PRE2POS stands for PREcision-based drive mechanisms for high-PREcision energy efficient POSitioning devices. It is an R&D project implemented under the European Union’s Horizon2020 research and innovation programme and carried out by a Consortium formed by ARQUIMEA and the Italian company Phi Drive. PRE2POS was focused on validating novel rotary actuators using an innovative motor that takes advantage of the micrometric deformation displacement of piezoelectric stacks to achieve infinite rotary or linear motion. The project also involved the analysis and definition of the next steps towards the industrialization and commercialization of the resulting product.

The final goal is to include the rotary actuators in in key equipment and mechanisms used in spacecraft, such as solar array drive mechanisms, antenna pointing mechanisms or deployment mechanisms like booms and masts where high precision, low weight, energy efficiency and low manufacturing costs are constantly sought by the end users.

The project was successfully completed in 2020 with the formal approval of the European Commission.

Currently, the main commercial actions have already started and are oriented to small new satellite platforms still under development that might be keener on using this disruptive technology to become more competitive.

CHALLENGE

The project team needed to develop a new cutting-edge solution aiming to improve the technical and economic performance of the equivalent products currently available.

A complete rotary actuator was developed and validated for the space market considering the dimensioning of the drive motor and the optimization of its performances.

Moreover, a smart design was developed to guarantee a cost-effective integration of the Pre2pos motor components into ARQUIMEA customized gimbal design.

Finally, since the idea was to use this solution in future small sat platforms that require off-the-self short lead time products, the gimbal needed to be a standard product, cost affordable and with a short lead time.

SOLUTION

RESULTS

A total of three EQM models of the system were produced to validate the solution. The acceptance test campaign of the EQM models was performed and completed at the end of 2019. This solution was successfully tested considering the design and operation requirements and conditions for space applications.

ARQUIMEA’s gimbal together with Phi Drive’s motor proved to be the right solution for the target applications in small sats.

At ARQUIMEA Agrotech we are committed to hydrothermal carbonisation technology (HTC) for the treatment of agricultural waste and its subsequent valorisation as a renewable fuel or for improving soil.

• 84M m3 of slurry is generated annually in Spain
• 15 times more slurry than meat is produced annually
• 24.000 Slurry pools are generated in Spain every year

Reduction of environmental impact of livestock farmers

Swine farmers undertake considerable efforts to reduce their environmental impact, especially in the use of important resources such as water.

However, the management of slurry (a liquefied manure resulting from a mixture of water, urine, excrement and feed waste) continues to pose a real challenge for livestock farmers. Poor slurry management can cause serious problems with odours, greenhouse gas emissions, soil contamination and surface and groundwater pollution, among other effects.

Valorisation of waste

Despite its high value as a mineral fertiliser, making the most of pig slurry continues to pose a major challenge.

We work on the valorisation of waste generated on farming operations as hydrochar or mineral fertiliser.

Impact

• Total elimination of pathogens
• Odour abatement
• Reduction of the environmental impact

At ARQUIMEA Agrotech we work towards the valorisation of agricultural waste and its transformation into bioplastics for animal production.

The bioproduct, obtained from bacteria and microalgae, will be employed to produce new materials for use in artificially inseminating pigs.

• 14% Of agricultural production in Spain consists of swine
• 2nd Spain’s position in the ranking of swine production in the EU
• 3rd Largest swine producer in the world

The swine industry, key to the Spanish economy

The pork production industry plays a key role in the Spanish economy, accounting for 14% of final agricultural production.

Artificial insemination is a very important link in this chain. However, swine production is not sustainable due to the large number of non-recyclable materials used in the process. Climate change and the evolution of the sector require progress in the development of advanced technological solutions that respect the environment and guarantee animal welfare.

Reduction of the impact on the environment

The new bioplastic material will reduce the environmental impact of the swine industry, in terms of the generation of plastic, through the introduction of new recyclable materials. Furthermore, livestock waste will also be recovered for use.

Impact

• Improved efficacy of artificial insemination
• Improved animal welfare
• Reduction in the use of plastics in the swine industry

At ARQUIMEA Agrotech we are working on the development of a novel bioproduct capable of enhancing plant growth, fighting pathogen agents, binding nitrogen, dissolving phosphor and plant resistance to stress caused by drought.

• 57% Of Spanish territory is covered by woodland
• 76% Of the land under cultivation is unirrigated land
• 5M Tons of tomatoes are produced annually in Spain

Abiotic stress as a negative factor on crops

Abiotic stress is defined as the negative impact on living organisms by non-living factors such as strong winds, drought or floods. Many of these phenomena are becoming more frequent and severe as a consequence of climate change.

Abiotic stress is the most damaging factor of all for the productivity and growth of crops worldwide.

Increased tolerance to environmental factors

At ARQUIMEA Agrotech we are working on the development of a unique market solution that acts as a biostimulant for plants and as a biotransformer for non-arable soils.

This product of natural origin will enhance vegetative development and increase tolerance to abiotic plant stress in agroforestry crops. Due to its composition, it can act simultaneously as a biostimulant, soil regenerator, combat plant pathogens and accumulate water.

Impact

• Improved crop growth and development
• Protection against pathogenic microorganisms
• Regeneration of dried out, or nutrient-poor, soils

We are researching the development of new natural solutions to combat some of the diseases of interest in agroforestry that threaten natural systems.

At ARQUIMEA Agrotech we are working on obtaining a compound of natural origin, formed by microorganisms, with the capacity to combat and eliminate the main plant pathogens that affect the Dehesas (pasturelands).

• +500,000 Trees affected in the last 25 years by plant pathogen related disease
• +1,000 Species affected by the dry disease
• TOP 100 Most damaging invasive alien species in the world as rated by IUCN

Dehesas, an ecosystem that is unique to the world

Dehesas are a type of ecosystem found exclusively in the southwest region of the Iberian Peninsula. Made up mainly of holm oaks, cork oaks and different types of pasture and scrubland, it has been a key factor in the development of livestock farming and the forestry products industry (firewood, cork, mushrooms, etc.).

However, this ecosystem is at serious risk of disappearing due to the action of various plant pathogens that kill holm oaks and cork oaks, preventing the affected land from being used again.

First solution on the market

At ARQUIMEA Agrotech we strive to develop a market solution capable of combating the main plant pathogens that affect Dehesas.

This solution involves protecting an ecosystem that is unique to the world, the source of products like acorn-fed Iberian ham, honey, cork and all kinds of lamb, beef and pork products.

Impact

• Recovery of an ecosystem that is unique to the world
• Reduction of pesticide use
• Biocontrol of diseases of interest in agroforestry

At ARQUIMEA Agrotech we are developing a microbial fuel cell that will enable the simultaneous production of hydrogen and electricity from agricultural waste in the future.

• 45% Percentage of greenhouse gas emissions to be avoided by 2030 to avoid catastrophic warming
• 1% Percentage of greenhouse gas emission reductions that current efforts will deliver
• 69% Of primary energy will be solar by 2050

Agricultural waste, an opportunity for generating clean energy

Despite the efforts of those in charge of livestock exports, the management of the waste generated continues to pose a challenge due to its high environmental impact.

At ARQUIMEA Agrotech we are committed to microbial fuel cells (MFC) as the technological basis for the development of a new generation of solar panels, which could contribute to solving two of the most critical problems facing society today: the energy crisis and the availability of clean water.

Solar panels based on microbial fuel cells

The development of a photo-microbial solar panel based on microbial fuel cell technologies will yield clean energy, producing electricity and hydrogen from solar energy and atmospheric CO2.

ARQUIMEA’s deployment mechanism is based on spring-motorized hinges designed to perform the rotation opening of a solar panel or any other deployable structure from the platform. The hinges carry out a soft movement of the solar panel, guaranteeing the motorization safety margins and avoiding return effects. Once opened, the device holds the panel fixed in 90^o position. Each hinge contains a mechanical switch controlling the proper deployment of the structure.

The HDRM and deployment mechanism can be used together or separate and typical applications include solar arrays, antennas, booms and masts, reflectors, cover doors, scientific instruments, shutter mechanisms, large structures, launch locks for gimbals, thrusters, stage separation, caging mechanisms, etc.

Impact

• Production of hydrogen and electricity
• Reduction of the environmental impact of farming operations

Event to present the project at Arquimea manufacturing facilities. Madrid 2021

THE CHERENKOV TELESCOPE ARRAY (CTA) OBSERVATORY PROJECT

The Cherenkov Telescope Array (CTA) observatory is a high-technology international scientific project that aims to create a scientific facility, unique in the world, which will allow further study and knowledge of the universe through the interaction in the Earth’s atmosphere of gamma rays from distant phenomena produced in outer space. 

The observatory intends to build one hundred Cherenkov-type telescopes at two locations: Roque de los Muchachos Observatory on the island of La Palma, Canary Islands (Spain), and in the Atacama Desert in Chile. The observatory will have three types of telescopes: large-sized telescopes (LST) with a diameter of 30 metres, medium-sized telescopes (MST) with a diameter of 12 metres and small-sized telescopes (SST) with a diameter of 4.3 metres. The project will create a global network of telescopes for the study of the universe. 

The Cherenkov Telescope Array project involves an investment of over €300 million and the participation of over 1,400 scientists and engineers from 32 countries; Spanish institutions such as the Canary Islands Astrophysics Institute (IAC), the Centre for Energy, Environmental and Technological Research (CIEMAT), and the Institute for High Energy Physics (IFAE), play a fundamental role in the project. 

Through the analysis of the electromagnetic phenomena produced in the atmosphere by gamma rays, scientists can collect data, study and analyse events in the universe that would otherwise be unidentifiable. 

The most important component of the telescopes is their camera, capable of detecting high-energy radiation with unprecedented precision and a sensitivity ten times higher than that of the existing Cherenkov telescopes. The telescope network is able to orientate itself within seconds, and in a coordinated manner, to measure a particular event. 

If all projections are met, the Cherenkov Telescope Array telescope network at the La Palma Observatory is expected to be operational from 2024 onwards. 

THE CHALLENGE OF THE CAMERAS OF THE LARGE-SIZED TELESCOPES (LST)

The Cherenkov Telescope Array observatory aims to create a global network of hundreds of telescopes of different sizes. Each telescope must meet CTA’s scientific objectives and satisfy the observatory’s operational needs and comply with the highest quality and safety standards. 

The challenge addressed by ARQUIMEA was to manufacture three cameras for the observatory’s Large-Sized Telescopes (LST) using a mass production system. Thanks to the industrialisation process, all the cameras will have the same specifications and characteristics and could be manufactured efficiently, at the right price and turnaround time. 

Each camera has a surface area of 9 m², weighs two tonnes and contains 265 optical sensors (photomultipliers) that are responsible for producing the required resolution. 

The greatest difficulty in a project of this nature is the engineering of diverse systems and their integration and verification throughout the entire manufacturing process. The cameras have over 5,000 different parts manufactured by a large number of suppliers in different countries. For example, the photomultipliers are produced in Japan. The manufacture of the structure, as well as the successful assembly, integration and testing of all the components, are the main challenges facing the camera production project. 

Coordination between science and industry in order to achieve this goal has been a major challenge throughout all phases of the project. 

THE SOLUTION OF THE CAMERAS OF THE LARGE-SIZED TELESCOPES (LST)

The Canary Islands Astrophysics Institute (IAC), which is responsible for managing the infrastructure, conducted an international tender for the manufacture of the cameras, and Arquimea was awarded the contract in 2020. 

The company has extensive experience in the manufacture, assembly, integration and testing of key components for this type of infrastructure, and has participated in major astrophysics projects such as the Large Telescope in the Canary Islands, as well as in other projects in highly demanding sectors such as the aerospace industry. 

The first camera that served as a prototype was manufactured by CIEMAT in 2018 and is currently operational at the Roque de los Muchachos Observatory on the island of La Palma. ARQUIMEA has worked in coordination with the IAC and CIEMAT to improve the design of the first camera and to manufacture the three new cameras. 

The aim was to focus on a mass production approach, with a certified quality control system. Efficiency and proper planning helped to overcome difficulties such as the shortage of chips that affects many sectors. 

Each 9 m2 camera has 265 multipliers and weighs two tonnes. The cameras are based on a modular design with all sensors and electronics on-board, ready to be installed on the carbon fibre arc of the telescope. 

These cameras are an essential component of the telescopes, as they are responsible for collecting and analysing the data. The cameras will enable both the source of the gamma ray and its energy spectrum to be measured with very high precision. 

The main components of the cameras are: 

• Cluster holder 
• Tubular structure 
• Air cooling system 
• Hydraulic cooling circuit 
• Multitool 
• Front door 
• Detectors and electronics 

Mixed manufacturing and assembly techniques have been used in the industrialisation process, including precision machining, deep hole boring, sheet metal forming, TIG and MIG welding, vibration Stress Relief, NDT’s, riveting, bolting, bonding, sealing, handling and assembly of large components. 

In addition to the above, different technologies have also been integrated, including: aluminium alloy structures, combined water-air active cooling, electrical mechanisms (shutter, target lens), hydraulic actuation, automation and sensing, hardware electronics, transport shock absorbers, among other technologies. 

MAIN ELEMENTS OF THE CAMERAS OF THE LARGE-SIZED TELESCOPES (LST)

THE RESULTS OF CHERENKOV TELESCOPE ARRAY (CTA) OBSERVATORY PROJECT

• Reduction of the manufacturing time of each camera from one year to four months. 
• Improvement of the original design of the prototype camera.
• Optimisation of production in terms of cost, time, testing, mass production, repeatability and maintenance.
• Successful implementation of a mass production approach with a certified quality control system.
• Successful completion of the manufacture, integration and testing of the more than 5,000 components of each camera.
• Manufacture of three 9 m2 cameras weighing two tonnes.
• Positive collaboration between science and industry with a common goal.

μHETsat, whose weight is less than 80kg, will not depart from ground as will be firstly carried to an altitude of approximately 35,000 feet. Its electric thrusters are a new winning feature that matches the needs of the New Space industry and of the many companies in the space sector that increasingly focus on minisatellites.

The μHETsat microsatellite has two deployable solar arrays consisting of one Aluminum Honeycomb panel in each wing, commonly known as Sandwich. They are lightweight but guarantee stiffness and strength, as well as better deployment capability. These panels are stowed during launch and, once in orbit, they will be fully deployed with the help of release and deployment mechanisms.

μHETsat Satellite. Source: SITAEL

CHALLENGE

The μHETsat team required a complete deployment solution for the solar panels, including Hold-Down and Release Mechanisms (HDRMs).

Moreover, the use of field resettable HDRMs was highly preferred for operational purposes, to save cost and time during the validation tests at system level.

Finally, since the μHETsat platform will be used as the baseline for future satellite missions, the HDRM and hinges needed to be standard products, cost affordable and with a short lead time.

SOLUTION

ARQUIMEA implemented the entire solution for the release and deployment of the solar array, consisting of one HDRM and one deployment mechanism with two spring-motorized hinges per panel. The HDRM solution is based on ARQUIMEA’s Hold-Down and Release Actuator called REACT. A cup-cone was designed to accommodate the REACT to the spacecraft and a bolt catcher was assembled to the solar panel to secure the bolt after release. The deployment mechanism is driven by springs with latch on deployed position and includes a sensor to detect the start and end of deployment.

An EQM model of the system was produced to validate the solution. The acceptance of the EQM was successfully performed and this solution was tested considering the design and operation requirements and conditions of the spacecraft and the specific characteristics of the solar array.

HDRM + DEPLOYMENT MECHANISM

ARQUIMEA’s REACT devices are low-shock Hold-Down & Release Mechanisms (HDRM) which function is to firmly fix a payload during transportation or launch and later release it by electrical activation. The REACT implements a redundant trigger with two different motorization options based on Shape Memory Alloys (SMA), covering wide actuation temperature ranges and providing on-site manual reset capability to the end user.

A cup-cone and a bolt catcher are used to integrate the REACT to the spacecraft, keep the solar panel stowed and secure the main bolt after the release, thus avoiding any potential damage in the structure.

ARQUIMEA’s deployment mechanism is based on spring-motorized hinges designed to perform the rotation opening of a solar panel or any other deployable structure from the platform. The hinges carry out a soft movement of the solar panel, guaranteeing the motorization safety margins and avoiding return effects. Once opened, the device holds the panel fixed in 90^o position. Each hinge contains a mechanical switch controlling the proper deployment of the structure.

The HDRM and deployment mechanism can be used together or separate and typical applications include solar arrays, antennas, booms and masts, reflectors, cover doors, scientific instruments, shutter mechanisms, large structures, launch locks for gimbals, thrusters, stage separation, caging mechanisms, etc.

RESULTS

The system EQM will complete the environmental tests at the Space Qualification Laboratory of the Italian Aerospace Research Center, where it will be exposed to mechanical vibration testing, simulating the violence of a rocket launch, as well as to the extreme temperatures and vacuum simulating the near-Earth orbital environment. Those tests will be carried out in May 2020.

ARQUIMEA’s HDRM + DEM proved to be the right solution for the solar array deployment. The safe release and deployment of the panels is critical to guarantee the success of the mission.

The QUANTUM project consisted of the upgrade of some functionalities of the ARQ-RSB01 digital ASIC, designed by ARQUIMEA under the REDSAT project for the first ELSA active antenna, keeping the configuration versality with added beam-hopping function. The new digital ASIC ARQ-RSB02, in combination with its companion, the analog ASIC ARQ-RSA02, allows controlling and managing the RF subassemblies of the ELSA+ phased array active antenna and enabling fast beam hopping as part of the ARQ-RSB02 design.

ARQ-RSB02 is a Full CMOS device designed by ARQUIMEA using the DARE180 rad-hard standard cell library belonging to IMEC and based on UMC’s 180nm technology. The beam-hopping function is implemented with a rad-hard distributed memory to store the antenna coefficients (attenuation and phase shift), along with the timing information that indicates how much time each set of coefficients is to be applied.

A supply chain coordinated by ARQUIMEA and formed by IMEC for the digital backend and foundry services, Fraunhofer IMS for wafer probing and die conditioning, and HIREX for the qualification tests, resulted in the production of thousands of qualified dice ready for integration into a Multi-Chip Module assembled by INDRA.

CHALLENGE

The performance upgrade required for the ARQ-RSB02 involved new design challenges in terms of radiation hardening, especially concerning the embedded SRAM. Deep analysis of the reliability and radiation hardness completed by adequate mitigation techniques (EDAC, scrubbing, etc.) as well as extensive validation tests were required to cope with the reliability figures requested by the customer.

The compatibility of the new ASIC with its predecessor, keeping the Fit, Form and Function (FFF) was also a strong constraint for the requirements definition and design phase.

SOLUTION

Any ASIC design or more generally microelectronic development, even those that are upgrades from proven flight versions shall follow a strict methodology to ensure the success of the project and the compliance with the customer and space requirements. The implementation of the beam-hopping function in the new version of the digital ASIC involved a feasibility analysis, the listing of associated risks and related mitigations. Those are based on ARQUIMEA’s own experience and available data from its partners. At the initial phase of the project, the SRAM was deemed critical due to relative sensitivity against radiation and high requirements in terms of error rate. The design relied on performing the adequate radiation mitigation techniques based on available radiation reports and guidelines. This allowed defining the best design and related testability approaches to ensure the target reliability figures.

DESIGN

The digital ASIC is designed to operate under a configurable daisy chain with its companion, the analog ASIC ARS-RSA02. It can be configured in two modes to provide:

• Active antenna control
• 32 memory locations (SRAM) to implement the beam hopping function
• Read current and voltage telemetries of the active elements of the antenna
• Control of the digital I/O for the configuration of active antenna RF MMICs
• Nominal and redundant channels.

The ASIC set procured in die form according to the ESCC-Q-ST-60-05C standard for hybrid circuits was assembled into a MCCM module.

IMPLEMENTATION AND ACCEPTANCE

The wafer manufacturing was performed using a full-mask approach under the UMC180L technology. On-Wafer Acceptance Test (WAT) including Scan Electron Microscope, Electrical Die Sort, dicing and die visual inspection based on the MIL-STD-883 TM2010 standard allowed the selection of the Flight Models.

In parallel, a user-Lot Acceptance Test (user-LAT) or a qualification of the die and associated assembly process was performed by the subcontracted test house to ensure that defect allowance was acceptable to validate the reliability figures defined by the customer. Those were obtained through radiation characterization, endurance, environmental and mechanical testing.

RESULTS

The Radiation characterization as well as the qualification were successful. Thousands of flight models were selected from the WAT and delivered to the customer.

In 2020, a new lot including the digital and the analog ASICs was requested by Airbus for a new communications satellite.

Ready to take the leap?
Let us help you.

ESAIL is an ESA Partnership Project with the Canadian operator exactEarth, built by LuxSpace (an OHB company), together with the Luxembourg Space Agency (LSA) to improve the next generation of satellite-based services for the maritime sector.

ESAIL is the first commercial microsatellite (110kg mass) developed under ESA’s SAT-AIS program for ship tracking. Once launched, the satellite will track the traffic of the vessels by detecting their Automatic Identification System (AIS) messages over the entire globe as it orbits the planet. The use of satellite based AIS data will enable many applications, such as fisheries monitoring, fleet management, environmental protection and security monitoring for maritime and government authorities and industry.

The ESAIL platform has two solar arrays with two panels in each wing, made with Aluminium Honeycomb, commonly known as Sandwich. They are light, but guarantee stiffness and strength, as well as better deployment capability. The panels are stowed during launch and once in the orbit, they will be fully deployed by means of the release and deployment mechanisms.

ESAIL was successfully launched onboard a Vega launcher from the European spaceport in French Guiana last September 2020.

On the other hand, LuxSpace is also developing a multi‐purpose, modular platform called Triton‐X, which will build on the manufacturing and testing heritage gained through ESAIL, using New Space‐style off-the-shelf components to deliver a fully-fledged satellite.

ESAIL Satellite. Source: ESA, www.esa.int

CHALLENGE

The ESAIL team prioritized the use of European technology for the Hold-Down and Release Mechanisms mounted in the solar panels. Moreover, the use of field resettable HDRMs was highly preferred for operational purposes, to save cost and time during the validation tests at system level.

Finally, since the ESAIL platform will be used as the baseline for the future modular platform Triton-X, the HDRM needed to be a standard product, cost affordable and with a short lead time.

SOLUTION

ARQUIMEA implemented a solution consisting of four devices per solar array, so a total of eight Flight Models plus one spare unit were provided to LuxSpace.

The HDRM solution is based on ARQUIMEA’s own proprietary Hold-Down and Release Actuator called REACT. More specifically, the device REACT v2 5KN standard operation temperature range was proposed.

A total of six Structural Models and two Engineering Models were manufactured and delivered to validate the solution prior to the Flight Models delivery. The mechanical and thermal vacuum tests for the acceptance of the EMs was performed at spacecraft level.

The HDRMs were validated and tested considering the design and operation requirements of the spacecraft and the specific characteristics of the solar array panels. The eight Flight Models were delivered to LuxSpace in September 2018.

ARQUIMEA’S HOLD-DOWN & RELEASE MECHANISMS REACT

ARQUIMEA’s REACT devices are low-shock Hold-Down & Release Mechanisms (HDRM) which function is to firmly fix a payload during transportation or launch and later release it by electrical activation. REACT implements a redundant trigger with two different motorization options based on Shape Memory Alloys, covering wide actuation temperature ranges and providing manual reset capability to the end user.

Typical applications of REACT include solar arrays, antennas, booms and masts, reflectors, cover doors, scientific instruments, shutter mechanisms, large structures, launch locks for gimbals, thrusters, stage separation, caging mechanisms, etc.

RESULTS

The satellite completed the environmental tests in the Centre Spatial de Liège, in Belgium, where it was exposed to mechanical vibration testing, simulating the violence of the rocket launch, as well as to the extreme temperatures and vacuum simulating the near-Earth orbital environment. The solar arrays were successfully deployed, confirming the mechanisms release performance after the rough mechanical and thermal vacuum tests.

ARQUIMEA’s REACT proved to be the optimal solution for such a critical operation like the release and deployment of the satellite solar arrays.

The ESAIL launch had to be postponed several times due to technical reasons, bad weather and because of the COVID-19. Finally, the satellite was launched in September 2020 and the solar panels were successfully released by the REACTs. Today, the satellite is fully operating as planned.