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Design Review

This project outlines the design evolution and final design of a window positioning system for a tank-launched infrared guided warhead. It includes analysis, project schedule, and funding details.

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Design Review

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  1. Raytheon Seekers Design Review Raytheon Seekers

  2. Raytheon Seekers Aaron Scrignar…..Team Leader Eric Draves……Historian Trevor Moody……Web Page Des., Mediator Stacy Davison……Document Coord., Financial Officer LaTanya Williams……Communicator Raytheon Seekers

  3. Outline • Client Description • Problem Definition • Project Needs • Design Philosophy • Design Method • Design Evolution • Final Design • Analysis • Remaining Project Schedule • Spring 2003 • Project Funding • Time Log • Conclusion Raytheon Seekers

  4. More about… Raytheon • Specializes in defense systems, government and commercial electronics, business aviation and special mission aircraft • Chairman & CEO: Daniel P. Burnham • $16.9 billion revenue in 2001 • 79,000 employees worldwide • Headquarters located in Lexington, MA Raytheon Seekers

  5. Client Contact • Brian Scott • Electronic Systems • B.S.E. from NAU in Mechanical Engineering • Masters Degree at U of A • Worked at Raytheon for seven years • Tucson, Arizona Raytheon Seekers

  6. Problem Statement • Preliminary design and proof-of-principal prototype needed for a window positioning system to be used in a tank-launched infrared guided warhead Raytheon Seekers

  7. Seeker Device Layout Raytheon Seekers

  8. Project Needs • Survive 10KG launch • Packaged in 0.2” thick by 2.9” diameter cylinder, excluding electronics • Move a Germanium lens .04” thick by .6” diameter to cover a photocell array • Lens must stay in position for 1 second, and move in and out of the field in less than 1 second Raytheon Seekers

  9. Raytheon Seekers

  10. Shock Response Spectra • Launch Conditions • Set Back: 10,000G • Balloting: 3,300G • Set Forward: 2,000G • Flight Conditions • Lateral: 0-3G • Vibration: 5G

  11. Scope of Design Constraints • One penny subject to 10,000 G’s weighs approximately 59 lbs. • The restricted thickness of the work area is about the thickness of 3 ½ quarters Raytheon Seekers

  12. Design Philosophy • K.I.S.S. • Minimize number of parts to reduce probability of failure • Keep close contact with client • Brings attention to potential design problems before it’s too late Raytheon Seekers

  13. Design Method • Brainstorming- Mechanism ideas • Mechanism Selection- Based on size constraints • Modeling- Cardboard model to assess geometries • Analysis- Hand calculations, Adams, Cosmos • Finalize Design- Select dimensions, Tolerance fitting • Fabrication- Large scale model and actual prototype Raytheon Seekers

  14. Design Evolution • Design One • Two solenoids • Sliding rails • Return spring • Design Problems • Large actuation distance • Unnecessary parts • Space limitation Raytheon Seekers

  15. Design Evolution • Design Two • Solenoid • Arm • Pin close to edge • Spring return • Design Problems • Arm deflection • Pivot position accentuates balloting forces • Requires a latching mechanism Raytheon Seekers

  16. Selected Design • Design Three • Solenoid • Arm • Mid-arm pin position • Spring return • Deflection supports • Counterweight Raytheon Seekers

  17. Component Selection • Solenoid – PO-6 3Volt • Arm – 7075 T6 Aluminum • Pin – Stainless Steel with bronze bushing • Frame –Ti-6A1-4V HT-46 Raytheon Seekers

  18. Selected Solenoid • Meets necessary criteria: - Dimensions - Actuation Length - Forces - Power Requirements Raytheon Seekers

  19. Full Arm Swept Angle: 53 Degrees Selected Solenoid (cont.) Raytheon Seekers

  20. Arm Design Raytheon Seekers

  21. PIN ARM BUSHING FRAMEPLATE Pin Connection Design Raytheon Seekers

  22. Frame Design Raytheon Seekers

  23. Modeling • Made actual size cardboard and CAD models to assess the fit of components Raytheon Seekers

  24. Analysis Justification • Deformation of surfaces are within tolerances defined by the optical engineer • Deformation of support structure for optical and antenna elements is within tolerance and creates no interference • No ultimate failures occur and probability of failure is less than 0.01% Raytheon Seekers

  25. Analysis • Hand Calculations • Arm deflection • Arm material failure for normal forces • Arm material failure for balloting forces • Pin material failure for balloting forces • Required swept angle of arm Raytheon Seekers

  26. Full Arm Swept Angle: 53 Degrees Analysis (cont.) Adams – Arm actuation time Raytheon Seekers

  27. Future Tasks • Component FEA analysis • Pin press fit calculations • Order materials • Fabrication Raytheon Seekers

  28. Remaining Project Plan Spring 2003 • Status Report #3 March 27 • Prototype Complete April 12 • Test in Rail Gun April 15 • Design Presentation April 22 • Capstone Conference April 25 • Finalize Web Page and Report May 2 Raytheon Seekers

  29. Project Funding • Raytheon provided $3,000 for project costs • Prototype $1900 • Travel Expenses $500 • Documentation Material $500 • Modeling $100 Raytheon Seekers

  30. Purchases to Date • 8 SP-25 solenoids (two 3-volt, four 6-volt, two 12-volt) – testing, prototype • 8 PO-25-6 (two 3-volt, four 6-volt, two 12-volt) – testing, prototype • Cork – modeling • Cutting supplies – modeling • Birch plywood – modeling • Balsa wood - modeling Raytheon Seekers

  31. Time Log • Aaron Scrignar 71.95 • Eric Draves 71.00 • Trevor Moody 43.25 • Stacy Snyder 32.55 • LaTanya Williams 39.75 _________________________ Total Hours: 258.5 hrs Raytheon Seekers

  32. Conclusion • The balanced swing arm design is simple and efficient in providing the required lens motion while withstanding the environmental constraints • Prototype fabrication will be complete by April 12, 2003 for Rail Gun test Raytheon Seekers

  33. Questions? Raytheon Seekers

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