T o p 7000 e , c

h A

) 4.00 s

) 6000 n t p M l o a m P A 5000 l n R ( o ( 3.00

t t g d n a e e

4000 i r , e e r

p u G s S

C 2.00 3000 e

2000 o r

1.00 g i

1000 a

0 0.00 0 5 10 15 20 25 30 0 5 10 15 20 25 30

Torque (Oz-In) 0

Torque (Oz-In) 6 / 2 2 1 0 - 2 0 2 8

Page 6 HT Switched Reluctance Motor

• Since the Maxon RE-25 motor has been used to actuate various S 6 th prototype drills system developed by Honeybee Robotics and a flight h o I n r t t

version of the Maxon RE-25 is the largest motor used on the e C r o Exploration Rover mission, some of the Maxon motor’s performance n u a r t i s o

characteristics provide a reasonable comparison for high e n

a o l

temperature motor. n

P

E l a • All test data are from motor test controlled by a custom controller x n t r e e t m

which we are still optimizing. a r e y

E P n Maxon SRM r o v b i r e RE-25 * Prototype o

n W

Characteristics Units m o e

Range Range r n k t s s

at 25°C at 460°C h

T o p e , c

Applied Voltage V 4.5 - 48 20 - 48 h A n t l o a l n Maximum Speed Rpm 5500 7500 o t g a i , e

G No-Load Speed rpm 4790 - 5500 7000-7500 s e o r No-Load Current mA 7 - 80 1000-1200 g i a Stall torque mNm 119 - 144 200 – 250 0 6 / 2 2 1 0

Motor Characteristics Comparison of Existing Maxon RE-25 to Current SRM Prototype - 2 0 2 *Maxon DC Motor, RE-25 mm,” 8 http://test.maxonmotor.com/docsx/Download/catalog_2008/Pdf/08_077_e.pdf

Page 7 High Temperature Drill

• The prototype high temperature drill S 6 th h

can operate with low thrust reaction o I n r t t

e in low gravity environment. C r o n u a r t i • Overall envelope is 6.8 inch x 4.3 s o e n

a inch x 18.8 in with 10 inches of drill o l n

P

E l

stroke. (system was designed to fit a x n t r e e

existing test chamber). t m a r e y

E • Two high temperature switched P n r o v b reluctance motors were integrated i r e o

n W

into the system to actuate the Z and m o e r n Auger axes. Both were driven by k t s s h

T the custom controller Honeybee has o p e , c

h developed using sensorless control A n t l o a l n algorithm. o t g a i , e

G • All components of the drill including s e o

gears, bearings and bushings were r g i selected based on the requirement a to survive above 460°C, at earth 0

atmosphere. 6 / 2 2 1 0 - 2 0 2 8

Page 8 High Temperature Drill S 6 th h o I n r t t

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T o p e , c

h A n t l o a l n o t g a i , e

G s e o r g i a 0 6 / 2 2 1 0 - 2 0 2 8

Page 9 High Temperature Drill

• The high temperature drill conducted three drilling tests at Venus-like S 6 th conditions (460°C temperature, mostly CO2 gas environment) h o I n r t t

successfully drilled into chalk to 6 inches deep in each test. e C r o n u • Typical test data show that the drill’s average Z-axis rate, in chalk, is a r t i s o e

about 0.3 in/min (6 inches in about 20 minutes); average drilling n

a o l n current is about 1.5 amps at 400 rpm. P

E l a x n • The extreme temperature drill remains functional after operating more t r e e t m than 20 hours at Venus-like conditions. a r e y

E P n r o v b i r e Drill Currrent Vs Position Drill Current in Amps o

n W

Drill Position in Inches m o e

10 r n k t s ) s h s 9 T h o c p e n I , c (

8 h A n n t o i l o t a i 7 l s n o o t g a P

i l , e

l 6

i G s r D e

/

5 o ) s r g p i m

4 a A (

t

n 3 e r r 0

u 2 6 C

/ l 2 l i 2 r 1 1 0 D - 2 0 2 0 8 0.00 5.00 10.00 15.00 20.00 Tmi e in M inuet s

Page 10 HT Brushless DC Motor & Resolver

• A brushless DC (BLDC) motor is configured as a permanent magnet S 6 th h

rotating past a set of current-carrying conductors. o I n r t t

e C

• A resolver looks very similar to a motor, that is, one end has terminal r o n u a r t i wires, and the other end has a mounting flange and a shaft. s o e n

a Internally there is a rotor and stator. A “signal” or reference winding o l n

P

E l

revolves inside a fixed stator. The output of the signal changes as a x n t r e e

the winding is moved (the rotor). This changing signal is directly t m a r e y

proportional to the angle which the rotor has moved through. E P n r o v b • The resolver, coupling to the motor, can provide motor shaft position. i r e o

n W

It can also be used to commutate the motor. m o e r n k t s s h

T o p e , c

h A n t l o a l n o t g a i , e

G s e o r g i a 0 6 / 2 2 1 0 - 2 0 2 8 BLDC Motor Resolver

Page 11 HT Brushless DC Motor & Resolver S BLDC Motor 6 th h o I n r t t

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G s e o r g i a 0 6 / 2 2 1 0 - 2 0 2 Motor shaft length was deliberately oversized 8 to allow coupling with an output shaft and the high temperature resolver. Page 12 HT Brushless DC Motor & Resolver

• The BLDC motor and resolver design also uses materials and S 6 th h o

components selected based on the requirement to survive I n r t t

e C

temperatures above 460°C, at earth atmosphere. r o n u a r t i s • The motor was tested at temperatures up to 460°C at speeds up to o e n

a o l 1000 rpm and under different load conditions from no-load to an n

P

E l a applied torque load of 80 mN-m. x n t r e e t m • The test on the resolver was performed at the same time as the a r e y

E BLDC motor by connecting it in tandem with the motor. The output P n r o v b i

from the resolver was compared with the COTS resolver attached to r e o

n W the motor for commutation. m o e r n k t s

• The first generation high temperature BLDC Motor and resolver s h

T o p demonstrated the feasibility of the design through verification that the e , c

h A n motor and resolver can operate at Venus-like condition for an t l o a l n o t extended period of time. g a i , e

G nd s

• The 2 generation BLDC motor and resolver are under development. e o r g

• To demonstrate immediate applicability to potential Venus missions, i the high temperature motor/resolver development will form the basis a

for development of a sample acquisition scoop and a robotic joint, 0 6 / 2

both of which will also be tested to TRL6. 2 1 0 - 2 0 2 8

Page 13 Summary & Conclusions

• The SR and BLDC motors are no longer expected to limit the life of S 6 th h

Venus surface operation. o I n r t t

e C

• Scalable high temperature motor, resolver and bearing developments r o n u a r t i allow for creation of long lasting sample acquisition and manipulation s o e n

a systems, booms, robot arms and even mobility systems that o l n

P

E l

operating outside of an environment-controlled landed platform on a x n t r e e

the surface of Venus. t m a r e y

E • The motor and resolver’s capability to survive for hours (and P n r o v b potentially longer) in Venus-like environment is a major benefit to i r e o

n W

future Venus science missions since it would allow time for m o e r n communication ground loops to optimize sample target selection and k t s s h

T allow for multiple samples to be acquired from the surface. o p e , c

h A n

• Aside from Venus exploration, other potential NASA and non-NASA t l o a l n o

applications for high temperature motors and mechanisms include t g a i , e

G actuation of fluid pumps, gimbals robotic joints and manipulation s e o

systems, as well as turbine, expendable launch vehicle and furnace r g i tending system components. a 0 6 / 2 2 1 0 - 2 0 2 8

Page 14 S 6 th h o I n r t t

e C r o n u a r t i s o e n

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E l a x n t r e e t m a r e y

E P n r o v b i r e The End o

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T o p e , c

h A n t l o a l n o t g a i , e

G s e o r g i a 0 6 / 2 2 1 0 - 2 0 2 8

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