Raytheon Seekers

1. Raytheon Seekers Infrared Seeker Calibration Mechanism 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. Presentation Outline • Client Description • Problem Definition • What is Infrared Imaging? • Project Requirements • Design Method • Prototype Design • Analysis Process • Project Spending • Time Log • Conclusion Raytheon Seekers

4. More about… Raytheon • One of the largest defense electronics contractors in the world. Leader in defense electronics, including: • Missiles; Radar, Sensors and Electro-Optics • Intelligence, Surveillance and Reconnaissance (ISR) • Missile Defense • Chairman & CEO: Daniel P. Burnham • 2002 Revenue • $16.8 Billion • 62% of sales to U.S. Department of Defense • 79,000 employees worldwide • Headquarters located in Lexington, MA Raytheon Seekers

5. Client Contact • Brian Scott • B.S.E. in Mechanical Engineering at NAU • M.S. in Mechanical Engineering at UofA • Employee of Raytheon since graduation • Missile Systems – Future Combat Systems • Tucson, Arizona Raytheon Seekers

6. Problem Statement A preliminary design and a proof-of-principal prototype are needed for a window positioning system to be used in a tank-launched projectile. The device must position a small germanium window into an infrared sensor’s optical path to perform Non-Uniformity Compensation. Raytheon Seekers

7. Project Requirements NUC Mechanism must: • Survive 10KG launch acceleration normal to the window face • Packaged in 0.235” thick by 2.89” diameter cylinder, excluding electronics • Move a 0.50” x 0.44” x 0.04” thick Germanium lens to cover a photocell array • Require less than 24 Watts at a maximum of 24 Vdc for less than 1 second • Move lens in and out of the field of the array in less than 1 second, and remain in position for 1 second Raytheon Seekers

8. Light at frequencies below visible red are considered infrared All objects emit infrared energy at ordinary temperatures Objects with higher temperatures emit more infrared energy What Is Infrared Imaging Raytheon Seekers

9. Infrared Seeker Operation • Modern “Heat Seekers”: • Employ advanced infrared sensor arrays • Utilize computer programs to select, target, and guide munitions towards specific images Raytheon Seekers

10. Non-Uniformity Compensation (NUC) NUC is necessary to adjust for different pixel sensitivities which could cause erroneous targeting by seeker computer Germanium Lens Moved in Front of IR Array Raw IR Image before NUC Blurred IR Image with Lens in Position Raytheon Seekers

11. Non-Uniformity Compensation (NUC) Computer algorithm adjusts gain factors of individual pixels so that a uniform image results from a uniform scene NUC Germanium Lens Moved Out of Position Raytheon Seekers

12. Seeker Head Layout Raytheon Seekers

13. Rail Gun Test • 155mm Howitzer fires projectile into water filled trough to provide firing conditions and “soft catch capability Raytheon Seekers

14. Acceleration Time Histories Raytheon Seekers

15. Acceleration Definition • Launch Conditions • Set Back 10,000G • Set Forward 2,000G • Lateral Balloting 3,300G • Flight Conditions • Lateral: 0-3G • Vibration: 5G Set Forward Set Back Lateral Balloting Raytheon Seekers

16. Scope of Design Constraints • One quarter subjected to 10,000 G’s weighs approximately 120 lbs. • The restricted thickness of the available volume is less than ¼ of an inch Raytheon Seekers

17. Design Philosophy • K.I.S.S. • Minimize complexity of the design to reduce probability of failure • Keep close contact with client • Bring attention to potential design problems before it’s too late Raytheon Seekers

18. Design Process • Brainstorming - Mechanism ideas • Mechanism Selection - Based on size constraints • Modeling - Cardboard & CAD models to assess geometries • Analysis - Hand calculations, Adams, COSMOS/M • Fabricate Prototype – CNC Raytheon Seekers

19. Final Design • Frame • Solenoid • Positioning Arm • Pin • Bushing • Return Spring Raytheon Seekers

20. Final Design

21. Frame Design • Frame supports components and other seeker optics • Modified to eliminate unnecessary weight • Recessed regions for return spring and counterweight clearance Raytheon Seekers

22. Frame Design • Frame • 6061-T6 Aluminum • Sult = 45 ksi • CNC work done by R&D Specialty Manco • Phoenix, Arizona

23. Selected Solenoid • 3 VDC pulling solenoid • Electro Mechanisms, Inc • Commercially available PO-25 • Fits within required dimensions • Provides minimum of 2 oz. of force at 3X nominal voltage (18 Watts) Raytheon Seekers

24. Positioning Arm • Positioning Arm • 7075-T6 Aluminum • Sult = 82.7 ksi • Bushing • Oilite Bronze - Oil Impregnated • Self Lubricating Bushing • Pin • AISI 4130 Steel • Sult = 106 ksi

25. Pin Connection Design Press Fit Withstands 120lb Vertical Force Raytheon Seekers

26. Analysis Justification • Deformation of surfaces are within tolerances defined by the optical engineer • Deformation of support structure for optics is within tolerance and creates no interference • No yielding through cross section of part • No ultimate failures occur Raytheon Seekers

27. Analysis Focus • Static Analysis • Pin joint withstands launch accelerations • Arm deflection does not produce ultimate failure • Dynamic Analysis • Solenoid and spring actuation times • Verification of solenoid adequacy Raytheon Seekers

28. Finite Element Analysis • COSMOS/M • 3-D 20 Noded Quadrilateral Elements • Body (Acceleration) Load • Modeled Positioning Arm & Components • 7075-T6 Al Arm • Germanium Lens • Oilite Brass Bushing • Tungsten Counterweight • Material properties specified for each component Raytheon Seekers

29. FEA Mesh

30. Von Mises Stress Plot smax = 80.3 ksi F.S. = 1.03 Does Not Yield Through Cross-Section Raytheon Seekers

31. Adams software used for dynamic analysis w.r.t. arm rotation Employed actual solenoid force function curve and spring force Analysis Performed: Actuation & return times Forces due to snubbing of arm rotation Verification of solenoid strength sufficiency over entire actuation distance Dynamic Analysis Raytheon Seekers

32. Actuation time = 0.027 sec Spring Return = 0.028 sec Adams Simulation

33. Prototype Cost Cost Per Unit $ 341.96 Raytheon Seekers

34. Total Project Spending Raytheon Seekers

35. Project Budget • Provided Funds by Raytheon • $ 3,000 • Total Project Spending • $ 1,906 • Donation to the College of Engineering & Technology • $ 1,094 Raytheon Seekers

36. Time Log Total Project Hours for Spring Semester 684.5 hrs Avg. Hours Per Team Member: 136.9 hrs Raytheon Seekers

37. Conclusion • The balanced swing arm design is simple and efficient in providing the required lens motion while withstanding the environmental constraints • A prototype that meets project specifications will be delivered to Raytheon on time and within budget Raytheon Seekers

38. Acknowledgements • Brian Scott • Raytheon Missile Systems • Dr. Ernesto Penado, Advisor • Dr. David E. Hartman, P.E. • Dr. John Tester • NAU Machine Shop • Don McCallum, Daniel, & Rus Raytheon Seekers

39. Questions?