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HOW A REAL DSN STATION IS BUILT

A beam waveguide antenna is designed so that sensitive electronics are relocated from the traditional feed cone in the center of the dish to an equipment room in the pedestal. This permits easier access for maintenance and future modification. The signal from a spacecraft is received by means of five precision radio frequency mirrors that reflect radio signals along a beam waveguide tube from the vertex of the antenna to the below-ground pedestal equipment room.

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Click on any photograph for a larger image.

Madrid Construction Site, December 15, 2002
With the ground assembly of the main reflector complete, the focus shifts to the assembly of the quadripod structure that needs to be lifted into place immediately after the main reflector.
Madrid Construction Site, December 19, 2002
The main reflector weighs approximately 125 metric tons so placing it on the alidade requires a large crane. One section of the main reflector ribs is removed to allow access for the crane boom.
Madrid Construction Site, December 20, 2002
The entire quadripod structure, including the four legs, the apex structure, the subreflector, and the subreflector positioner mechanism is lifted into position as a single assembly.
Madrid Construction Site, December 20, 2002
With the quadripod in place, the last section of the main reflector, previously removed for crane access, is swung into position. This is bolted into place, prior to final welding.
Madrid Construction Site, February 9, 2003
The panels are installed on the completed main reflector dish. When they are all in place, a precision alignment process is followed to ensure the proper shape of the main reflector surface.
Madrid Construction Site, April 1, 2003
While the antenna appears to be complete, much work is still to be done. Inside the pedestal installation of all the electronics begins; the main reflector alignments have begun; and outside the motor generator building nears completion, and construction of other supporting facilities continues.
Madrid Antenna Completed
Before the antenna is ready to go on line for its first official deep space communication task, calibration activities and demonstration tracks are undertaken.

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