Tim Furniss/LONDON
To meet the growing demand for its satellites, Hughes Space and Communications - has added 3,800m2 (41,000ft2) of test space at its factory in El Segundo, California.
The extra space provided by a new thermal stress chamber, an enhanced near-field antenna range testbed, and a large, dual-capacity thermal vacuum chamber brings to 55,700m2 the satellite manufacturing area - creating the world's largest commercial communications satellite factory.
Hughes is one of the "Big Five" that dominate the worldwide large geostationary communications satellite manufacturing market - with Lockheed Martin and Space Systems/ Loral of the USA; the Anglo-French Matra Marconi Space (soon to add Germany's Daimler-Benz Aerospace Space division); and France's Aerospatiale.
The Hughes Integrated Satellite Factory can now simultaneously conduct thermal vacuum tests on four spacecraft and thermal stress testing on two. Antenna testing can be conducted in five near-field test areas and the company will soon operate a compact Ku-band antenna range testing area.
Hughes' new thermal vacuum chamber can accommodate two craft simultaneously
"These additions mean we can continue to shorten our production cycle times. We can also manage our personnel and capital resources better, and can reduce programme risk," says Donald Cromer, president of Hughes Space and Communications.
An illustration of the shortened production cycles is given by one of Hughes' most recent contracts, to build the PAS 6B satellite for PanAmSat, which has to be launched by an Ariane 4 booster before the end of the year.
The factory is dedicated to the design and manufacture of the HS 376; the HS 601 - the world's most widely purchased commercial communications satellite; the new HS 702, claimed by Hughes as the world's most powerful communications satellite; and two lines of mobile communications satellites , one for geostationary orbit (Thuraya) and the other for medium Earth orbit (ICO).
Since Hughes acquired the building in 1955, it has evolved into a state-of-the-art factory, capable of supporting the company's backlog of 40 satellites. More room in which to design, manufacture and test spacecraft is going to continue to be required as the demand for telecommunications satellites continues to increase and satellites get bigger.
The new thermal vacuum chambers with a 2,225m3 testing area are used to simulate the environment of space: the heat from the sun and the coldness and vacuum of space. The massive chamber required the construction of a separate building, adjacent to the main factory floor. Weighing more than 450,000kg, it is the largest of its shape and can simultaneously be used to test two of Hughes' largest spacecraft.
More important than size, however, is the horizontal orientation of the chamber, which allows technicians to move the satellite quickly and easily in and out.
To leverage the areas common in all satellites, the factory is organised into areas of specialisation, such as structures, propulsion, payload integration and test, antenna fabrication, solar array assembly, and integration and test.
As a spacecraft is constructed, it passes through each of these "bays." When a spacecraft finally enters one of two 13m high bays, it undergoes final integration and test before shipment to the launch site.
| THE HUGHES BACKLOG - satellites to be launched | |||||
| Satellite | Model | Owner | Launch | Launch Vehicle | |
| 1 | BSAT-1b | HS 376 | B-SAT | 1998 | Ariane 4/V108 |
| 2 | Thor III | HS 376 | Telenor | 1998 | Delta II |
| 3 | Astra 2A | HS 601HP | SES | 1998 | Proton |
| 4 | Galaxy X | HS 601HP | PanAmSat | 1998 | Delta III |
| 5 | JCSAT-6 | HS 601 | JSAT | 1998 | Atlas II |
| 6 | Astra 1 | HHS601HP | SES | 1998 | TBD |
| 7 | Morelos III | HS601HP | SatMex | 1998 | Ariane 4 |
| 8 | UHF F/O F9 | HS 601 | US Navy | 1998 | Atlas IIA |
| 9 | Sirius 3 | HS376HP | NSAB | 1998 | Ariane 4 |
| 10 | Orion 3 | HS601HP | Orion AP | 1998 | Delta III |
| 11 | ICO F1 | HS 601 | ICO | 1998 | Atlas IIAS |
| 12 | Galaxy XI | HS 702 | PanAmSat | 1998 | Sea Launch |
| 13 | BONUM-1 | HS376HP | BONUM | 1998 | Delta II |
| 14 | PAS 6B | HS601HP | PanAmSat | 1998 | Ariane 4 |
| 15 | Asiasat 3S | HS601HP | Asiasat | 1999 | Proton |
| 16 | UHF F/O F10 | HS 601 | US Navy | TBD | Atlas IIA |
| 17 | TDRS-H | HS 601 | NASA | 1999 | Atlas IIA |
| 18 | Galaxy XIII | HS 702 | PanAmSat | 1999 | TBD |
| 19 | Galaxy XIV | HS 702 | PanAmSat | 1999 | TBD |
| 20 | ICO F2 | HS 601 | ICO | TBD | TBD # see note |
| 21 | ICO F3 | HS 601 | ICO | TBD | TBD |
| 22 | ICO F4 | HS 601 | ICO | TBD | TBD |
| 23 | ICO F5 | HS 601 | ICO | TBD | TBD |
| 24 | ICO F6 | HS 601 | ICO | TBD | TBD |
| 25 | ICO F7 | HS 601 | ICO | TBD | TBD |
| 26 | ICO F8 | HS 601 | ICO | TBD | TBD |
| 27 | ICO F9 | HS 601 | ICO | TBD | TBD |
| 28 | ICO F10 | HS 601 | ICO | TBD | TBD |
| 29 | ICO F11 | HS 601 | ICO | TBD | TBD |
| 30 | ICO F12 | HS 601 | ICO | TBD | TBD |
| 31 | TDRS-I | HS 601 | NASA | 2000 | Atlas IIA |
| 32 | TDRS-J | HS 601 | NASA | 2000 | Atlas IIA |
| 33 | Thuraya-1 | HS-GEM | Thuraya | 2000 | TBD |
| 34 | AMRC 1 | HS702 | AMRC | 2000 | TBD |
| 35 | AMRC 2 | HS702 | AMRC | 2000 | TBD |
| 36 | Arik F1 | HS702 | Telesat | 2000 | TBD |
| 37 | Thuraya-2 | HS-GEM | Thuraya | TBD | TBD |
| 38 | Confidential | HS601HP | - | - | - |
| 39 | GOES N* | HS 601 | NOAA | 2001 | Delta III |
| 40 | GOES O* | HS 601 | NOAA | 2003 | Delta III |
| Notes: # ICO 2-12 to be launched 1999-2000 using five Delta III, three Proton, and three Sea Launch boosters * GOES are weather satellites | |||||
Source: Flight International
