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Raytheon Seekers1 Infrared Seeker Calibration Mechanism.

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Presentation on theme: "Raytheon Seekers1 Infrared Seeker Calibration Mechanism."— Presentation transcript:

1 Raytheon Seekers1 Infrared Seeker Calibration Mechanism

2 Raytheon Seekers2 Aaron Scrignar……Team Leader Eric Draves………..Historian Trevor Moody…….Web Page Des., Mediator Stacy Davison……..Document Coord., Financial Officer LaTanya Williams…Communicator

3 Raytheon Seekers3 Presentation Outline Client Description Problem Definition What is Infrared Imaging? Project Requirements Design Method Prototype Design Analysis Process Project Spending Time Log Conclusion

4 Raytheon Seekers4 More about… 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

5 Raytheon Seekers5 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

6 Raytheon Seekers6 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.

7 Raytheon Seekers7 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

8 Raytheon Seekers8 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

9 Raytheon Seekers9 Infrared Seeker Operation Modern “Heat Seekers”: –Employ advanced infrared sensor arrays –Utilize computer programs to select, target, and guide munitions towards specific images

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

12 Seeker Head Layout Raytheon Seekers

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

14 Raytheon Seekers14 Acceleration Time Histories

15 Raytheon Seekers15 Launch Conditions –Set Back 10,000G –Set Forward 2,000G –Lateral Balloting 3,300G Flight Conditions –Lateral: 0-3G –Vibration: 5G Acceleration Definition Set Back Lateral Balloting Set Forward

16 Raytheon Seekers16 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

17 Raytheon Seekers17 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

18 Raytheon Seekers18 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

19 Raytheon Seekers19 Final Design Frame Solenoid Positioning Arm Pin Bushing Return Spring

20 Final Design

21 Raytheon Seekers21 Frame Design Frame supports components and other seeker optics –Modified to eliminate unnecessary weight –Recessed regions for return spring and counterweight clearance

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

23 Raytheon Seekers23 Selected Solenoid 3 V DC 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)

24 Positioning Arm –7075-T6 Aluminum –S ult = 82.7 ksi Pin –AISI 4130 Steel –S ult = 106 ksi Bushing –Oilite Bronze - Oil Impregnated –Self Lubricating Bushing

25 Raytheon Seekers25 Pin Connection Design Press Fit Withstands 120lb Vertical Force

26 Raytheon Seekers26 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

27 Raytheon Seekers27 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

28 Raytheon Seekers28 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

29 FEA Mesh

30 Raytheon Seekers30 Von Mises Stress Plot  max = 80.3 ksi F.S. = 1.03 Does Not Yield Through Cross-Section

31 Raytheon Seekers31 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

32 Adams Simulation Actuation time = sec Spring Return = sec

33 Raytheon Seekers33 Prototype Cost Machine Work & Parts Frame (2) Arm (2) Pin & Bushing (2) Solenoids (14) Solenoid Screws (144) Miscellaneous (Spring, Wire, etc.) $ $ - $ $ $ $ 5.00 TOTAL$ Cost Per Unit $

34 Raytheon Seekers34 Total Project Spending Modeling Supplies $ Prototype Cost $ Documentation $ Presentation Supplies $ Travel & Miscellaneous $ TOTAL $1,905.92

35 Raytheon Seekers35 Project Budget Provided Funds by Raytheon –$ 3,000 Total Project Spending –$ 1,906 Donation to the College of Engineering & Technology –$ 1,094

36 Raytheon Seekers36 Time Log Total Project Hours for Spring Semester hrs Avg. Hours Per Team Member: hrs

37 Raytheon Seekers37 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

38 Raytheon Seekers38 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

39 Questions?


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