Raytheon Seekers Infrared Seeker Calibration Mechanism Raytheon

Raytheon Seekers Infrared Seeker Calibration Mechanism Raytheon Seekers 1

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 2

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 3

More about Raytheo One of the largest defense electronicsn 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 4

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 5

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 NonUniformity Compensation. Raytheon Seekers 6

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 7

What Is Infrared Imaging 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 Raytheon Seekers 8

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 9

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 Blurred IR Image with Lens in Position Raw IR Image before NUC Raytheon Seekers

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

Seeker Head Layout Raytheon Seekers

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

Acceleration Time Histories Raytheon Seekers 14

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

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 16

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 17

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 18

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

Final Design

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

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

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 23

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

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

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 26

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 27

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 28

FEA Mesh

Von Mises Stress Plot max 80.3 ksi F.S. 1.03 Does Not Yield Through Raytheon SeekersCross-Section 30

Dynamic Analysis 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 Raytheon Seekers 31

Adams Simulation Actuation time 0.027 sec Spring Return 0.028 sec

Prototype Cost Machine Work & Parts Frame (2) Arm (2) Pin & Bushing (2) Solenoids (14) Solenoid Screws (144) Miscellaneous (Spring, Wire, etc.) 450.00 115.00 89.92 24.00 5.00 TOTAL Cost Per Unit 683.92 341.96 Raytheon Seekers 33

Total Project Spending Modeling Supplies 42.00 Prototype Cost 683.92 Documentation 400.00 Presentation Supplies 50.00 Travel & Miscellaneous 730.00 TOTAL Raytheon Seekers 1,905.92 34

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

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

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 37

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 38

Questions?