Positioning & Testing Systems

Defense and Aerospace

Precision Positioning and Testing Systems

We build custom robotic positioning systems that operate at massive scales yet with micron precision for military aviation tests, acoustic sonar development, and antenna measurements.

Our Related Defense Solutions

9-Axis Portal Acoustic Positioning Test Robot

Developed within the scope of the TÜBİTAK MAM, Aselsan, and Naval Forces National Sonar Project, this is our massive portal gantry robot product with a 3000 kg payload capacity that moves transducer towers synchronously in 9 axes over an underwater acoustic test pool and positions them underwater with micron accuracy. The system's axis control and position verification infrastructure is designed with a Siemens S7-1500 PLC control unit.

Solved Problems and Challenges

During the underwater acoustic performance measurements of military sonar transducers weighing up to 3 tons, they must be transported and positioned in the underwater pool with a 9-axis degree of freedom without flexing despite water resistance and without the slightest axial oscillation. Since sound waves reflecting from the pool walls (acoustic echo) disrupt measurement accuracy, it is imperative that the positioners are aligned with sub-millimeter precision and operate with high accuracy in narrow time windows where reflections will not disrupt the data collection process.

Theoretical Background and Study

In our portal robot systems, Gantry Sync (synchronization) algorithms are used to prevent the flexing of the X1-X2 dual-motor drive mechanism. Closed-loop feedback data from linear encoders is processed using real-time 3D kinematic transformation matrices. In this way, while the transducer is moved in 9 axes in the underwater pool, the positional deviation of each axis is corrected at the micrometer level, ensuring linear positional stability.

Aviation APU Starter and Sensor Test Benches

This is our high-speed regenerative test bench product that enables the testing of Auxiliary Power Unit (APU) Starter Motors and speed/position sensors used in military and civil aviation for Turkish Airlines (THY) Technic. The system performs fault detection and calibration by creating torque-speed graphs of the motors in real-time.

Solved Problems and Challenges

To realistically simulate the dynamic load-speed characteristics of the motor in tests of APU (Auxiliary Power Unit) generator systems of jet engines, dynamometer load benches must be designed. The most critical theoretical problem of this process is that the systems must operate at very high speeds without flexing and vibrating, requiring dynamic data acquisition (DAQ) capability at the millisecond level.

Theoretical Background and Study

In aircraft engine test systems, closed-loop regenerative loading units are used to simulate the starter motor torque loads produced by jet turbines. Torque, speed, and temperature data obtained from the test bench are analyzed by passing through filters with millisecond precision via high-speed data acquisition cards (DAQ), simulating the behavior of the motor during start-up.

Antenna Spherical Near-Field (SNF) Multi-Axis Measurement Platform

This is our precision robotic positioning system product developed for the Yeditepe University Antenna Measurement Laboratory, which tests and analyzes the radiation patterns of radar antennas and RF communication units by multi-axis scanning in an anechoic chamber environment.

Solved Problems and Challenges

When performing radiation tests of radar antennas in anechoic chamber environments, electromagnetic waves reflecting from the laboratory surfaces disrupt measurement accuracy. To overcome this obstacle, it is mandatory to position the RF scanner receivers in multiple axes with micron precision and align them with the tested antenna in perfect axial linearity.

Theoretical Background and Study

Spherical/cylindrical coordinate transformation algorithms and FFT transformations are used for near-field and far-field measurements of radiation patterns of radar and RF antennas in anechoic chamber environments.

Antenna Spherical Near-Field Measurement Platform

Product Specifications and Performance Standards

Positioning Accuracy

±0.05 mm Axial Accuracy

Under a 3000 kg load, an axial linear motion positional error margin of less than 0.05 mm thanks to linear encoder feedbacks.

Data Acquisition and Control Speed

100 kHz DAQ Sampling

100 kHz high sampling frequency to capture instantaneous changes in torque, speed, and electrical parameters at the millisecond level in APU engine test benches.

Multi-Axis Integration

9 Degrees of Freedom (9-DOF) Gantry

3D scanning of transducers from all directions with the integration of A, B, C rotation axes connected to X1, X2, Y, Z linear axes and an underwater rotary table.

Ideal Application Areas

Military Sonar Test Facilities: Acoustic pool calibrations of hull-mounted sonar domes and towable transducer arrays.

Aviation Engine and Parts Maintenance Hangars: Test systems for APU starter motors, generators, and speed sensors of military cargo and fighter aircraft.

Radar and Communication R&D Centers: Near-field and far-field radiation pattern verification chambers for microwave, RF, and 5G/6G communication antennas.