1. Raytheon Seekers1 Design Review Raytheon Seekers

2. 2 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 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

4. Raytheon Seekers4 More about… 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

5. Raytheon Seekers5 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

6. Raytheon Seekers6 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

7. Raytheon Seekers7 Seeker Device Layout

8. Raytheon Seekers8 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

9. Raytheon Seekers9

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

11. Raytheon Seekers11 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

12. Raytheon Seekers12 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

13. Raytheon Seekers13 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

14. Raytheon Seekers14 Design Evolution Design One –Two solenoids –Sliding rails –Return spring Design Problems –Large actuation distance –Unnecessary parts –Space limitation

15. Raytheon Seekers15 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

16. Raytheon Seekers16 Selected Design Design Three –Solenoid –Arm –Mid-arm pin position –Spring return –Deflection supports –Counterweight

17. Raytheon Seekers17 Component Selection Solenoid – PO-6 3Volt Arm – 7075 T6 Aluminum Pin – Stainless Steel with bronze bushing Frame –Ti-6A1-4V HT-46

18. Raytheon Seekers18 Selected Solenoid Meets necessary criteria: - Dimensions - Actuation Length - Forces - Power Requirements

19. Raytheon Seekers19 Selected Solenoid (cont.) Full Arm Swept Angle: 53 Degrees

20. Raytheon Seekers20 Arm Design

21. Raytheon Seekers21 Pin Connection Design PIN BUSHINGFRAME PLATE ARM

22. Raytheon Seekers22 Frame Design

23. Raytheon Seekers23 Modeling Made actual size cardboard and CAD models to assess the fit of components

24. Raytheon Seekers24 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%

25. Raytheon Seekers25 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

26. Raytheon Seekers26 Analysis (cont.) Adams – Arm actuation time Full Arm Swept Angle: 53 Degrees

27. Raytheon Seekers27 Future Tasks Component FEA analysis Pin press fit calculations Order materials Fabrication

28. Raytheon Seekers28 Remaining Project Plan Spring 2003 Status Report #3March 27 Prototype CompleteApril 12 Test in Rail Gun April 15 Design PresentationApril 22 Capstone ConferenceApril 25 Finalize Web Page and ReportMay 2

29. Raytheon Seekers29 Project Funding Raytheon provided $3,000 for project costs –Prototype $1900 –Travel Expenses$500 –Documentation Material$500 –Modeling$100

30. Raytheon Seekers30 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

31. Raytheon Seekers31 Time Log Aaron Scrignar71.95 Eric Draves71.00 Trevor Moody43.25 Stacy Snyder32.55 LaTanya Williams39.75 _________________________ Total Hours: 258.5 hrs

32. Raytheon Seekers32 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

33. Raytheon Seekers33 Questions?