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 Venus 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 Mars 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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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 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
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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
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E P n r o v b i r e The End o
n W m o e r n k t s s h
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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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