Sarnatech's moulded plastic parts - a bearing and giant thrust race - form the mobile base of KVH's new TracVision A5 ultra-low profile satellite TV antenna designed specifically for passenger vehicles. Using KVH's revolutionary hybrid phased-array technology, it provides in-motion access to more than 300 live satellite TV and music channels via virtually all in-vehicle passenger entertainment systems in sport utility vehicles, mini-vans and cars.

The first and only low-profile antenna available for passenger vehicles, it is available through approximately 800 retail locations nationwide, such as Tweeter, large regional chains, internet/catalog retailers, and individual retail locations that specialize in high-end home and car audio/video products.

Having already provided the perfect bearing solution for KVH's successful TracVision L2 and G6 mobile satellite antennas, Sarnatech BNL's expertise was called upon once again for the ground-breaking TracVision A5 project when the bushing solution KVH was trialling failed due to high friction problems.

With the overall height of the antenna fixed at just four-and-one-half inches, Sarnatech BNL's design team had to come up with an ultra-thin bearing in ultra-quick time. But, having worked closely with KVH before, the team understood the application and the potential problems. The TracVision A5 project had been alive for two years, but in just two weeks with Sarnatech, the bearing design was approved and the first prototype produced two weeks later.

The bearing is very thin - just three-eighths inches high - with the pitch circle of the raceway designed as large as possible to offer maximum support. Integrated features include belt drive teeth around the outer edge, brass inserts to fix it to the unit, and moulded pads on one side to provide extra stability.

Being plastic, the Sarnatech BNL product is approximately 50 percent less weight than an equivalent bearing in stainless steel and costs approximately one-third to one-half the price.

"When the bushing system we were testing failed, Sarnatech BNL was the first call we placed as we knew they could provide the engineering support that was needed in a very short time period", said Gerry Maynard, Senior Mechanical Engineer at KVH. "We had a problem and they solved it. They told us what they could do, delivered what we needed on budget and in time for a successful launch."

In addition to a bearing solution, KVH needed to find a way to support the perimeter of the 30 and one-half inch wide antenna and asked the Sarnatech BNL's design team for ideas. The result is a giant thrust race with an outside diameter of 25 inches. Manufacturing a plastic part of this size causes problems with tooling in terms of the expense due to wasted space in the tool, said Terry Holmes, Vice President of Sales and Marketing for Sarnatech.

The team overcame this by sectioning the part in order to make it both cost effective and easy to manufacture with each part being moulded in one shot. The finished part is made up of eight identical sections which fit together effortlessly by way of an integral connection clip design.

KVH is delighted with Sarnatech BNL's solutions for this very high profile project. "Sarnatech BNL is a valued supplier and contributor to the initial success of our TracVision A5 program", said Paula Conway, KVH's TracVision A5 Program Manager. "Their overall responsiveness to day-to-day changes has resulted in a smooth and timely product launch."

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