Posts by superdish66

  • Ghost Tracker 4.2 Project

    The Ultimate Azimuth Axis: The "DH Nativity" Meets Aerospace Zero-Backlash Tracking

    Let's do a fundamental update on the mechanics of the Azimuth axis. After two days of calculations, measurements, and in-depth study of the structure, we made a drastic but engineeringly perfect decision, contrary to what was described earlier: no deformation or distortion of the original system.

    We have definitively discarded the idea of using external lever arms or complex custom systems. Why? Because the original DH antenna design, conceived 30 or more years ago and carefully studied, already possessed a brilliant geometry. Tangential traction (the chain pulling on a constant-radius curved track) is the cleanest and most linear way to distribute forces on a 4.2-meter sail and the relative weight of the structure. The limitation of the DH at the time wasn't the idea, I believe, but the budget constraints on commercial motors and gearboxes.

    We simply took that perfect geometric "nativity" and elevated it to the aerospace mechanics standards of 2026. Here is how we structured the new kinematics to guarantee a constant 0.01° pointing:

    • The "Iron on Iron" Monoblock: The Delta ECM-B3H motor (1.3kW with a 24-bit absolute encoder) is directly coupled to a massive Apex AE155 planetary gearbox via a CNC-milled adapter flange. The 100:1 reduction ratio immensely multiplies the motor's 8.34 Nm, creating an immovable driving force (see dimensioned photos).
    • Farewell to the Old System: Let's analyze the attached photo showing the old transmission covered in grease. There you can see the old DC gearmotor (black cylinder at the bottom) anchored to a lightweight plate, with three commercial sprockets guiding a standard chain. That system had loose tolerances that generated the famous "play" at every direction reversal. This entire plate and these gears will literally be cut away. In their place, our CNC workshop will mill from solid a massive 20 mm thick steel bracket, designed to cancel out any bending.
    • The Central H7 Sprocket (Traction): We must forget the mechanical play visible in the old photo. The new motor sprocket (the central one at the bottom) will be made of top-of-the-line tempered steel. But the real magic will be done by the CNC lathe: the standard pre-hole will be bored to precisely accommodate the massive 40 mm smooth shaft of the Apex gearbox. By requiring an absolute geometric tolerance (H7) and milling a calibrated keyway, the coupling will become a monoblock. Zero radial slip between shaft and tooth.
    • Extreme Load Idler Sprockets (The Omega Path): As seen in the old photo, the two upper sprockets serve to press the chain downwards, forcing it to embrace the central sprocket and forming the Greek letter Omega (Ω). We will replicate this vital geometry, but with armored hardware. The new idlers will not be simple bolted wheels, but industrial sprockets equipped with highest-quality sealed ball bearings integrated into the hub. They will be the only ones capable of withstanding the extremely high radial loads generated by the new 1.3kW traction without yielding a single millimeter.
    • "Piano Wire" Traction: We will use about 5 meters of industrial roller chain strictly pre-stretched at the factory (to prevent future elongation). The chain will run on the smooth back of the original DH half-moon (which will not be milled) and will be anchored at both ends by massive stainless steel turnbuckles. By tightening the turnbuckles to the maximum, the preload will physically cancel out the physiological internal play (backlash) of the gearbox gears.
    • The Immovable Foundation (Clam-Shell): To discharge all this force to the ground without destroying the mount and without drilling into the original pole, we will anchor the base using a massive split collar made of C45 steel (bridge Clam-Shell). The system will integrate two opposing bolts (Push-Pull) for millimeter-precise micro-adjustment of the geographic South before the final vise-like tightening.

    By combining the precision of over a billion steps per sprocket revolution (thanks to the Delta-Apex coupling) and the total rigidity of the pre-stretched chain, we have mathematically locked in the precision at 0.01°. No jerks, no "slack" in the transmission. When the PLC points at the satellite, the structure will be rock solid.

    In summary: we proudly keep intact the entire design process, kinematic analysis, and original construction logic of the DH antenna. We haven't deformed or distorted a winning system; we have simply equipped it with the "muscles" and nanometric precision necessary to dominate today's ultra-high frequencies.

    If you have any technical curiosity about these components or the Omega architecture, feel free to write!

  • Ghost Tracker 4.2 Project

    The Heavy-Duty Electronics of the Master Control Panel

    Today I am sharing with you the photos of the heavy-duty electronic components that have finally arrived and will make up the Master control panel.

    The goal of this project is to replace the old magnetic pulse logic to achieve "Zero-Backlash" spatial tracking with a guaranteed positioning accuracy of 0.01°. Here is the industrial hardware that will make all of this possible:

    • The "Brain": Delta AX-308E Motion Controller (Photos 1 and 2) This is the main PLC (model AX-308EA0MA1P). We are abandoning the old positioners: this controller communicates via an ultra-high-speed EtherCAT network protocol. It will be the one translating the coordinates into microscopic fractions of a degree, interfacing with the 24-bit absolute encoders of the motors (we are talking about over 16 million positions read per single shaft revolution).
    • The "Muscles" of the Azimuth: Delta ASDA-B3A 1.5kW Servo Drive (Photos 5 and 6) The power module (ASD-B3A-1521-E) dedicated to the horizontal axis. Its task will be to tame the powerful 1.3kW Azimuth servomotor. It will manage accelerations and decelerations (S-Curve ramps) to fluidly sweep the Clarke Belt (Horizon-to-Horizon), discharging enormous force to the ground without generating "jerks" on the mechanics.
    • The "Muscles" of the Elevation: Delta ASDA-B3A 400W Servo Drive (Photos 7 and 8) The little brother (ASD-B3A-0421-E) dedicated to the declination axis. It will drive the 400W motor connected in "Direct Drive" (without reducers) to the new ISO 3 class ball screw.
    • Absolute Cleanliness: Schaffner EMC Filter (Photo 3) A massive 16A at 230V FN2070 mains filter. In a system that must lock onto the highly delicate Ka-Band and uses encoders with nanometric resolutions, having a power supply free from noise and electromagnetic interference is vital. It cleans the current before it enters the Servo Drives.
    • The Nervous System: 10-Meter Shielded Cables (Photo 4) The custom coils provided for the project. They include the Power cables, the Feedback cables (for encoder telemetry), and the Brake cables. They will travel from the Master panel directly to the military connectors of the motors located outside on the antenna.

    If you have any curiosity about the parameters or technical choices, feel free to ask.

  • Ghost Tracker 4.2 Project

    Summary of the Azimuth Axis Traction Group

    In the photos, you can see the two beasts side-by-side before the "mating" (mechanical coupling): the 1.3kW Delta ECM-B3H servomotor that generates the movement, and on the left, the Apex Dynamics AE155 planetary gearbox that multiplies its force. To do this with aerospace tolerances (zero backlash), a powerful motor simply wasn't enough. We needed a monolithic gearbox.

    Specifically: on the right, with the blue cap on the shaft, is our 1.3kW Delta ECM-B3H servomotor (featuring an integrated brake and an absolute encoder). On the left is the mechanical masterpiece: a massive Apex Dynamics two-stage inline planetary gearbox, model AE155. The key specification here is the reduction ratio: 100:1. This means the Delta motor makes 100 revolutions to turn the huge Apex output shaft just 1 single time. This disproportionately multiplies the motor's native 8.34 Nm torque, turning the axis into a true, unmovable, and surgically precise "tank".

    How are they mounted? It's not a simple "plug and play". To join a square servomotor to a circular gearbox while maintaining total torsional rigidity, Apex manufactured a specific adapter flange (code P0403401402).

    Here is what is added and how the coupling works:

    • The Adapter: The black bell mounted on the back of the Apex has been milled to perfectly match the 130x130mm square flange of the Delta motor.
    • The Shaft: The Delta motor features a 22 mm diameter shaft (Specified on the drawing as S=22). The Apex gearbox receives the shaft via a calibrated compression collar.
    • The Union: You remove the blue cap, insert the motor shaft into the Apex adapter, and tighten the M8x15 screws.

    The result is a rigid "iron-on-iron" monoblock. No belts, no pulleys, no slipping. When the Delta encoder tells the PLC it has moved by a thousandth of a degree, we are mathematically certain that the dish has made exactly that movement.

    The DH Mount Integration: Completing the Azimuth Axis

    Now that we have the motor-gearbox monoblock (Delta + Apex) ready and sealed, how will we transfer this monstrous force to the antenna mount without destroying everything or creating mechanical play?

    The CNC workshop will perform precision machining to anchor everything to the mount's central pin (the "Base Can"). Here is how we structured the fastening:

    • The "Clam-Shell" Collar (The Fixed Anchor): To secure the motor body to the base, the workshop will mill two half-shells from solid C45 steel that will clamp the Base Can like a vise. A strict directive for the workshop will be to never drill the through-cylinder of the original structure, so as not to weaken it.
    • The Cantilever Plate (Anti-Collision): Integrated into the C45 collar, a 15 mm thick plate will be made to act as a support for the monoblock. This plate will be deliberately offset laterally: a crucial workaround to prevent any collision between the motor body and the antenna during the 25° of travel planned for the DH mechanics' "Power Declination" option.
    • The Lever Arm (ARM-AMAG-50): This is the dynamic element that will transmit the motion. The Apex gearbox output shaft will engage into this arm, which will be milled from solid Anticorodal alloy. To maintain our "Zero Backlash" dogma (no mechanical play), the coupling hole for the shaft and the keyway will be lathe-machined with absolute geometric tolerances (ISO H7/j6).

    With this "iron-on-iron" interlocking, the Azimuth (AZ) axis will be definitively completed. The entire structure will be able to pan the dish for a 160° dry run excursion, discharging all wind tension onto the Apex gearbox and keeping the metrological precision of the Delta encoder entirely intact.

    The Final Result: 0.01° Absolute Precision

    To conclude this deep dive into the Azimuth axis, let's connect the dots to understand exactly why we are doing all this.

    By combining the extreme resolution of the Delta motor's absolute encoder, the force multiplication and zero backlash of the Apex gearbox (100:1 ratio), and the zero-tolerance coupling of the CNC-milled arm on the saddle, we will obtain a surgical kinematic chain.

    The mathematical and mechanical result of this combination will guarantee us a spatial positioning precision of 0.01 degrees (if not even lower).

    This is a fundamental and non-negotiable goal for the Ghost Tracker: when it comes to "tracking" and keeping a target centered using the extremely narrow lobe of ultra-high frequencies (like the future Ka-Band), a single millimeter of mechanical play would mean completely losing the alignment and zeroing the signal. With this "iron-on-iron" configuration, tracking will simply be absolute.

  • Ghost Tracker 4.2 Project

    Elevation Update: Custom ISO 3 Actuator Build and Arrival of the Delta 400W Servo!

    Work on the Ghost Tracker project (a motorized 4.2m solid DH dish for C/Ku/Ka band tracking) is proceeding at a fast pace, and today I want to share the mechanical and electronic heart of the elevation axis.

    On my DH Horizon-to-Horizon Polar mount, the elevation adjustment (Power Declination) needs to guarantee a vital range of 30-35 degrees. The 75 cm (750 mm) total length for the new axis is no accident: it was calculated down to the millimeter to exactly replicate the geometry and operational distances outlined in the original DH manual for this specific mount. However, the similarity with the original ends here.

    To move a 4.2-meter dish with the surgical precision required by higher frequencies (and under impressive wind loads), commercial linear actuators proved unsatisfactory: too much mechanical play (backlash), imprecise rolled screws, and undersized bearings. Therefore, I decided to have a custom, aerospace-grade telescopic linear actuator built.

    Today I completed the collection of the main components. Here is what's on the bench:

    Mechanical and Electronic Specs:

    • Ball Screw (Custom): This is not your usual commercial screw. It is a 32 mm diameter shaft machined from solid, 75 cm long. The real magic is the tolerance class: Ground ISO 3. This means the pitch error is infinitesimal and backlash is literally zero.
    • Coupling: KTR Rotex GS 24. I chose the 98 Shore-A red elastomer spider: rigid enough to transfer torque instantaneously with zero slip, yet perfect for dampening high-frequency micro-vibrations.

    • The Motor (Just Arrived!): Everything will be driven by a 400W Delta AC servo motor (ECM-B3M Model). It features an ultra-high-resolution absolute encoder, an integrated holding brake, and EtherCAT control. A precision monster .

      How the actuator will be built:

      Since a bare ground screw cannot be mounted outdoors, this marvel will go to the CNC machine shop in the coming days. It will be housed inside a solid steel telescopic sleeve, locked at the base by a Class C5 HIWIN FK25 flanged support (equipped with preloaded angular contact bearings). The ball nut will push the inner steel tube, exactly like the shaft of a massive shock absorber.

    The expected result? An actuator capable of absorbing tons of axial thrust, while guaranteeing a real mechanical positioning precision of 0.01 mm. No compromises.

    See you soon for the next updates...

  • Ghost Tracker 4.2 Project

    Project Update: Ghost Tracker 4.2 – Motion Control Arrival & Electrical Architecture Finalized!

    I am thrilled to share a major update on the Ghost Tracker 4.2 project. After weeks of meticulous engineering, load balancing, and EMC (Electromagnetic Compatibility) planning, we have officially locked in the electrical architecture.

    The most exciting news? Our massive motion control package from SIT Automation is scheduled to arrive next week (June 29th)! Starting next week, we will begin the physical assembly of both the indoor Master Panel and the pole-mounted Tactical Box. I will be updating this thread with high-res photos as we build, wire, and test these units.

    For now, let's dive deep into the schematics and the hardware that will bring this beast to life.

    1. The Motion Control Arsenal (Delta Electronics)

    To achieve the sub-arcminute tracking precision required for this build, we partnered with SIT Automation for a top-tier Delta Electronics EtherCAT ecosystem. Here is what is arriving next week:

    • The Brain: Delta AX-308EA0MA1P. This is an advanced EtherCAT motion controller capable of executing complex multi-axis trajectories with microsecond latency.
    • Azimuth Axis (Heavy Duty):
      • Drive: Delta ASD-B3A1521--E (1.5kW, 230V, EtherCAT, STO safety).
      • Motor: Delta ECM-B3H-FB1313SS1 (1.3kW, 8.34Nm torque, 1500/4000rpm). We opted for a high-torque motor equipped with an absolute encoder, mechanical brake, and ruggedized military-grade connectors to withstand outdoor elements.
      • Cabling: 10-meter dedicated Power, Feedback, and Brake cables.
    • Elevation Axis (Precision):
      • Drive: Delta ASD-B3A-0421-E (0.4kW, 230V, EtherCAT, STO safety).
      • Motor: Delta ECM-B3M-CB0604SB1 (0.4kW, 1.27Nm torque, 3000/6000rpm, absolute encoder, brake, bulk connectors).
      • Cabling: 10-meter Feedback and combined Power/Brake cables.
    • EMC Filtration: Schaffner FN2070-16-06. A heavy-duty 16A 230VAC network filter placed directly upstream of the drives to prevent high-frequency PWM switching noise from polluting our clean logic network.

    2. Power Distribution Architecture (Master Panel)

    The Master Panel is built inside a heavy-duty Schneider Electric NSYCRN86300P enclosure. We split the power distribution into two distinct branches: Branch C1 (Non-UPS Heavy Force) and Branch C2 (UPS-Protected Life Support).

    Here is the Mermaid schematic for the AC distribution:

    Component Breakdown & Specifications:

    • QG1 (Main RCBO): We are using a highly specialized 16A Type A/F RCBO with an automatic reclosing motor (re-arms at 10s/60s/300s). This prevents the station from going offline due to nuisance tripping during thunderstorms.
    • QF1 (Drive Protection): Upgraded to a 16A ElektroNova MCB to handle the aggressive inrush currents generated by the capacitors of the Delta drives during power-up.
    • KM1 & EDM Safety: We utilize a Finder 25A 24Vdc modular contactor with a dedicated lateral auxiliary block (Finder 022.35 1NO+1NC). The Normally Closed (NC) contact feeds the External Device Monitoring (EDM) loop back to our safety relays, confirming the physical disconnection of the drives in an emergency.

    3. Logic, Safety & EMC Management

    Electromagnetic compatibility is critical when mixing 1.5kW servos with delicate RF and network signals. We implemented a strict galvanic separation of grounds.

    EMC & Safety Specifics:

    • Dual Ground Bars: We use two independent Arnocanali multi-hole brass bars. One handles PE (Protective Earth) for the main grid and chassis safety. The other handles FE (Functional Earth / 0V) for delicate sensor logic. They meet at a single, removable star-point to prevent ground loops.
    • Shield Clamping: Motor power cables emit massive EMI. We strip the outer jacket and use Phoenix Contact SKS 14 spring clamps to bond the 360-degree braided shield directly to the galvanized backplate before they enter the drives.

    4. The Tactical Box (Outdoor Pole Hub)

    Mounted high on the mast just below the tracking mechanism, the Tactical Box (IP65 ABS enclosure) acts as the eyes and ears of the system, minimizing cable runs to the moving parts.

    It contains:

    • Mean Well HDR-15-5: 5V DIN rail power supply.
    • PUSR DR302 Gateway: Converts Modbus RTU/RS485 data from the mast sensors to TCP/IP.
    • Hikvision Pinhole Camera: For visual confirmation of the target alignment.
    • Green Laser Module: Used for nocturnal calibration and pointing verification.
    • Schneider XACA4813 Pendant: A heavy-duty, tethered control pendant with an integrated E-Stop for manual override during maintenance on the roof.

    Next Steps

    The hardware is en route. Next week, my trusted panel builders (Cablatori Innovation s.r.l.) and I will lock ourselves in the lab to begin cutting DIN rails, crimping wires, and configuring the EtherCAT loop.

    I will post a detailed photo-log of the assembly process. Let me know if you have any questions about the component choices or the schematics!

  • 51.5°E Belintersat 1

    Testing on this Sat TBS Universal Analyzer - TBS 6908

    All Tpx found (11204 H 2500 from 52°East neighbour)

    From Africa Beam in this night time 11090 H 30000, QPSK Modulation, is the only one lockable. In late afternoon signal is better from here.

    According to Lyngsat 11130 H 30000 DVB-S2 8PSK changed FEC from 5/6 to 3/5

    11170 H 30000 DVB-S2 8PSK 3/5 has been intercepted (No Lock). Could it be New Freq. Package from Africa Beam?

  • 52.5°E Al Yah 1

    Quote from superdish66

    11842 V 27500 DVB-S2 8PSK 2/3 - Lockable from here, on the limit in this time

    ...

    My evening tests from my place Both Polarizations - in H with TBS 6908, in V with TBS 6983 - with TBS Universal Analyzer

    Really hard Modulations and FECs in H. Later should be better, but surely not reachable ATM with my setup

  • TBS Universal & Signal Analyzer

    Same good reception with TBS 6983 6908 5927

  • TBS Universal & Signal Analyzer

    The Latency Question

    During your V-Box test, did you notice a delay between the moment you pressed the physical button to pulse the motor and the moment the SNR value actually updated on your screen?

    If so, how would you quantify this delay? Are we talking about a fraction of a second (e.g., 200-300 ms), or is it slightly longer?

    This specific estimation is going to be the most critical parameter (the "Settling Time" or "Sampling Rate") that I will need to code into the Delta AX-308 PLC's logic. If the PLC pushes the EtherCAT motors faster than the TBS card and your software can update the Modbus register, the system will overshoot the focal peak and start oscillating endlessly (pendolamento) without ever locking.

    Since you were the human feedback loop in that video, your estimation of that delay is golden data for my offline PLC simulation!

    Once again, outstanding work. I am counting down the days until June 29th when the Delta hardware arrives, and I can't wait to test this release!

    superdish66