Design & Development of Air Bearing Table for On

Ground Testing of AOCS Hardware

Dr. Muhammad Yasir Asim Khan M. Mazhar Zia M.Mubeen.Anwar Yawar Sibtain Rizvi
GS EM&C Division GS Propulsion Sys Div. GSEM&C Division GS EM&C Division GS EM&C Division
SUPARCO SRDC SUPARCO SRDC SUPARCO SRDC SUPARCO SRDC SUPARCO SRDC
Lahore, Pakistan Lahore, Pakistan Lahore, Pakistan Lahore, Pakistan Lahore, Pakistan
muhdyasir@hotmail.com asim.khan31@hotmail.com ned_university@yahoo.com mubeen.engr2@gmail.com yawarsr@yahoo.com

Abstract—Air bearing table is used to validate attitude of gravity (CG) of lifted structure can be controlled in all three
control strategies for small satellites and to validate the axes by fine trimming masses.
performance of satellite sensors and actuators on ground with
frictionless environment before launch. It can only be done by II. DESIGN DETAILS
using a test platform that floats on the continuous airstream and
hence allowing free rotation around all three axes. The system is Air Bearing Table is compact, reliable and
employed to develop, improve, and carry out tests of sensors versatile equipment used for testing AOCS hardware and
(magnetometer, sun sensor), actuators (reaction wheel, magnetic algorithms. The detail of each component is given below.
torquer), and algorithms in the experimental framework. In
order to simulate weightlessness, it is essential for the platform to
be completely balanced in all axes. Another important A. Spherical Air Bearing
consideration is that the combined center of gravity (COG) of the The spherical air bearing is designed and manufactured in-
lifted structure should be coincident or very close to the center of house with Al-6061. The diameter of rotor is selected as 5
rotation (COR) of bearing. inch as it fulfilled the loading requirement. There are seven
small holes in the stator proportionally spaced that provide the
In this paper the design detail of developed air bearing table
air film cushion between rotor and stator in loaded condition
is discussed. It provides a cost effective mean to test small
satellites and their AOCS hardware. The diameter of air bearing [1]. The air film thickness varies with the load on the bearing.
is selected as 5 inch as it fulfilled the loading requirement which
is integrated with the platform. The designed load is selected to
be 100kg class satellites. Modular design approach is adopted in
order to accommodate different sizes of air bearing and hence
enhancing the lifting capability of the platform. The sensitivity of
platform is tested to be as small as 5 grams. The vertical
balancing of the system (Z-axis) is done by adding counter
weights at each corner of the platform, while horizontal
balancing is carried out with the help of trimming masses in two
axes(X,Y). The platform allows tilt angle of 30° about X and Y
axes while free rotation of 360° about Z-axis. The system is tested
for the dummy weight of 75kg at continuous pressure of 4bar. Fig. 1. Rotor (left) and Stator (right), main components of Spherical Air
For the desired lifting mass, appropriate air compressor is Bearing
selected that can supply maximum pressure of 8 bar. A control
panel is also provided to regulate the air flow according to the B. Platform
experimental needs. FEM analysis is carried out for the platform
to check the maximum lifting capability of the system. The A platform of suitable dimensions 940x940mm is chosen. In
results were found within safe limits. order to reduce the inert mass of the lifted structure, platform
is manufactured with Al-6061. The platform is painted
Keywords—Air Bearing Table, AOCS (Attitude and Orbit Conrols afterwards to make it scratch resistant. The designed platform
System), Sensors, Actuators, FEM (Finite Element Method) is also reinforced at the bottom as can be seen in the Fig. 2.
I. INTRODUCTION
The developed air bearing table is designed for testing small
satellites and their AOCS hardware. This table allows a free
360° rotation around the vertical axis and a 30°rotation around
the horizontal axes. The platform has been tested for a dummy
weight of 75kg and achieved the desired level of performance.
A modular design approach is adopted in order to enhance its
weight lifting capacity. A set of rotor and stator with larger
size can be integrated with the system for that purpose. Center

Fig. 2. Designed platform for Air Bearing
C. Table and Control panel
Table is made up of SS and capable of accommodating small
and large stator on it. It is properly balanced and also has a
ring of aluminum mounted on it that restricts the movement of
the main platform up to 30 degree about X and Y axes.
Control panel at the front end has an air regulator, plug valve
and air filter for the absorption of moisture from the
compressed air, shown in Fig.3. Pressure gauge is also
installed on the control panel that provides the real time
operating pressure of the system.
Fig. 3. Table and control panel
D. Compressor
Selection of air compressor is an important parameter for the
air bearing design that affects the lifting capability of the
system. For the desired lifting mass, appropriate compressor is
selected that can give a continuous air stream of 3.7 CFM at 2
bar. Maximum pressure of the compressor is 8 bars.
E. Dummy Weights
The Dummy weights are manufactured in order to check the
lifting capability of the system. These weights can be placed
and removed from the platform easily. There are eight dummy
weights, each has a mass of 25kg and are fixed on the platform
during the testing phase.
Fig. 4. Dummy Weight
III. BALANCING SYSTEM
In order to simulate weightlessness, it is very important for the
platform to be completely balanced in all axes. Another
important consideration while designing the system is that the
combined COG of the lifted structure should be exactly
coincident to the center of rotation of bearing [2]. This is
achieved through CAD modeling and assigning densities to all
components, then balancing the system in Z-axis to make
them coincident or as close as possible. Balancing in
horizontal plane is achieved through trimming masses while
vertical balancing is achieved by attaching counterbalance
mass with the platform. The detail of balancing is given
below.
A. Horizontal Balancing
For fine CG adjustment of the lifted platform, trimming
masses are installed on the platform in X and Y axes. These
trimming masses are actually the weights that can be moved
manually on a threaded rod with fine pitch [3]. These masses
can be motorized with slight design changes. In addition, the
slots are provided on the lifted platform for the sliding the
base of these trimming masses that in turn increase the
balancing capability of the system.
Fig. 5. Fine CG adjustment in horizontal axis
B. Vertical Counterbalancing
Weights are added at each corner of the platform in order to
counterbalance the system in Z-axis. A slot is also added in
the rod just to enhance the balancing capability. Weights with
different sizes were manufactured to accommodate different
payloads on the platform.
 (b)

Fig. 6. Counter Balancing Weight

IV. FEM ANALYSIS

FEA Analysis of Air Bearing Platform has been performed in
ANSYS.Inc. The results are shown in Error! Reference
source not found.7 and Error! Reference source not (c)
found.8: Fig. 8. FEM based analysis (a) Deformation with applied load at corners
(Overall); (b) Deformation with applied load at corners (Z-axis); (c) Stress
Analysis (Von-Misses)
a) Deformation of 1.15mm at corners with applied load
of 140N (With Max. expected load of 2000N at the
center)
b) STRESS – 14 MPa V. ADVANTAGES
Following are various distinct advantages of our developed
Stress is found within safe limit. Maximum stresses are found
Air Bearing Table:
at center where the platform is fixed with the table, whereas
• Easy to maintain.
enough stiffness ensures safe operation.
• Low cost
• Modular design to accommodate different sizes of air
bearing
• Provides real time confidence about the proper
behavior of physical system to be used in space
for years
• Provides testing of AOCS algorithms which is the
main requirement of space worthy hardware
before launch
• In-house developed table has already been tested
Fig. 7. FEA Model for the dummy weight of 75 kg
• Capability of CG adjustment in all three axes
• Sensitive / Responsive to 5gm
• Lifting capacity can be enhanced to 200kg with
slight modifications

VI. DEVELOPED AIR BEARING TABLE

Developed air bearing table is shown in Fig. 9. The system
provides a frictionless rotation of the platform in all three
axes.
(a)
 Fig. 9. Developed Air Bearing Table

VII. CONCLUSION
In conclusion it can be said that the developed air bearing
table is a reliable and cost effective way of testing the AOCS
hardware on ground. It is very difficult to procure such
equipment for the developing countries like Pakistan as Space
qualified manufacturers exploit their skills and charge a lot of
money. Sometimes restrictions have to be faced during
procurement process. It is anticipated that the development of
air bearing table will provide self reliance in the field of
AOCS hardware testing. Its design, features, functions are all
conceived by the team working in GS-EM&C Div, SRDC-L,
SUPARCO.
REFERENCES

[1]. WANG Fu-sheng, BAO Gang, “Static characteristics of new type

externally pressurized spherical air bearings” J. Cent. South Univ.
Technol. (2011)

[2]. Richard Boynton, “Using a spherical air bearing to simulate

weightlessness” 55th annual conference of the society of Allied
Weight Engineers, Inc. Atlanta, Georgia 3-5 June 1996.

[3]. J. Prado., G. Bisiacchi., L. Reyes., E. Vicente., F. Contreras., M.

Mesinas., and A. Juárez. “Three axis air-bearing based platform for
small satellite attitude determination and control simulation,”
Journal of Applied Research and Technology, Aug 2005.