Rotating Electro Mechanical Microwave Sub-Systems Brochure

Cobham Defense Systems
Rotating Electro Mechanical Microwave Sub-Systems
Radar and R.F. Microwave Products
Military Space Air
Traffic
Control
Commercial
Kevlin Corporation doing business as Cobham Antenna Systems
The most important thing we build is trust.
Cobham Antenna Systems
596 Lowell Street
Methuen, Massachusetts 01844 USA
Tel (978) 557-2400
Fax (978) 557-2800
www.cobham.com
kevlin.sales@cobham.com
While every effort is made to ensure the accuracy of the information contained in this brochure, no responsibility can be accepted
for any errors or omissions. All photography is copyright and is used with thanks to the respective owners.
This paper contains 50% recycled fibres and is bleached in a totally chlorine free
process. The virgin fibre content of this paper is elemental chlorine free and
comes from managed forests.

Advanced Rotating Solutions That Meet
Customers’ Complex Challenges in
Military, Commercial, Air Traffic Control & Custom Applications
Decades of Proven Leadership in RF Rotary Joints & Subassemblies
Kevlin Corporation located in Methuen, MA is
doing business as Cobham Antenna Systems.
With over 40 years experience in the industry,
we are the world’s leading designer and
manufacturer of standard and custom RF
rotary joints and electro-mechanical
rotating subsystems.
Cobham Antenna Systems has an active rotary joint design
base that now exceeds 4,000 models and can integrate
additional rotating products for a complete rotating
subassembly. Our products are used in a myriad of
applications ranging from submarine periscopes and
shipboard avionics to ground-based, vehicle-mounted,
air traffic control, airborne and space-based systems.
We are the prime supplier of rotary joints to the U.S. Air
Traffic Control (ATC) market.
Cobham Antenna Systems has a long heritage of designing
and manufacturing complex products capable of meeting
our customers’ most demanding mechanical and electrical
specifications. We welcome the opportunity to serve you.
Cobham Antenna Systems Product Classes
RF Rotary Joints
Slip Rings
Pedestals Rotating Subassemblies
Motors, Gears
Azimuth Positioning Units
Airborne Systems
B-52, B-1B Bomber, F-14, F-15, F-16, F-18
Fighters, APS-116 Submarine Hunter, GD-53
Multi-Mode Radar, Longbow Helicopter,
“MODAR” Weather & Wind Shear, C-130
Transport, MSSA, Joint Stars - Synthetic
Aperture Radar, PAC-3 Missile, APN-242,
F-5 Upgrade, Pershing Missile, Eurofighter,
V-6 Helicopter, HISAR/Global Hawk, AWACS
Upgrade
Shipboard Systems
SPS-48E, MK - 92 Fire Control, MILSTAR,
CORT - Fire Control, HR-76 Search & Tracking,
SPS - 67, TRACKSTAR, IPD -TAS, Submarine
Periscope, SPQ-9B, Photonics – Periscope
Air Traffic Control
TDWR, ASDE, ASDE-3, MSSR, FPS-117
Upgrade, ARSR-3/ARSR-3 Upgrade, TRACS/
TRACS Upgrade, ASR- 4, 5, 7, 8, Convert
ASR-8 to ASR - 9, ASR-9, S511, ASR-10,
MODE-S Beacon, MODE-S ARSR-1,
MODE-S ARSR-2, ARSR-3 Upgrade to MODE-S,
ARSR-3 Upgrade – ATCBI-6, MODE-S
FPS-20, Long Range Surveillance, Various
International ATC, FPS-130 / ARSR-4, ARSR-4
Upgrade (SLEP)
Ground Based Radar
Tradex, TPX-46 Improved Hawk, MILSTAR
Terminal, WSC 6 Upgrade, TPS-63, ILADDS,
FAAR, ATNAVICS, ALCOR, Falcon, AR 320,
HADR, AN FPS-117 Peace Shield, FPS-117
Upgrade, TRACS, MATCALS, FPS-110, 548,
TPS-78SS, INDIA -Tracking, Test Bed / MIT
Space Qualified
Numerous Classified, X-SAR - European
Space Program, N.A.S.A. Space Shuttle, Earth
Orbiting Satellite, SERIO II for Europe, DISPIN
Antenna, ODIN Satellite, Mars Pathfinder,
Hubble Telescope, Mars Exploration Rover
Commercial Systems
Train-mounted, Plane-mounted, Cruise shipmounted,
and Vehicle-mounted for SUV (TV)
and Commercial Vehicles, Weather Radar,
Medical Imaging

Standard & Custom Products, from Simple to Complex
SATCOM, Telemetry, Test Ranges,
Data Links, Radar, Communications,
Medical, Commercial & Space
Rotary Joints and Slip Rings
Cobham Antenna Systems rotary joints and slip rings
are passive rotating transmission lines designed
to pass DC and RF signals between the stationary
and rotating sections with minimal degradation.
They are true electromechanical devices.
• Products as simple as 1 channel (1 inch long),
or as complicated as 33 channels (16 feet long)
• Optional slip rings and encoders
for diverse platform applications, including military
and commercial SATCOM terminals, telemetry,
test ranges and data links. Standard rotary joints
are generally available with shorter lead times and
lower cost than custom products.
• Standard products available for frequency
ranges from DC-50 GHz
• Precision ball bearing designs employed in all standard
Cobham Antenna Systems products for rotational
stability and long life
Custom Designs
Cobham Antenna Systems is the world’s foremost developer
and manufacturer of custom state-of-the-art rotary joint
and rotary joint sub-system technology. Cobham Antenna
Systems engineering expertise in custom designs saves our
customers considerable effort and expense. Our extensive
and diverse custom design database will allow the selection
and modification of mature designs with proven field history.
Our extensive history, design and test capabilities
provide the options needed when configuring complex
rotating solutions. Let us work with your engineers to
specify the perfect solution.
• Custom designs overcome the challenge of mechanical
constraints and stringent RF requirements
• Non-contacting designs available for improved
specifications and high reliability
Standard Designs
Cobham Antenna Systems product line contains
standard rotary joint designs, available in a wide
variety of coaxial and waveguide configurations
• Precious metal contacts utilized in wideband coaxial
designs for broad-band frequency performance
and long life
Rotary Joints
Single Channel Coaxial
Dual Channel Coaxial
Dual Channel Dual Axis
Dual Channel Waveguide
3 Channel
4 Channel Waveguide
4 Channel w/ Slip Ring
5 Channel w/ Slip Ring and Encoder
7 Channel w/ Slip Ring and Encoder
11 Channel w/ 114 circuit Slip Ring
17 Channel w/ Slip Ring and Encoders
32 Channel w/ Slip Ring

Design Integration & Flexibility
Integrated Subassemblies
Complete Antenna/Pedestal Drives &
Rotary Joint/Slip Ring/Encoder Packages
Many of Cobham Antenna Systems rotary joint designs
incorporate ancillary components to create integrated subassemblies
designed to suit unique customer needs.
Let us package the complete assembly: rotary joint, slip ring,
optical joint, media joint, pedestal, azimuth positioning unit,
gears, motor, and controller. Add in the antenna and
plumbing and we can give you the complete, tested
quality unit for further system integration.
Typical Integrated Sub-System
Cobham Antenna Systems is a complete subassembly supplier with
the capability to leverage the resources of other Cobham companies
and partners to design complete antenna/pedestal/drive packages,
in addition to producing rotary joint/slip ring/encoder assemblies.
• In-house manufacturing capability to supply
build-to-print pedestals
• Integrated subassembly packages including additional rotating
devices such as fiber optic and fluid rotating joints
• Integrated, bolt on or stand alone slip rings available to allow
passage of AC/DC and data signals (up to 100 MHz) in addition
to the RF frequencies of the rotary joint
• Integrated encoders, resolvers, or inductosyns ® available as
part of a rotary joint or rotary joint/slip ring package to enable
azimuth positioning
Fiber Optic Rotary Joint
Antenna Mount
Gearmotor with APG
(encoder/resolver)
Slip Ring
RF Rotary Joint
Fluid Rotary Joint
Waveguide Rotary
Joint Channels
Slip Ring
Dual Optical
Encoder
Coax Rotary Joint
Channels
Inductosyn® is a registered trademark of Ruhle Companies, Inc.

Space Products
Commercial Products
Space Flight-Qualified
Technologies
Cost-Effective Commercial
Antenna Platforms for video,
internet, telecom, data and TV
Cobham Antenna Systems has the time-proven capability
to provide rotary joints and subassemblies that exceed the
exacting standards required for space applications. To ensure
a high degree of confidence in the finished products, we
thoroughly manage all required documentation, materials,
testing and cleanliness.
• Proven track record supplying flight hardware on high
profile space platforms
- High and low gain antennas on Mars Pathfinder
and Mars Rovers
- All NASA Space Shuttles
Thermal RF Testing
Thermal Vacuum
Cobham Antenna Systems offers a diverse range of
economical solutions for mechanically steered antenna
platforms used in commercial satellite, television and
communication systems.
• Patented platform design solutions, integrating RF path,
slip ring circuits, rotating and positioning mechanisms and
antenna support structure in a highly reliable package
• Specialized designs available in single and dual
channel configurations
• Frequencies covering DC-50 GHz range; most
commonly L, S, and Ku Band
- Numerous military and commercial satellites
• ISO9001-2008 quality system to provide foundation for
engineering and manufacturing support required to supply
custom space hardware
• Outstanding platform performance in any environment;
land, sea or air
• High volume production capability; quantities
exceeding 50,000 units delivered
• Class 100 clean benches in an enclosed controlled access
area where critical subassemblies and components are
assembled and tested
• Typical Cobham Antenna Systems space product documentation
Vibration
Torque
- Program Management
- Qualification Test Reports
- Acceptance Test Reports
- Progress Reports
- End Item Data Packages
- Project Control
- Preliminary Design Reviews
- Critical Design Reviews
- Final Design Reviews
- Product Assurance Plans
- Manufacturing In-Process Inspections
- Verification Control Documents
- Configuration Control
- Design and Development Plans
- Top Assembly Drawings
- Parts and Materials Lists
- Work Breakdown Structures
Static Loads
Special project laminaire
flow clean bench in a
temperature controlled
clean room environment

Engineering, Manufacturing & Test Capabilities
Overhaul & Repair
Your Full-Service Source for Repair,
Refurbishment and Upgrade.
Engineering
Coordinate Measuring
Electrical Test
Assembly
Overhaul & Repair
Cobham Antenna Systems’ engineering department has extensive experience in
rotary joint design and the largest rotary joint engineering staff in the world.
Our engineering department can provide any level of technical support a
customer may require.
Design Tools
Cobham Antenna Systems Engineering Department is
equipped with the latest Computer Aided Design (CAD),
Computer Aided Manufacturing (CAM), Computer Aided
Engineering (CAE), and 3D RF and mechanical design
tools, as well as internally developed design programs.
• Cradle-to-grave documentation control
• Rapid generation of code to drive our turning and
machining centers
• Ability to shorten new product lead times by eliminating
prototypes and generating optimized designs
• SolidWorks 3D CAD software
• SolidWorks Simulation – Finite Element Analysis (FEA)
• Mastercam CAM software
• Computer Simulation Technologies (CST) CAE for
complex RF modeling
Engineering
Cobham Antenna Systems has the most experienced and
innovative RF rotary joint engineering staff in the world.
• Unmatched technical ability to perform any task involving
design, manufacture and test of sophisticated rotary joints
or other rotating components
• Key technical, manufacturing and management personnel
on staff for over twenty-five years
• Many junior engineers and senior managers with strong
track records in the electrical, mechanical and quality
aspects of microwave and rotating technology.
Machining
Cobham Antenna Systems advanced machine shop turns
and machines all high-precision parts, fixtures and tooling
required to build our products, ensuring superior quality
control and dependable on-time delivery.
• State-of-the-art numerically controlled machining centers
• Extensive conventional turning and machining equipment
• Complementary precision model shop to support
quick-turn-around engineering programs
Assembly
Cobham Antenna Systems modern 80,000 square foot
design and production facility consolidates all assembly
work in one location.
• World’s largest dedicated rotary joint assembly area
• Complete coaxial cable and connector manufacturing
and assembly area
• Environmentally safe painting facility
Testing and Clean Room Facilities
Cobham Antenna Systems electrical test department is
expertly staffed and fully equipped.
• State-of-the-art automatic network analyzers; frequency
capabilities from DC to 50 GHz
• Full array of high power transmitters, temperature
chambers, and other electronic monitoring equipment
• Precision phase matching, Time Domain Reflectometer
(T.D.R.), automated encoder testing and comprehensive
slip ring testing
• Cobham Antenna Systems maintains class 100 clean
benches in a controlled access clean room where critical
subassemblies and components are assembled and tested
Quality Control
Cobham Antenna Systems stringent Quality Assurance
Program monitors and supports all departments and facilities.
• In-process inspection stations
• ISO 9001-2008 and AS9100B certified
Quality Management Systems
Environmental Test
Cobham Methuen is the industry’s leading specialist in
complete refurbishment of rotary couplers.
As the world leader in rotary joint manufacture and
technology, Cobham Antenna Systems has the capability
to overhaul & repair your rotary joints, enhancing radar
system performance. Our extensive design database reduces
the design time, liability issues, and other problems normally
associated with radar hardware modifications.
• Maintain, restore and upgrade all rotating components,
whether manufactured by Cobham Antenna Systems or
another supplier
• Depot repair and refurbishment facility for the FAA and
many other government agencies and prime contractors
Product life can be extended significantly with full
refurbishment. In most cases, complete overhaul of a rotary
coupler is recommended over a quick point of failure fix.
Experience has demonstrated that quick fixes tend to lead
to premature unit failures. A complete overhaul can be
performed in less time and at a fraction of the cost of a new
unit. Overhauled units are returned to the customer in a
“like-new” condition with the same one year warranty
offered on new products. By performing a complete
overhaul the unit can be refurbished several times before
the life cycle is complete and replacement is required.
Cobham Overhaul & Repair
All Cobham Defense Systems companies offer you the
industry’s most comprehensive repair, refurbishment and
upgrade capabilities. Moreover, we provide this service for
all classes of military and commercial-grade microwave
products… regardless of manufacturer or country of origin.
Radar & R.F. Upgrade Capabilities
Cobham has the expertise to support all of your
requirements to upgrade your radar and R.F.
microwave systems.