Mobile Satellite Internet System

Since the 1950's the Winegard Company has been a leading manufacturer of quality television reception products. While maintaining a leadership role in this global industry, the company continues to improve products by continually pursuing innovative solutions. Recently DataTech International, LLC, a partner of Winegard Company, and an innovator in Satellite, Off-Air, Telemetry antenna and mobile reception products, invited Colmek to assist in the design of a newly proposed Mobile Satellite Internet System.

The new system would be designed for individuals, businesses, government and military, allowing the user immediate access to broadband connectivity from any location in the world. Consisting of a .74 Meter dish stowed in a horizontal position, the unit would be able to quickly deploy into an upright position with the ability to rotate 370 degrees. Once connected applications such as Voice-Over Internet Protocol (VoiP), Virtua Private Networks (VPN), Secured Private Networks (SPN), Transportable Wi-Fi Access and Real Time Webcasts would be available.

The product would provide a solid uplink without access to a cellular, DSL or T1 line. Despite having produced a prototype design, one that weighed heavily on previously successful products, this new system would require DataTech to pursue significant mechanical design changes departing from their traditional engineering principals. The real challenge was to produce an esthetically pleasing product that could be rapidly deployed while addressing specific space constraints, overall weight and long-term functionality. Knowing the critical importance of this new product, the engineering staff at Colmek Systems set forth to find the best solution for the new DataTech system.

Immediately Colmek engineers found the existing linear actuator design would not generate enough force through the required range of motion. "There clearly existed a mechanical disadvantage in the DataTech prototype design; we needed more lifting force in order to properly deploy the satellite dish", said Jason Martin of Colmek Systems. Drawing from his vast experience in tackling mechanical challenges, Martin was confident he would be able to solve the problem. "I looked at a variety of engineered options and then selected a solid 4 bar linkage which would provide a robust yet lightweight design without sacrificing articulation." After he was set on the needed design a force analysis was completed on the model to determine how much lifting force would be found in each position.

The analysis generated positive results, proving that Martins' design was the best solution for the new product. At this point the project was handed over to Jim Brown, a Colmek manufacturing engineer. Brown reviewed and selected the needed materials, paying special attention to sturdiness and safety. By using a mixture of pre-cast aluminum and steel components, the systems rigidity was greatly enhanced allowing for a deployed wind resistance of up to 60 m.p.h. "I paid special attention to adding rigidity and safety features that would insure the unit operated in a manner that would not damage other components or harm assembly personnel", Brown stated.

The gearing mechanism was also simplified in order to minimize wear and reduce any long-term warranty expenses. All mechanical system drawings were then completed using 3-D Pro-Engineering software and presented to DataTech on-time and under budget. Ultimately Colmek's utilization of an innovative design change coupled with cost minded material selection allowed DataTech the ability to produce a mobile satellite internet system which emphasized space, weight and function. This new rock solid system can now deploy and find a signal in less than 30 seconds! At present time DataTech is in the production phase with a full product launch scheduled for Spring 2005.