GNC 2008

7
th
International ESA Conference on Guidance, Navigation & Control Systems
2-5 June 2008, Tralee, County Kerry, Ireland
REACTION WHEEL UNIT DESIGN UPDATE AND RE-QUALIFICATION
V. Yce
1
, P. van Put
2
.
1
Project Manager, Bradford Engineering BV, De Wijper 26, Heerle, The Netherlands.
2
Chief Technical Officer, Bradford Engineering BV, De Wijper 26, Heerle, The Netherlands.
v.yuce@bradford-space.com

ABSTRACT

In August 2006, Bradford Engineering (BE) acquired the Reaction Wheel Business from Stork Product Engineering
(SPE). The true origin of this technology finds itself in Astrium Ltd. (Mechanisms Product Group, Stevenage), which in
turn had transferred the Reaction Wheel Unit (RWU) technology successfully to SPE in June 2001.

Bradford Engineering has transferred and absorbed all necessary information and hardware (test hardware, tooling,
documents, know-how/knowledge and skills) to enable to continue this activity with the same quality and confidence as
Astrium Ltd. In order to demonstrate the successful transfer and to prove that BE is a qualified supplier, a RWU design
update and re-qualification program is currently in progress under GSTP4 funding. In the frame of this program firstly
an existing RWA has been refurbished by BE personnel, where after the design update and re-qualification plan has
been initiated to achieve a complete rebuild of a W18 or W45 RWA and a single channel Wheel Drive Electronics
(WDE) on Qualification Model (QM) level.

The RWU design update and re-qualification will be performed on the W18 or W45 type of Reaction Wheel Assembly
(RWA) with the digital WDE (MIL-1553B). This technology was delivered e.g. for the Rosetta, XMM and Integral
missions. The W18 and W45 type RWA offer superior performances in terms of momentum storage, torque and wheel
speed measurement and have excellent zero-crossing and micro vibration characteristics.

The RWA implements the latest technology in terms of bearing/lubrication system and heater function. The Rosetta,
XMM and Integral projects are well documented and well explored in terms of endurance tests (life tests). Through the
RWU update and re-qualification approach, maximum leverage of heritage is obtained and overall program risks are
minimized.

REACTION WHEEL UNIT TECHNOLOGY

The Reaction Wheel Unit (RWU) consists typically of four Reaction Wheel Assemblies (RWA) (see Fig. 1), and one 4-
channel Wheel Drive Electronics (WDE) Unit.

W
D
E

C
h
a
n
n
e
l

1
W
D
E

C
h
a
n
n
e
l

2
W
D
E

C
h
a
n
n
e
l

3
W
D
E

C
h
a
n
n
e
l

4

Fig. 1. Typical Reaction Wheel Unit configuration
GNC 2008
7
th
International ESA Conference on Guidance, Navigation & Control Systems
2-5 June 2008, Tralee, County Kerry, Ireland

The RWA provides the momentum storage and reaction torque capability and consists primarily of a rotating mass
supported on a bearing / lubrication system and is driven by an ironless, brushless DC electric motor. The RWA also
includes the motor commutation logic circuitry and phase switching electronics. These are located within the evacuated
housing of the RWA.

The WDE provides the electrical interface between the RWA and the other sections of the spacecraft. The major
function of the WDE is to produce the required motor drive currents in response to the command signals for reaction
torque magnitudes and polarity. These require the WDE to act as a current source while the RWA accelerates and as a
current sink while the RWA decelerates. In addition, the WDE provides wheel speed magnitude and direction data,
WDE temperature control and RWA motor current telemetry. The latest design of the WDE contains a digital MIL-
STD-1553B TM/TC I/F to the higher level system.

Reaction Wheel Assembly

The prime function of a Reaction Wheel Assembly (RWA) is to operate as a part of an Attitude and Orbit Control
System (AOCS) on a spacecraft. It may be used in two ways:

I As a Momentum Wheel - when the RWA imparts a momentum bias to the spacecraft, giving it stability
about one axis and also to counteract disturbance torques acting on the spacecraft.
II As a Reaction Wheel - when the RWA provides reaction torques (by accelerating the wheel) to re-orientate
the spacecraft. A momentum wheel may also provide reaction torque.



Fig. 2. Cross-section of a W45 type Reaction Wheel Assembly

The RWA is constructed as a modular assembly, whose individual parts may be assembled, measured and tested
independently. This means interchangeability of the sub-assemblies is possible prior to integration (if necessary) with a
minimum delay in the programme. The RWA is an integrated electromechanical and electronic unit. It comprises the
wheel and bearings, the electric motor, the commutation electronics, and the baseplate and housing.

Two main variants of the RWA exist depending on the requirement for momentum storage: W18 and W45. The W18
provides nominally 18 Nms momentum storage at 4000 RPM, whereas the W45 provides 40 Nms at 4000 RPM. The
W18 allows adapting the rotor mass to store up to 25 Nms of momentum (indicated as W18ES).
GNC 2008
7
th
International ESA Conference on Guidance, Navigation & Control Systems
2-5 June 2008, Tralee, County Kerry, Ireland

The wheel, motor and electronics are hermetically sealed, and the whole assembly evacuated to approximately 1 mbar.
This avoids contamination, corrosion during extended ground storage and rapid depressurization on launch. It also
allows windage effects to be ignored during ground testing.

The rotation of the wheel is effected by a brushless ironless DC motor, the rotor of which is incorporated into the wheel
rim. The rotor contains samarium-cobalt permanent magnets and backing rings, which efficiently contribute to the
rotary wheel inertia. The mass efficiency is further increased by the design of the stator, whose ironless glass fiber
construction makes it as light as possible.

The motor has inherently high efficiency due to its 4-phase design. High switching accuracy is achieved using
optoelectronic sensors activated by a wheel-mounted shutter. Adjustment of the phase switching point is achieved using
slots in the commutation block, which allow angular movement. A high-resolution speed signal is also obtained from a
second set of slots incorporated into the same shutter.

The wheel, a high inertia rim supported on a conical disc, is mounted on a central shaft using a pair of angular contact
ball bearings. Lubrication is achieved from 3 separate sources:

Loading of a carefully controlled quantity of free oil into the bearing during assembly of the bearings.
A custom bearing cage impregnated with oil.
A Nylasint reservoir impregnated with oil mounted between the 2 bearings.

The cage is impregnated with oil to ensure that it does not behave like a sponge and absorb the free oil that is added to
the bearings during their assembly. Oil migrates from the reservoir to the bearings. The reservoir is sleeved to ensure
that the only free surface is immediately adjacent to the bearing; the flow of oil is further enhanced by the presence of
an oil meniscus between the bearing and reservoir, created during the build, which allows the oil to migrate easily from
the reservoir to the bearings. A heater is provided to ensure that:

In an environment of 15 C the bearings are maintained above an acceptable operating temperature.
To allow oil to be forced to the exposed surface of the reservoir and encourage migration into the bearings.

The angular contact ball bearings are axially preloaded to ensure positive ball location, especially at high speeds. This
preload is applied using a composite stack of disc springs compressed by a set amount. The composite stack consists of
a low rate spring, set just below fully compressed, in series with 2 high rate springs in parallel. This configuration
allows accurate setting of the preload, with room to accommodate minor variations due to thermal effects, whilst
providing a change to the high rate springs during vibration to maximize the first natural frequency of the wheel rim.
This non-linear effect plus the inherent friction damping within the spring pack configuration and coulomb friction
between the shaft and bearing inner race (due to the oil film) help to minimize Q factors during vibration. The wheel
is protected against vibration in a rocking mode by a disc in line with the lower bearings. The triangular structure of
the cone and the disc gives the wheel inherent stiffness and also helps reduce the loads transmitted to the bearings.

The Motor Commutation Electronics are mounted within the sealed housing, and thus protected from contamination.
This configuration is also the most space efficient. The electronics are mounted on a printed circuit board, with the heat-
dissipating components on a separate aluminum hot plate. The surface of the baseplate supporting the electronics is
positioned as far from the rotating magnets of the rotor as possible; this minimizes eddy current effects.

Material selection plays a critical part in the design process. An aluminum alloy has been chosen for the majority of
structural parts. This material has the following advantages:

high strength
low density
long-term stability against creep
ease of machining
ease of anti-corrosion treatment
good heat conductivity
good electrical conductivity
adequate radiation shielding.

The shaft, bearing housing and major components in the preload loop are manufactured from Titanium alloy for high
strength (the disc springs are stainless steel) and low mass.
GNC 2008
7
th
International ESA Conference on Guidance, Navigation & Control Systems
2-5 June 2008, Tralee, County Kerry, Ireland
In the motor, the magnets are samarium cobalt, with mild steel backing rings. The stator consists of copper windings
mounted onto a glass fiber ring. Where applicable, all components have protective finishes (e.g. anodizing) to prevent
galvanic corrosion between dissimilar materials, and to increase thermal emmissivity of some components. The shaft is
chrome-plated to avoid fretting by the bearings.

The rotor is basically a shallow conical shape with the heavy magnets and backing rings concentrated at the periphery to
ensure that the required inertia for the RWAs is achieved for the minimum mass.

Typically static and dynamic balance requirements of better than 1.0 gcm and 10 gcm are achieved by adding balance
masses above and below the backing rings at the required angular position and is verified using a state-of-the-art
balancing machine.

Wheel Drive Electronics

The Wheel Drive Electronics (WDE) is typically a 4-channel unit (see Fig.3), which provides the interface between four
independent Reaction Wheel Assemblies and the spacecraft electrical subsystems. Each channel contains an Auxiliary
Power Supply (APS), which is isolated from the power bus, to provide secondary power to the internal WDE
electronics and also to the RWA Motor Commutation Electronics. All internal converters within a single WDE channel
are synchronized to an internal oscillator running at a nominal frequency of 130 kHz, or the sub harmonic 65 kHz.

The WDE accepts a digital torque command via the MIL-STD-1553B telecommand interface. This value is used to
drive the WDE Power Amplifier. The Power Amplifier circuit can deliver a full-scale current output of 2.25 A into an
RWA motor terminal voltage of 55 V. The Power Amplifier therefore also has the ability to absorb power from the
RWA and dissipate it as heat within the WDE baseplate.

Wheel speed, Overspeed-Trip status (OST), heater and direction status is available as digital telemetry on the MIL-
STD-1553B interface. Analogue telemetry including OST, RWA bearing and WDE heat sink temperatures is provided
via a channel TM connector for in-orbit use.

A separate SCOE/AIT connector is provided to enable monitoring of wheel current, wheel voltage, wheel speed, torque
demand polarity and wheel direction during ground based system level testing.

Fig.4 depicts the functional schematic of a WDE channel.


Fig.3. Layout of a four-channel WDE configuration

GNC 2008
7
th
International ESA Conference on Guidance, Navigation & Control Systems
2-5 June 2008, Tralee, County Kerry, Ireland

T
a
c
h
o
D
i
r
e
c
t
i
o
n
O
S
T

(
o
v
e
r
-
s
p
e
e
d

t
r
i
p
)
H
e
a
t
e
r

s
t
a
t
u
s

Fig.4. Functional schematic of a WDE channel

RWU Characteristics

Table 1 presents a summary of the characteristics of the RWU.

Table 1. RWU characteristics summary
W18 W18E W18ES W45
Momentum storage at 4000 RPM 18 Nms 22 Nms 25 Nms 40 Nms
Speed range max operational 4000 RPM
Speed range max qualified 6000 RPM
Max gross torque 0.248 Nm at max current (2.25 A)
Max torque loss at 4000 RPM
Typical torque loss after run-in
0.037 Nm
0.024 Nm
Min reaction torque at 4000 RPM > 0.21 Nm at max current (2.25 A)

RWA dimensions 295x123 mm 295x123 mm 295x123 mm 365x123 mm
RWA mass 4.95 kg/wheel 5.50 kg/wheel 5.85 kg/wheel 6.95 kg/wheel
WDE mass 2.05 kg/channel
Max power 169 W (Full Speed Full Torque)
29 W (Full Speed Zero Torque)
Proven in-orbit life and life-test > 13 years (SOHO)
GNC 2008
7
th
International ESA Conference on Guidance, Navigation & Control Systems
2-5 June 2008, Tralee, County Kerry, Ireland

Heritage

The RWU technology has heritage in the programmes depicted below.




RWU Technology Benefits

- High Performance / High Quality: The RWU design is primarily aimed for customers and applications requiring
maximized Performance and Quality.
- Torque level over complete speed range: Capable of delivering > 0.2 Nm from -4000 RPM to +4000 RPM.
- Momentum storage range: Momentum storage of 18 Nms (adaptable up to 25 Nms) and 40 Nms for W18
respectively W45 RWA.
- Torque rise time: Fixed and low torque realization time over entire speed range to 100 ms (within 5% of requested
torque).
- Digital interface: Latest build standard of the WDE contains a digital MIL-1553B TM/TC interface.
- Zero-crossing and low RPM performance: >540,000 zero-crossings (-125 RPM to +125 RPM) accumulated by
life-test. Separate life test has accumulated >158 million revolutions at 60 RPM.
- Life test and in-orbit heritage: In-orbit heritage present from ESA cornerstone programmes like SOHO, XMM,
Integral and Rosetta (ADM-Aeolus to be launched in 2008). BE RWAs have accumulated in excess of 0.75
million operational hours for these missions. The in-orbit heritage is supported by life-tests since 1996.
- Micro-vibration performance: Fully characterized and understood micro-vibration performance data available.
Ability to commit to a measured micro-vibration level.
- Evacuated RWA housing: Evacuated RWA housing allows testing under any on ground condition and avoids
degradation of RWA materials (e.g. corrosion) during extended on-ground storage.
- Remote Wheel Drive Electronics: Remote WDE allows for remote energy dumping leading to practically no
restrictions on braking cycles.
- Tacho signal: High accuracy wheel speed monitor (240 pulses/rev) available.
- Overall supplier flexibility: Customer insight and intervention into the design review and RWU MAIT processes
are naturally maximized by Bradford.





Radarsat, 1995
Earth Observation
SOHO, 1995
Solar observatory
Seastar, 1997
Remote sensing
XMM, 1999
X-ray observatory
Integral, 2002
Gamma-ray observatory
Rosetta, 2004
Comet Rendezvous
ADM-Aeolus, 2008
(expected)
Wind measuring
Olympus, 1989
Telecommunication Outstanding Flight Performance
(>0.75 million Flight Hours accumulated to date)
Skynet 4 (3 sats), 1998
Military Telecom
APEX, 1994
Harsh rad.testbed
GNC 2008
7
th
International ESA Conference on Guidance, Navigation & Control Systems
2-5 June 2008, Tralee, County Kerry, Ireland

RWU Life-test Status

Table 1 presents a summary of the wheels in life test. Firstly notice the SOHO FM5 wheel running at + and - 4000 RPM
continuously since 1996. Secondly, notice the zero-crossing model wheels of which ZXM#3 has already accumulated
over 540,000 zero-crossings since 2002.

The ZXM wheels have recently been taken out of life-test and have been functionally tested. The conclusion for both
wheels is that their performance is well within requirements confirming their survivability of very severe operational
conditions.

Table 2. Life-test summary
Rack Programme Wheel Type Rotor Mass
[kg]
Vibration Level
[gRms]
Remarks
1 Generic EM 70 Nms RWA 5.03 12.11 Lateral
18.90 Axial
Built Q4/96, Life Test commenced
24-Dec-1996 running continuously at 2500
RPM.
1 Generic QM 70 Nms RWA 5.03 12.19 Lateral
17.48 Axial
Built Q4/96, Life Test commenced
24-Dec-1996 running continuously at 6000
RPM.
2 ZXM#1 40 Nms RWA 4.46 10.63 Lateral
7.29 Axial
Between mid 1997 and Nov 2002 cycling
between 300 and 1000 RPM.
Since December 2002: 60 RPM continuous.
2 ZXM#3 40 Nms RWA 4.46 10.63 Lateral
7.29 Axial
Between mid 1997 and Nov 2002 cycling
between 300 and 1000 RPM.
Since May 2001:
5722 zero-crossings/ month @ 125 rpm
> 540000 cycles accumulated to date
(May 2008).
3 SOHO FM5 40 Nms RWA 4.62 7.71 Lateral
10.78 Axial
Life Test commenced 15-Aug-1996 running
on a 6 hour cycle between + and 4000
RPM.

Fig. 5 depicts the life-test racks and the SOHO FM5 RWA in life-test. As presented by table 2, the SOHO FM5 RWA
has been in life-test since 1996, confirming the excellent in-orbit performance of the SOHO RWAs in-orbit (see Fig.
6).




















Fig. 5. Life-test racks and SOHO FM5 in life-test


GNC 2008
7
th
International ESA Conference on Guidance, Navigation & Control Systems
2-5 June 2008, Tralee, County Kerry, Ireland




























Fig. 6. SOHO FM1 RWA in-orbit performance


TECHNOLOGY TRANSFER PROGRAMME

As a first step to master the RWU technology, Bradford Engineering initiated under national funding a Technology
Transfer Programme. The main tasks within this programme are presented below with the description of the major
activities within these tasks.

Task 1: Initiation of Knowledge and Capabilities Transfer
- Preparation and validation of Bradford MAIT facilities
- Physical transfer of RWU MAIT H/W to Bradford facilities
- Physical transfer of RWU paper copy documentation into the Bradford archive
- Review of all available project documentation
- Import of all digital project documentation into the Bradford documentation system
- Import and generation of electrical schematics according Bradford in-house standards
- Import and generation of mechanical design drawings according Bradford in-house standards
- Import of electrical, structural, thermal and performance models into Bradford project office

Task 2: Familiarization with Hardware
- RWU manual review
- Critical AIT procedures update to Bradford in-house standards
- Initiation of Bradford AIT personnel training
- Setup and restart of life-test wheels
- EGSE health-check and familiarization
- Functional performance test campaign of an existing RWA

The technology transfer programme was initiated in August 2006, and has been successfully finalized in April 2007.

Notice from the task descriptions above, that as a result of the technology transfer programme, Bradford gained the
necessary understanding of the technology to further upgrade it in the follow-up programme. Furthermore, training of
its AIT personnel was initiated including that the necessary MAIT facilities have been established.

SOHO RW1 friction torque versus speed
-0.02
-0.015
-0.01
-0.005
0
0.005
0.01
0.015
0.02
-3000 -2500 -2000 -1500 -1000 -500 0 500 1000 1500 2000 2500 3000
RPM
N
m
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
Oct-07
-
1
9
0
/
+
1
9
0

r
p
m

z
o
n
e
GNC 2008
7
th
International ESA Conference on Guidance, Navigation & Control Systems
2-5 June 2008, Tralee, County Kerry, Ireland

TECHNOLOGY UPDATE AND RE-QUALIFICATION PROGRAMME

In August 2007, the RWU technology update and re-qualification programme was initiated as follow-up to the
technology transfer programme (presented in the previous paragraph). Due to the fact that this programme is quite
elaborate, the technology update and re-qualification programme has been phased. This allowed for an intermediate
point in the programme to assess the progress made by Bradford, before kicking off the next phase (see Fig.7). The
technology update and re-qualification programme is under supervision of ESA and Astrium Ltd.; where Astrium Ltd.
has committed the original designers of the RWU technology for the supervision of the programme.


Fig.7. Phasing logic of the technology update and re-qualification programme

The contents of the activities within both phases as depicted by fig.5 are discussed in the following paragraphs.

Phase 1: Critical Procedure Validation and Design Review

Two main tasks exist within the first phase of the programme. These tasks are described below.

Task 1: Critical Procedure Validation
Execution of the critical MAIT procedures to refurbish an existing (Flight) RWA as part of validating the critical
procedures, the facilities and the training status of the AIT personnel;
- Strip-down and inspection procedure
- Bearing housing assembly procedure
- RWA sub-assembly procedure (including vibration and balancing)
- RWA general assembly procedure (including evacuation)
- Full functional test procedure

Task 2: Design Review
Preparation and review of a typical PDR data-package to be generated by Bradford in order to validate the level of
understanding of Bradford of the RWU technology;
- Structural analysis
- Thermal analysis
- .

Phase 1 of the programme has been finalized successfully on the 6
th
and 7
th
of March by means of a Test Review Board
and Design Review Meeting. With successful closure of phase 1, the second phase of the programme has been released.

By successfully performing phase 1 described above, Bradford has proven firstly to master all critical AIT procedures
involved in the production of an RWA. Secondly, has proven to understand in high engineering detail the RWU
technology. With this phase of the programme closed, Bradford has received support from ESA to start bidding for
institutional programmes.











GNC 2008
7
th
International ESA Conference on Guidance, Navigation & Control Systems
2-5 June 2008, Tralee, County Kerry, Ireland

Phase 2: Design Evolution

Five main tasks exist within the second phase of the programme which are executed according to Fig.8. Notice that a
CDR is implemented prior to the start of the manufacturing of the QM RWU.



Fig.8. Flow logic of tasks within phase 2 of the programme

The tasks to be executed within phase 2 are described below.

Task 1: RWU Design Evolution
Within this task, the RWU design is modernized without losing the necessary links to its heritage. Primarily the
design of the electronics in the RWU is improved as the RWA is mechanically already optimized. As a result of the
modernization, the design documentation will be updated for CDR.
- Construction of a generic RWU requirement specification
- Dual I/F type (analogue and digital) generic WDE design to be established
- Obsolescence update of the RWU
- RWU electrical and mechanical parts rationalization
- Design documentation update for CDR

Task 2: RWU Manufacturing Evolution
The manufacturing evolution primarily focuses on optimizing and then consolidating the RWU supplier chain;
especially regarding the suppliers of the critical components of the RWU. As part of this, the critical parts suppliers
will be audited and a long-term agreement will be established.
- Review of the original supply chain
- Definition and review of an alternative supply chain to improve cost and schedule efficiency
- Audits of the critical suppliers
- Consolidation of the renewed supply chain

Task 3: EGSE Modernization
The present EGSE design for use during acceptance testing of an RWU or at customer level, has only limited
functionality and in some cases is even outdated. In order to improve the automation during acceptance testing and
to better meet the needs of the customer, Bradford will design modernized unit testers according in-house and
customer needs.
- Construction of an EGSE requirement specification according in-house and customer needs
- Design of in-house EGSE for acceptance testing of RWU
- Design of customer EGSE for use by the customer

Task 4: QM RWU MAIT
A single channel of electronics and a W45 RWA will be produced using the inputs from the Design- and
Manufacturing Evolution tasks. After the MAI phase, the QM RWU will be subjected to tests (e.g functional,
vibration, shock, thermal, EMC, ...) in the frame of a qualification test campaign. After the qualification test
campaign the QM hardware will be entered into a continuous life test.
- RWU parts procurement and manufacture
- QM RWA and WDE MAIT
- Spare Bearing Housing Assemblys MAIT
- QM RWU life test initiation
GNC 2008
7
th
International ESA Conference on Guidance, Navigation & Control Systems
2-5 June 2008, Tralee, County Kerry, Ireland

Task 5: EGSE MAIT
In order to facilitate the QM RWU qualification test campaign, the modernized EGSE design for in-house use
(from task 3) will be manufactured and acceptance tested. After successful acceptance testing it will be inserted
into the QM RWU qualification test campaign.
- EGSE parts procurement and manufacture
- EGSE MAIT

The present status of the programme is that Bradford is halfway to CDR, where CDR will be end of September 2008. It
is currently planned to achieve full qualification of the updated RWU technology first quarter of 2009.

The reader should notice from the tasks detailed above, that the design update activities in general are intended to
further improve the manufacturability and testability of the RWU. In other words, the present qualification status,
performance and functionality of the RWU equipment is already sufficient for any of the upcoming institutional
missions; this programme is primarily to ensure a more cost and schedule effective RWU product for future missions.

CONCLUSIONS

The RWU technology has been successfully used on a considerable number of high-profile science missions in the past
(e.g. SOHO, XMM, INTEGRAL, ROSETTA and ADM-Aeolus), and has in the meantime a proven in-orbit and in life-
test track record (up to 13 years for SOHO). The high performance, high reliability and functionality of the RWU, in
combination with the flexibility of Bradford as a supplier make the technology excellently suitable for future Science
and Earth Observation missions.

The technology transfer has successfully been completed, and by closure of phase 1 of the Technology Update and re-
Qualification programme, Bradford has proven to have transferred and understood the RWU technology; hence most
importantly has mastered the critical AIT procedures involved in the production of an RWA. With this successful status
in the programme, Bradford is ready to bid for forthcoming missions.

The formal closure of phase 2 of the Technology Update and re-Qualification programme will be in the first quarter of
2009.