Rotating Electro Mechanical Microwave Sub-SystemsCobham Defense Systems

Radar and R.F. Microwave Products

Military Space air

traffic

control

coMMercial

cobham antenna Systems 596 lowell Street Methuen, Massachusetts 01844 USatel (978) 557-2400 fax (978) 557-2800 www.cobham.com kevlin.sales@cobham.com

This paper contains 50% recycled fibres and is bleached in a totally chlorine free process. The virgin fibre content of this paper is elemental chlorine free and comes from managed forests.

The most important thing we build is trust.

While every effort is made to ensure the accuracy of the information contained in this brochure, no responsibility can be accepted for any errors or omissions. All photography is copyright and is used with thanks to the respective owners.

Kevlin corporation doing business as cobham antenna Systems

Advanced Rotating Solutions That Meet Customers’ Complex Challenges in

Decades of Proven Leadership in RF Rotary Joints & Subassemblies

Kevlin corporation located in Methuen, Ma is doing business as cobham antenna Systems. With over 40 years experience in the industry, we are the world’s leading designer and manufacturer of standard and custom rf rotary joints and electro-mechanical rotating subsystems.

cobham antenna Systems has an active rotary joint design base that now exceeds 4,000 models and can integrate additional rotating products for a complete rotating subassembly. our products are used in a myriad of applications ranging from submarine periscopes and shipboard avionics to ground-based, vehicle-mounted, air traffic control, airborne and space-based systems. We are the prime supplier of rotary joints to the U.S. air traffic control (atc) market.cobham antenna Systems has a long heritage of designing and manufacturing complex products capable of meeting our customers’ most demanding mechanical and electrical specifications. We welcome the opportunity to serve you.

Cobham Antenna Systems Product Classes

rf rotary Joints Slip rings pedestals rotating Subassemblies Motors, Gears azimuth positioning Units

Airborne SystemsB-52, B-1B Bomber, f-14, f-15, f-16, f-18 fighters, apS-116 Submarine Hunter, GD-53 Multi-Mode radar, longbow Helicopter, “MoDar” Weather & Wind Shear, c-130 transport, MSSa, Joint Stars - Synthetic aperture radar, pac-3 Missile, apn-242, f-5 Upgrade, pershing Missile, eurofighter, V-6 Helicopter, HiSar/Global Hawk, aWacS Upgrade

Shipboard SystemsSpS-48e, MK - 92 fire control, MilStar, cort - fire control, Hr-76 Search & tracking, SpS - 67, tracKStar, ipD -taS, Submarine periscope, SpQ-9B, photonics – periscope

Air Traffic ControltDWr, aSDe, aSDe-3, MSSr, fpS-117 Upgrade, arSr-3/arSr-3 Upgrade, tracS/tracS Upgrade, aSr- 4, 5, 7, 8, convert aSr-8 to aSr - 9, aSr-9, S511, aSr-10, MoDe-S Beacon, MoDe-S arSr-1, MoDe-S arSr-2, arSr-3 Upgrade to MoDe-S, arSr-3 Upgrade – atcBi-6, MoDe-S fpS-20, long range Surveillance, Various international atc, fpS-130 / arSr-4, arSr-4 Upgrade (Slep)

Ground Based Radartradex, tpX-46 improved Hawk, MilStar terminal, WSc 6 Upgrade, tpS-63, ilaDDS, faar, atnaVicS, alcor, falcon, ar 320, HaDr, an fpS-117 peace Shield, fpS-117 Upgrade, tracS, MatcalS, fpS-110, 548, tpS-78SS, inDia -tracking, test Bed / Mit

Space Qualifiednumerous classified, X-Sar - european Space program, n.a.S.a. Space Shuttle, earth orbiting Satellite, Serio ii for europe, DiSpin antenna, oDin Satellite, Mars pathfinder, Hubble telescope, Mars exploration rover

Commercial Systemstrain-mounted, plane-mounted, cruise ship-mounted, and Vehicle-mounted for SUV (tV) and commercial Vehicles, Weather radar, Medical imaging

Military, Commercial, Air Traffic Control & Custom Applications

Rotary Joints

Single channel coaxial

Dual channel coaxial

Dual channel Dual axis

Dual channel Waveguide

3 channel

4 channel Waveguide

4 channel w/ Slip ring

5 channel w/ Slip ring and encoder

7 channel w/ Slip ring and encoder

11 channel w/ 114 circuit Slip ring

17 channel w/ Slip ring and encoders

32 channel w/ Slip ring

SATCOM, Telemetry, Test Ranges, Data Links, Radar, Communications, Medical, Commercial & Space

Rotary Joints and Slip Rings

cobham antenna Systems rotary joints and slip rings are passive rotating transmission lines designed to pass DC and RF signals between the stationary and rotating sections with minimal degradation. They are true electromechanical devices.

• Products as simple as 1 channel (1 inch long), or as complicated as 33 channels (16 feet long)

• Optional slip rings and encoders

Standard Designs

cobham antenna Systems product line contains standard rotary joint designs, available in a wide variety of coaxial and waveguide configurations

for diverse platform applications, including military and commercial SATCOM terminals, telemetry, test ranges and data links. Standard rotary joints are generally available with shorter lead times and lower cost than custom products.

• Standard products available for frequency ranges from DC-50 GHz

• Precision ball bearing designs employed in all standard cobham antenna Systems products for rotational stability and long life

• Precious metal contacts utilized in wideband coaxial designs for broad-band frequency performance and long life

Custom Designs

cobham antenna Systems is the world’s foremost developer and manufacturer of custom state-of-the-art rotary joint and rotary joint sub-system technology. cobham antenna Systems engineering expertise in custom designs saves our customers considerable effort and expense. our extensive and diverse custom design database will allow the selection and modification of mature designs with proven field history.

our extensive history, design and test capabilities provide the options needed when configuring complex rotating solutions. let us work with your engineers to specify the perfect solution.

• Custom designs overcome the challenge of mechanical constraints and stringent rf requirements

• Non-contacting designs available for improved specifications and high reliability

Standard & Custom Products, from Simple to Complex

Many of cobham antenna Systems rotary joint designs incorporate ancillary components to create integrated subas-semblies designed to suit unique customer needs.let us package the complete assembly: rotary joint, slip ring, optical joint, media joint, pedestal, azimuth positioning unit, gears, motor, and controller. add in the antenna and plumbing and we can give you the complete, tested quality unit for further system integration.

cobham antenna Systems is a complete subassembly supplier with the capability to leverage the resources of other cobham companies and partners to design complete antenna/pedestal/drive packages, in addition to producing rotary joint/slip ring/encoder assemblies.

• In-house manufacturing capability to supply build-to-print pedestals

• Integrated subassembly packages including additional rotating devices such as fiber optic and fluid rotating joints

• Integrated, bolt on or stand alone slip rings available to allow passage of ac/Dc and data signals (up to 100 MHz) in addition to the rf frequencies of the rotary joint

• Integrated encoders, resolvers, or inductosyns® available as part of a rotary joint or rotary joint/slip ring package to enable azimuth positioning

Fiber Optic Rotary Joint

Gearmotor with APG (encoder/resolver)

RF Rotary Joint

Typical Integrated Sub-System

Antenna Mount

Slip Ring

Fluid Rotary Joint

Design Integration & Flexibility

Integrated Subassemblies Complete Antenna/Pedestal Drives & Rotary Joint/Slip Ring/Encoder Packages

Waveguide Rotary Joint Channels

Slip Ring

Dual Optical Encoder

Coax Rotary Joint Channels

Inductosyn® is a registered trademark of Ruhle Companies, Inc.

cobham antenna Systems has the time-proven capability to provide rotary joints and subassemblies that exceed the exacting standards required for space applications. to ensure a high degree of confidence in the finished products, we thoroughly manage all required documentation, materials, testing and cleanliness.

• Proven track record supplying flight hardware on high profile space platforms

- High and low gain antennas on Mars pathfinder and Mars rovers

- all naSa Space Shuttles

- numerous military and commercial satellites

• ISO9001-2008 quality system to provide foundation for engineering and manufacturing support required to supply custom space hardware

• Class 100 clean benches in an enclosed controlled access area where critical subassemblies and components are assembled and tested

• Typical Cobham Antenna Systems space product documentation

- program Management

- Qualification test reports

- acceptance test reports

- progress reports

- end item Data packages

- project control

- preliminary Design reviews

- critical Design reviews

- final Design reviews

- product assurance plans

- Manufacturing in-process inspections

- Verification control Documents

- configuration control

- Design and Development plans

- top assembly Drawings

- parts and Materials lists

- Work Breakdown Structures

cobham antenna Systems offers a diverse range of economical solutions for mechanically steered antenna platforms used in commercial satellite, television and communication systems.

• Patented platform design solutions, integrating RF path, slip ring circuits, rotating and positioning mechanisms and antenna support structure in a highly reliable package

• Specialized designs available in single and dual channel configurations

• Frequencies covering DC-50 GHz range; most commonly l, S, and Ku Band

• Outstanding platform performance in any environment; land, sea or air

• High volume production capability; quantities exceeding 50,000 units delivered

Space Products Commercial Products

Space Flight-Qualified Technologies

Cost-Effective Commercial Antenna Platforms for video, internet, telecom, data and TV

Special project laminaire flow clean bench in a temperature controlled clean room environment

Thermal RF Testing Thermal Vacuum

Vibration Torque

Static Loads

cobham antenna Systems’ engineering department has extensive experience in rotary joint design and the largest rotary joint engineering staff in the world. our engineering department can provide any level of technical support a customer may require.

cobham Methuen is the industry’s leading specialist in complete refurbishment of rotary couplers.

Design Tools

cobham antenna Systems engineering Department is equipped with the latest computer aided Design (caD), computer aided Manufacturing (caM), computer aided engineering (cae), and 3D rf and mechanical design tools, as well as internally developed design programs.

• Cradle-to-grave documentation control

• Rapid generation of code to drive our turning and machining centers

• Ability to shorten new product lead times by eliminating prototypes and generating optimized designs

• SolidWorks 3D CAD software

• SolidWorks Simulation – Finite Element Analysis (FEA)

• Mastercam CAM software

• Computer Simulation Technologies (CST) CAE for complex rf modeling

Engineering

cobham antenna Systems has the most experienced and innovative rf rotary joint engineering staff in the world.

• Unmatched technical ability to perform any task involving design, manufacture and test of sophisticated rotary joints or other rotating components

• Key technical, manufacturing and management personnel on staff for over twenty-five years

• Many junior engineers and senior managers with strong track records in the electrical, mechanical and quality aspects of microwave and rotating technology.

Machining

cobham antenna Systems advanced machine shop turns and machines all high-precision parts, fixtures and tooling required to build our products, ensuring superior quality control and dependable on-time delivery.

• State-of-the-art numerically controlled machining centers

Your Full-Service Source for Repair, Refurbishment and Upgrade.

as the world leader in rotary joint manufacture and technology, cobham antenna Systems has the capability to overhaul & repair your rotary joints, enhancing radar system performance. our extensive design database reduces the design time, liability issues, and other problems normally associated with radar hardware modifications.

• Maintain, restore and upgrade all rotating components, whether manufactured by cobham antenna Systems or another supplier

• Depot repair and refurbishment facility for the FAA and many other government agencies and prime contractors

product life can be extended significantly with full refurbishment. in most cases, complete overhaul of a rotary coupler is recommended over a quick point of failure fix. experience has demonstrated that quick fixes tend to lead to premature unit failures. a complete overhaul can be performed in less time and at a fraction of the cost of a new unit. overhauled units are returned to the customer in a “like-new” condition with the same one year warranty offered on new products. By performing a complete overhaul the unit can be refurbished several times before the life cycle is complete and replacement is required.

Cobham Overhaul & Repair

all cobham Defense Systems companies offer you the industry’s most comprehensive repair, refurbishment and upgrade capabilities. Moreover, we provide this service for all classes of military and commercial-grade microwave products… regardless of manufacturer or country of origin.

Radar & R.F. Upgrade Capabilities

cobham has the expertise to support all of your requirements to upgrade your radar and r.f. microwave systems.

Engineering, Manufacturing & Test Capabilities Overhaul & Repair

Assembly Overhaul & Repair

Environmental Test

Electrical TestCoordinate MeasuringEngineering

• Extensive conventional turning and machining equipment

• Complementary precision model shop to support quick-turn-around engineering programs

Assembly

cobham antenna Systems modern 80,000 square foot design and production facility consolidates all assembly work in one location.

• World’s largest dedicated rotary joint assembly area

• Complete coaxial cable and connector manufacturing and assembly area

• Environmentally safe painting facility

Testing and Clean Room Facilities

cobham antenna Systems electrical test department is expertly staffed and fully equipped.

• State-of-the-art automatic network analyzers; frequency capabilities from Dc to 50 GHz

• Full array of high power transmitters, temperature chambers, and other electronic monitoring equipment

• Precision phase matching, Time Domain Reflectometer (t.D.r.), automated encoder testing and comprehensive slip ring testing

• Cobham Antenna Systems maintains class 100 clean benches in a controlled access clean room where critical subassemblies and components are assembled and tested

Quality Control

cobham antenna Systems stringent Quality assurance program monitors and supports all departments and facilities.

• In-process inspection stations

• ISO 9001-2008 and AS9100B certified Quality Management Systems