Inside the Apollo "8-Ball" FDAI (Flight Director / Attitude Indicator)

The Apollo FDAI, or "8-ball," was a critical instrument that displayed the spacecraft's orientation (roll, pitch, and yaw) using a rotating black-and-white ball and guidance needles. The ball could rotate in three axes through a complex internal mechanism involving motors and hollow shells, allowing astronauts to monitor and control the spacecraft's attitude during lunar missions. The instrument could display data from multiple sources, including the Inertial Measurement Unit and the Apollo Guidance Computer, selected via panel switches.

During the Apollo flights to the Moon, the astronauts observed the spacecraft's orientation on a special instrument called the FDAI Flight Director / Attitude Indicator . This instrument showed the spacecraft's attitude—its orientation—by rotating a ball. This ball was nicknamed the "8-ball" because it was black albeit only on one side . The instrument also acted as a flight director, using three yellow needles to indicate how the astronauts should maneuver the spacecraft. Three more pointers showed how fast the spacecraft was rotating. Since the spacecraft rotates along three axes roll, pitch, and yaw , the ball also rotates along three axes. It's not obvious how the ball can rotate to an arbitrary orientation while remaining attached. In this article, I look inside an FDAI from Apollo that was repurposed for a Space Shuttle simulator1 and explain how it operates. Spoiler: the ball mechanism is firmly attached at the "equator" and rotates in two axes. What you see is two hollow shells around the ball mechanism that spin around the third axis. For the missions to the Moon, the Lunar Module had two FDAIs, as shown below: one on the left for the Commander Neil Armstrong in Apollo 11 and one on the right for the Lunar Module Pilot Buzz Aldrin in Apollo 11 . With their size and central positions, the FDAIs dominate the instrument panel, a sign of their importance. The Command Module for Apollo also had two FDAIs, but with a different design; I won't discuss them here.2 Each Lunar Module FDAI could display inputs from multiple sources, selected by switches on the panel.3 The ball could display attitude from either the Inertial Measurement Unit or from the backup Abort Guidance System, selected by the "ATTITUDE MON" toggle switch next to either FDAI. The pitch attitude could also be supplied by an electromechanical unit called ORDEAL Orbital Rate Display Earth And Lunar that simulates a circular orbit. The error indications came from the Apollo Guidance Computer, the Abort Guidance System, the landing radar, or the rendezvous radar controlled by the "RATE/ERROR MON" switches . The pitch, roll, and yaw rate displays were driven by the Rate Gyro Assembly RGA . The rate indications were scaled by a switch below the FDAI, selecting 25°/sec or 5°/sec. The ball inside the indicator shows rotation around three axes. I'll first explain these axes in the context of an aircraft, since the axes of a spacecraft are more arbitrary.4 The roll axis indicates the aircraft's angle if it rolls side-to-side along its axis of flight, raising one wing and lowering the other. Thus, the indicator shows the tilt of the horizon as the aircraft rolls. The pitch axis indicates the aircraft's angle if it pitches up or down, with the indicator showing the horizon moving down or up in response. Finally, the yaw axis indicates the compass direction that the aircraft is heading, changing as the aircraft turns left or right. A typical aircraft attitude indicator omits yaw. I'll illustrate how the FDAI rotates the ball in three axes, using an orange as an example. Imagine pinching the horizontal axis between two fingers with your arm extended. Rotating your arm will roll the ball counter-clockwise or clockwise red arrow . In the FDAI, this rotation is accomplished by a motor turning the frame that holds the ball. For pitch, the ball rotates forward or backward around the horizontal axis yellow arrow . The FDAI has a motor inside the ball to produce this rotation. Yaw is a bit more difficult to envision: imagine hemisphere-shaped shells attached to the top and bottom shafts. When a motor rotates these shells green arrow , the hemispheres will rotate, even though the ball mechanism the orange remains stationary. The diagram below shows the mechanism inside the FDAI. The indicator uses three motors to move the ball. The roll motor is attached to the FDAI's frame, while the pitch and yaw motors are inside the ball. The roll motor rotates the roll gimbal through gears, causing the ball to rotate clockwise or counterclockwise. The roll gimbal is attached to the ball mechanism at two points along the "equator"; these two points define the pitch axis. Numerous wires on the roll gimbal enter the ball along the pitch axis. The roll control transformer provides position feedback, as will be explained below. Removing the hemispherical shells reveals the mechanism inside the ball. When the roll gimbal is rotated, this mechanism rotates with it. The pitch motor causes the ball mechanism to rotate around the pitch axis. The yaw motor and control transformer are not visible in this photo; they are behind the pitch components, oriented perpendicularly. The yaw motor turns the vertical shaft, with the two hemisphere shells attached to the top and bottom of the shaft. Thus, the yaw motor rotates the ball shells around the yaw axis, while the mechanism itself remains stationary. The control transformers for pitch and yaw provide position feedback. Why doesn't the wiring get tangled up as the ball rotates? The solution is two sets of slip rings to implement the electrical connections. The photo below shows the first slip ring assembly, which handles rotation around the roll axis. These slip rings connect the stationary part of the FDAI to the rotating roll gimbal. The vertical metal brushes are stationary; there are 23 pairs of brushes, one for each connection to the ball mechanism. Each pair of brushes contacts one metal ring on the striped shaft, maintaining contact as the shaft rotates. Inside the shaft, 23 wires connect the circular metal contacts to the roll gimbal. A second set of slip rings inside the ball handles rotation around the pitch axis. These rings provide the electrical connection between the wiring on the roll gimbal and the ball mechanism. The yaw axis does not use slip rings since only the hemisphere shells rotate around the yaw axis; no wires are involved. In this section, I'll explain how the FDAI is controlled by synchros and servo loops. In the 1950s and 1960s, the standard technique for transmitting a rotational signal electrically was through a synchro. Synchros were used for everything from rotating an instrument indicator in avionics to rotating the gun on a navy battleship. A synchro produces an output that depends on the shaft's rotational position, and transmits this output signal on three wires. If you connect these wires to a second synchro, you can use the first synchro to control the second one: the shaft of the second synchro will rotate to the same angle as the first shaft. Thus, synchros are a convenient way to send a control signal electrically. The photo below shows a typical synchro, with the input shaft on the top and five wires at the bottom: two for power and three for the output. Internally, the synchro has a rotating winding called the rotor that is driven with 400 Hz AC. Three fixed stator windings provide the three AC output signals. As the shaft rotates, the voltages of the output signals change, indicating the angle. A synchro resembles a transformer with three variable secondary windings. If two connected synchros have different angles, the magnetic fields create a torque that rotates the shafts into alignment. The downside of synchros is that they don't produce a lot of torque. The solution is to use a more powerful motor, controlled by the synchro and a feedback loop called a servo loop. The servo loop drives the motor in the appropriate direction to eliminate the error between the desired position and the current position. The diagram below shows how the servo loop is constructed from a combination of electronics and mechanical components. The goal is to rotate the output shaft to an angle that exactly matches the input angle, specified by the three synchro wires. The control transformer compares the input angle and the output shaft position, producing an error signal. The amplifier uses this error signal to drive the motor in the appropriate direction until the error signal drops to zero. To improve the dynamic response of the servo loop, the tachometer signal is used as a negative feedback voltage. The feedback slows the motor as the system gets closer to the right position, so the motor doesn't overshoot the position and oscillate. This is sort of like a PID controller. A control transformer is similar to a synchro in appearance and construction, but the rotating shaft operates as an input, not the output. In a control transformer, the three stator windings receive the inputs and the rotor winding provides the error output. If the rotor angle of the synchro transmitter and control transformer are the same, the signals cancel out and there is no error voltage. But as the difference between the two shaft angles increases, the rotor winding produces an error signal. The phase of the error signal indicates the direction of the error. In the FDAI, the motor is a special motor/tachometer, a device that was often used in avionics servo loops. This motor is more complicated than a regular electric motor. The motor is powered by 115 volts AC at 400 hertz, but this won't spin the motor on its own. The motor also has two low-voltage control windings. Energizing the control windings with the proper phase causes the motor to spin in one direction or the other. The motor/tachometer unit also contains a tachometer to measure its speed for the feedback loop. The tachometer is driven by another 115-volt AC winding and generates a low-voltage AC signal that is proportional to the motor's rotational speed. The photo above shows a motor/tachometer with the rotor removed. The unit has many wires because of its multiple windings. The rotor has two drums. The drum on the left, with the spiral stripes, is for the motor. This drum is a "squirrel-cage rotor", which spins due to induced currents. There are no electrical connections to the rotor; the drums interact with the windings through magnetic fields. The drum on the right is the tachometer rotor; it induces a signal in the output winding proportional to the speed due to eddy currents. The tachometer signal is at 400 Hz like the driving signal, either in phase or 180º out of phase, depending on the direction of rotation. For more information on how a motor/tachometer works, see my teardown. The FDAI has three servo loops—one for each axis—and each servo loop has a separate control transformer, motor, and amplifier. The photo below shows one of the three amplifier boards. The construction is unusual and somewhat chaotic, with some components stacked on top of others to save space. Some of the component leads are long and protected with clear plastic sleeves.5 The cylindrical pulse transformer in the middle has five colorful wires coming out of it. At the left are the two transistors that drive the motor's control windings, with two capacitors between them. The transistors are mounted on a heat sink that is screwed down to the case of the amplifier assembly for cooling. Each amplifier is connected to the FDAI through seven wires with pins that plug into the sockets on the right of the board.6 The function of the board is to amplify the error signal so the motor rotates in the appropriate direction. The amplifier also uses the tachometer output from the motor unit to slow the motor as the error signal decreases, preventing overshoot. The inputs to the amplifier are 400 hertz AC signals, with the magnitude indicating the amount of error or speed and the phase indicating the direction. The two outputs from the amplifier drive the two control windings of the motor, determining which direction the motor rotates. The schematic for the amplifier board is below. 7 The two transistors on the left amplify the error and tachometer signals, driving the pulse transformer. The outputs of the pulse transformer will have opposite phases, driving the output transistors for opposite halves of the 400 Hz cycle. This activates the motor con