This thesis discusses the design of a novel pan-and-tilt unit, which can be used in several fields of application, with the aim of designing a lightweight and cost-efficient product. The unit is engineered to withstand severe vibrations, high shock loads and extreme temperature fluctuations, ensuring reliable performance in a harsh maritime environment. The pan-and-tilt unit is designed to comply with several military standards and to be operational with high accuracies during several thermal and vibration loads. However, during the analysis of requirements it was discovered that achieving operational accuracy during the proposed standards for vibration (AECTP400) would result in an overly stiff and heavy design. This insight led to a reassessment of the system, allowing for a slight loosening of the vibration operationality criterion.

Evaluating the full list of requirements the main design driver was the operationality during deck vibrations, leading to a stiffness driven design instead of a strength driven design. A conceptual design study explored several configurations, including L-brackets, U-brackets and a T-bracket concept. A trade-off led to the development of a compact T-bracket design, integrating high-tech components as a ring encoder, band brake and bearing pair. Initial concepts made from aluminum showed promising weight reductions but introduced excessive stresses on the bearings made from 100Cr6 steel, ultimately leading to a shift to a full stainless steel design for improved material compatibility. Welding was chosen as the primary production technique due to its accessibility and flexibility for thin walled stainless steel, though additive manufacturing is identified as a promising alternative for future iterations, especially for enabling complex geometry.

Various design options were explored and evaluated based on mechanical robustness, weight efficiency and manufacturability. A modal analysis, thermal analysis and shock analysis proved the pan-and-tilt unit could be constructed with thin-walled stainless steel. The thermal analyses included research on the bearing stresses, asymmetric radiation and internal heat generated. The findings offer a comprehensive assessment of viable design choices, justifying the selection of the final conceptual design. This research contributes to the advancement of stabilized pan-and-tilt platforms in dynamic and extreme environments.