Clockwise from main image: Harwin is embracing Industry 4.0 in its highly automated connector assembly processes; signal, power and even Coax cables can be routed through one high reliability connector; new materials and innovative fasteners provide high reliability in harsh aerospace environments
millions of pounds. TheWarwick University Satellite Project (WUSAT) is one such cubesat and is designed to exploit the European Space Agency’s (ESA) “fly your own satellite” programme. Having already achieved success with
launches at altitudes of 30kmand 88km, the current phase ofWUSAT is to achieve an International Space Station deployment into a low earth orbit at an altitude of 400km. Such an ambition requires high-level
reviews and approvals, as explained by the WUSAT director at theUniversity of Warwick,DrWilliamE Crofts, who tells me: “WUSAT satellites are launched via European Space Agency launch programmes, hence our satellites are required to pass highly demanding test procedures which are reviewed by panels of ESA experts.” This will include rigorous vibration
testing tomeet the extreme vibration conditions experienced at launch. At each stage, the satellite’s components and sub- systemsmust also pass tough environmental test procedures, including thermal extremes and safe operation in a vacuum. Commenting on the role that high
connections to see recent innovations in space and aviation connection products
facility and for themanufacturing operations in Portsmouth. Themanufacturing assembly line for the
Gecko connector is a dedicated, highly automated process with connected sensor systems for processmonitoring as well as itemand orientation detection. The assembly line embraces the latest guidelines in Industry 4.0 for fully connected operations. Green pointed out the steps the
connectors go through at every stage of the production operation, which doesn’t just assemble the connector frompurchased components but fabricates the whole assembly fromraw stock, including moulding the plastic parts, turning the wire stock to the correct dimensions and even performing the plating process. Having best practicemethods
throughout its operations led to the recent
EN9100 aerospace accreditation that was awarded toHarwin to add to its existing ISO 9001 certification, all of which helps to extend the company’s reach into other demandingmarkets.
REACHING FOR SPACE A very promising emergingmarket for aerospace connectors is in the space industry, which is gainingmore accessibility through the use of “cubesats”, according to Green. “At themoment, we’re working with
Surrey Space andWarwickUniversity on small cube satellite developments, where reliability, size and weight are the key parameters for components,” he explains. Cubesats are typically 10x10x10cmand
are built for either commercial or scientific use and are able to be launched in clusters for feesmeasured in thousands rather than
reliability connectors play in achieving such ambitions,Dr Crofts says: “We rely entirely on the very highest quality of connector, as provided byHarwin, to ensure that we are able to pass through these rigorous design reviews and eventually produce a satellite that performs reliably in the harshness of a space environment. Our longstanding relationship withHarwin is a key feature of our success as a satellite engineering team.”
CONTINUOUS DEVELOPMENT With the future looking so promising in such demandingmarkets,Harwin is continuing to invest in its skills and technology tomake sure it will always have a role to play as the aerospace arena continues to expand. Withmy heritage firmly being in
manufacturing, I was fascinated by the AdvancedManufacturing Research Centre sign next to a small door in the new building which we passed towards the end of the tour. A glance through the door window revealed a large space with clusters of activity revealing tantalisingly little to the curious onlooker. “The company’s future lies over that threshold,” explains Green as he ledme away to conclude the tour. EE
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April 2017 /// Environmental Engineering /// 41
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