Robber Bakker - Airborne

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Robber Bakker - Airborne

  1. 1. TC-SKAR Thermoplastic Composite – Square Kilometer Array Reflector R.Bakker – Airborne Technology Centre
  2. 2. Content • SKA Introduction • TC SKAR – Concept – Design – Analysis – Prototype – Conclusions
  3. 3. • Aus • afrika
  4. 4. SKA Project timeline
  5. 5. TC SKAR Radical new design for automated production of a thermoplastic reflector • >3000 reflectors in total • Rate of 2 per day in total • Sub assemblies possible as locations up to 3000 km apart • Low cost production
  6. 6. TC SKAR • Press forming • Material tests • Induction welding • Reflector tests & consultancy • Consortium lead • Design • Consolidation • Cost analysis
  7. 7. Design concept baseline • Single reflector skin • Automated fibre placement of UD- tape, press-forming into shape • Modular design • Standard skin sections and stiffeners • Induction welding of all parts into 1 reflector • Symmetric shape
  8. 8. Material choice • Thermoplastic carbon composite • Thermoplastic – Robust – Machinable – Joining by welding – Easy to form • Industrial grade – low cost • Carbon – High stiffness – Low CTE – Low weight
  9. 9. Baseline design Overview • Diameter of 15 [m] • Focal ratio of 0.42 [-] • Total mass appr. 1586 kg (excl. QP & feed) • 5 skin panels per pie section • Rib and ring components for integrated support structure
  10. 10. Baseline design Tangential stiffeners • Mid-ring: low, non-critical blade stiffener in the center • Center: Critical blade stiffener, reflector is mounted on this ring to the pedestal • Ring 1: non-critical blade stiffener • Outer ring: Semi-critical blade stiffener Radial stiffeners • Radial mid-ring: low, non-critical blade stiffener in the center • Quadrapod stiffeners section 1: Critical and relative heavy T-stiffener • Non-quadrapod stiffener section 1: semi- critical T-stiffener • Quadrapod stiffeners section 2: Critical and relative heavy T-stiffener • Non-quadrapod stiffener section 2: semi- critical blade-stiffener
  11. 11. Structural analysis rms results • Gravity 90 degree elevation: • Wind load: • Thermal load: • 90 degrees elevation + 12 [m/s] wind + low temperature: • Manufacturing: • Total: 0.44 [mm] 0.06 [mm] 0.04 [mm] 0.41 [mm] 0.50 [mm] 0.61 [mm]
  12. 12. Reflectivity • Reflectivity carbon composite insufficient • Addition of metallic mesh • Embedded in the composite resin • Contribution to noise insignificant compared to bare metal mesh
  13. 13. Welding • All joints can be welded • Induction welding • Automated process • No addition of material
  14. 14. Reflector prototype test Representative of the production process chain when manufacturing Westerbork panel • Testen van gehele paneel in bedrijf 2 meter 1,5meter
  15. 15. Demonstrator panels Westerbork
  16. 16. Westerbork • Press formed beam (untrimmed in photo’s)
  17. 17. Conclusions • Fully integrated composite design possible – Stiffness, CTE, reflectivity and other requirements • Automated processes can be utilized for series production – Skin, stiffeners, strips and other reinforcements • Rate of 1 per 2 days possible with current processes • Material durability further tested on- site

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