1. All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of D'Appolonia. NU-GEAR MOLE PROJECT Progress Presentation Development of a Space Subsurface Penetrometer for Soil Investigation based on an Ultra-Compact Nutating Gearbox ESA Contract 18340/04/NL/MV Noordwijk,21st November 2005 Donato Zangani, D’Appolonia S.p.A., Pierre Coste ESA TEC-IMM donato.zangani@dappolonia.it

2. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 2 of 25 Project Programme DLR has developed a subsurface penetrometer, Mole, as part of the Beagle 2 Lander. The Mole advances into the soil by an internal hammer system driven by an electric motor and a gear reduction unit. To achieve the required reduction ratio, a train of 4 planetary gears (involving 20 gears) was employed. DLR would like to explore the possibility to substitute the existing configuration with the Nutating Gear System, invented by STAM.

3. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 3 of 25 Hammering Mechanism courtesy of ESA

4. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 4 of 25 Testing of Mole The Mole in laboratory during development and under test in simulated Mars landscape (courtesy of DLR Institute of Space Simulation)

5. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 5 of 25 Technical Objectives To develop an improved Mole carrying sensors for identifying mineralogy, organic compounds, and water content of soils To make it more reliable, efficient, compact and allow a longer autonomy of the device To reduce dimensions and weight and increase the reliability of the system compared to previous solutions

6. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 6 of 25 Work Programme WP 1: Design –WP1100: Nugear Conceptual Design –WP1200: Numerical Simulation and Modelling –WP1300: Nugear Detailed Design –WP1400: Mole Study and Design WP 2: Prototyping –WP2100: Nugear Prototyping and Testing –WP2200: Shell Prototyping –WP2300: Mole Integration WP 3: Testing –WP3000: Test of the Mole

7. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 7 of 25 3D - MODEL Commercial-in-Confidence

8. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 8 of 25 Animation Commercial-in-Confidence

9. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 9 of 25 Rapid-Prototype Scale 4,5:1

10. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 10 of 25 Gear Manufacturing Methodology 2. electrode shaped like the tooth counterpart is manufactured by wire erosion 1. definition of the tooth profile 3. tooth to be manufactured by dye sinking EDM (+ orbital movement of the electrodes for good surface finishing)

11. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 11 of 25 Gear Manufacturing Approach 1 The limited space for discharge of the material at the tip of the electrode caused a very bad quality of the surface at the bottom of the tooth as weel as excessive erosion of the tooth tip

12. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 12 of 25 Gear Manufacturing Approach 2 Manufacturing trials have comprised the use of both graphite and cupper electrodes, the latter providing the best results. It is critical the movement of the parts/electrodes.

13. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 13 of 25 Electrode and Parts

14. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 14 of 25 A big hand or a small component?...

15. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 15 of 25 …yes it is a small component!

16. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 16 of 25 What a small gears!

17. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 17 of 25 Gears of Stage 1

18. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 18 of 25 Mating of gears

19. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 19 of 25 The Gearmotor assembled

20. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 20 of 25 Verification of the Dimensional Requirements

21. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 21 of 25 STAM Test Bench

22. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 22 of 25 Nugear Testing at STAM

23. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 23 of 25 NUGEAR – Test Results

24. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 24 of 25 Final Activities Optimisation of the prototype to increase the output torque Laboratory testing at STAM of the updated prototype Final testing at DLR on the MOLE under representative service conditions

25. D. Zangani, P. Coste, Contract 18340/04/NL/MV, ESA ESTEC - ITI Final Presentations’ Day – 21st November 2005 Slide 25 of 25 Summary of NUGEAR advantages A high gear ratio may be easily achieved The meshing and precision is substantially improved in comparison with a differential train formed by spiral bevel gears Materials and surface treatments for specific use in space application can be used Thank You