Post on 20-Jan-2016
Adjunct Missile Seeker Adjunct Missile Seeker Deployment MechanismDeployment Mechanism
Design Review
Adjunct Missile Seeker Deployment Mechanism 2
RF2IR Team MembersRF2IR Team Members• Ryan Moore
– Mechanical Engineering• Scott Nielsen
– Optical Sciences• Karl Heiman
– Aerospace Engineering • Philip Pierson
– Optical Sciences• David Kraemer
– Electrical Engineering• Thomas Jefferson
– Material Sciences
• Brian Perona– Raytheon Missile Systems– Project Sponsor
• Dr. Larry Sobel– AME Department– Faculty Advisor
• Charles Hodges– Project Mentor
Adjunct Missile Seeker Deployment Mechanism 3
OutlineOutline
• Introduction• Requirements• Design Overview• Trade Studies• Software Subsystem Design• Interfaces• Analysis• Requirements Review
Adjunct Missile Seeker Deployment Mechanism 4
Project OverviewProject Overview
Raytheon Missile Systems– Designs, develops, and produces critical
missile systems for national defense
Project motivation– Enable a missile to utilize long range strike
capability of radar frequency (RF) guided systems with the precision of infrared (IR) guided systems with little drag penalty
Adjunct Missile Seeker Deployment Mechanism 5
Concept of OperationConcept of Operation
• The IR seeker will only be deployed during the terminal phase of flight
Adjunct Missile Seeker Deployment Mechanism 6
Project StatementProject Statement
• Design an adjunct seeker deployment mechanism (ASDM)– Mechanism will be deployed on a proven
missile design– Seeker will deploy during the terminal flight
phase– Design shall minimize impacts to existing
system
Adjunct Missile Seeker Deployment Mechanism 7
RequirementsRequirements
• System must adhere to these specific requirements. – Physical Properties– Dome Properties– Environmental Concerns– Electrical Constraints – Performance
Adjunct Missile Seeker Deployment Mechanism 8
Major Design ConstraintsMajor Design ConstraintsProperty Value UnitLength 4 inchesDiameter 8 inchesWeight 1 lbsOperational Temperature ITARFlight Speed ITARStorage Life ITARAvailable power ITARDeployment Time ITARDeployed Time ITARDeployment Shock ITARReliability 99.99967 %
Adjunct Missile Seeker Deployment Mechanism 9
Design OverviewDesign Overview
Our mechanism will be located near the front of the missile and fit into the allotted space specified by the customer.
Adjunct Missile Seeker Deployment Mechanism 10
Design Overview (cont)Design Overview (cont)
• Our design is a spring driven slide rail system
Adjunct Missile Seeker Deployment Mechanism 11
SubsystemsSubsystems
• Assembly: Seeker deployment mechanism– Three Main Subsystems
• Door Mechanism• Deployment Mechanism• Electronics
Adjunct Missile Seeker Deployment Mechanism 12
Door MechanismDoor Mechanism
• Shape and size of door
Adjunct Missile Seeker Deployment Mechanism 13
Door MechanismDoor Mechanism
Adjunct Missile Seeker Deployment Mechanism 14
Deployment Mechanism Deployment Mechanism ComponentsComponents
Driving SpringDampener
Adjunct Missile Seeker Deployment Mechanism 15
Slide TrackSlider
Deployment Mechanism Deployment Mechanism ComponentsComponents
Mounting Bracket
Adjunct Missile Seeker Deployment Mechanism 16
Mechanism AssemblyMechanism Assembly
Allotted space for design
Adjunct Missile Seeker Deployment Mechanism 17
Mechanism AssemblyMechanism Assembly
Sliding rail
Adjunct Missile Seeker Deployment Mechanism 18
Mechanism AssemblyMechanism Assembly
Slider
Adjunct Missile Seeker Deployment Mechanism 19
Mechanism AssemblyMechanism Assembly
Seeker mountedto slider
Adjunct Missile Seeker Deployment Mechanism 20
Mechanism AssemblyMechanism Assembly
Brace for spring and dampener
Adjunct Missile Seeker Deployment Mechanism 21
Mechanism AssemblyMechanism Assembly
Damping unit
Adjunct Missile Seeker Deployment Mechanism 22
Mechanism AssemblyMechanism Assembly
Spring Driver
Adjunct Missile Seeker Deployment Mechanism 23
Deployed StateDeployed State
Adjunct Missile Seeker Deployment Mechanism 24
Trade StudiesTrade Studies
• The following trade studies were completed to achieve this design– Structural Materials – Dome Materials– Door Mechanism– Electrical Sensor Types– Drive/Actuation Devices
Adjunct Missile Seeker Deployment Mechanism 25
Trade Studies (Cont.)Trade Studies (Cont.)
• Following slides present an example of the decision matrix used and the results of the various trade studies
• Finer details are available during the questioning session
Adjunct Missile Seeker Deployment Mechanism 26
Structural MaterialsStructural Materials
• Chosen material: Ti 6Al-4V– Based on availability and decision matrix ranking
Criterion TotalWeight 100%
Material Rank Weight Rank Weight Rank Weight Rank Weight Rank WeightAl 2024-T6 7 2.45 6 1.2 4 1 12 1.2 6 0.6 6.45Al 6061-T6 6 2.1 3 0.6 2 0.5 10 1 6 0.6 4.8Al 7075-T6 10 3.5 4 0.8 2 0.5 9 0.9 6 0.6 6.3Al 356 5 1.75 5 1 5 1.25 10 1 6 0.6 5.6Mg AZ80A-T5 9 3.15 2 0.4 1 0.25 13 1.3 5 0.5 5.6Ti-13V-11Cr-3Al 12 4.2 8 1.6 10 2.5 2 0.2 2 0.2 8.7Ti-13V-2.7Al-7Sn-2Zr 13 4.55 7 1.4 12 3 2 0.2 2 0.2 9.35Ti 6Al-4V 11 3.85 9 1.8 11 2.75 2 0.2 2 0.2 8.8SS 304 1 0.35 10 2 6 1.5 6 0.6 10 1 5.45SS 416 2 0.7 11 2.2 9 2.25 8 0.8 10 1 6.95SS 430 4 1.4 11 2.2 8 2 6 0.6 10 1 7.2SS 17-7PH 8 2.8 13 2.6 7 1.75 5 0.5 10 1 8.65C-C composite 3 1.05 1 0.2 13 3.25 1 0.1 1 0.1 4.7
Cost35% 20% 25% 10% 10%
Specific σy Etensile
Thermal Expansion Machinability
Adjunct Missile Seeker Deployment Mechanism 27
Trade Studies ResultsTrade Studies Results• Dome Material
– Sapphire
• Door Mechanism– Torsion spring ejection
• Electrical Sensors– Microcontroller: TI MSP430F167– Position sensor: Honeywell SS46– Temperature sensor: TI TMP123
• Drive Actuation– Linear spring with damper
Adjunct Missile Seeker Deployment Mechanism 28
Software Subsystem DesignSoftware Subsystem Design
• Software Modules– Primary Deployment Module (PDM)
• Manages deployment sequence and error procedures, sends seeker deployment complete to circuit cards (120 Lines of code)
– Temperature Sensor Module (TSM)• Reads missile temperature to load calibration data (40 Lines)
– Door Actuation Module (DAM)• Manages door deployment sequence and indicate (80 Lines)
– Seeker Actuation Module (SAM)• Manages seeker deployment sequence and indicate
(80 Lines)
Adjunct Missile Seeker Deployment Mechanism 29
Software Flow DiagramSoftware Flow Diagram
TSMActivation
Signal Recieved
Yes
No → Wait
Stored Calibration
Data
DAM
SAMDoor Released
YesNo
Seeker Indexed
Circuit Cards Read Seeker
DataYes No
Loop Limit 2
No
Send Seeker Failure to
Circuit Cards
Yes
Loop Limit2
No
Yes
Load Data
PDMPrimary Deployment Module
Adjunct Missile Seeker Deployment Mechanism 30
InterfacesInterfaces
• Physical Interfaces– Seeker Analog and Digital Connectors– Sensor connections to microcontroller (μC)
• Software Interfaces– Variables passed from TSM, DAM, and SAM
to PDM• Temperature, Door_Eject_Ind, Seeker_Index_Ind
– Stored calibration data passed to μC
Adjunct Missile Seeker Deployment Mechanism 31
Design Space AnaysisDesign Space Anaysis
• Tin cans, a cardboard tube, and a wood block were modified to approximate the final system
Seeker 1
Seeker 2
Seeker 3
Adjunct Missile Seeker Deployment Mechanism 32
Aerodynamic AnalysisAerodynamic Analysis
• Flow properties at pt. 1 are given by Raytheon
• Flow properties at pt. 2 are determined using shock tables
• Results flow into dome analysis and force analysis
12
Adjunct Missile Seeker Deployment Mechanism 33
Optical AnalysisOptical Analysis
• An analysis will be done to determine the amount of defocus provided by the additional dome
• This defocus must be within the limits of the provided seeker
Adjunct Missile Seeker Deployment Mechanism 34
Force AnalysisForce Analysis
• System input:– Aerodynamic forces – Frictional constants
• System outputs:– Required structural
stresses– Actuation force– Clamping force
Seeker
Faero,x
Faero,y
Factuation
Ffriction
Mstructure
Adjunct Missile Seeker Deployment Mechanism 35
Internal Structural AnalysisInternal Structural Analysis
• Finite element computer modeling is used to ensure assemblies will support loading requirements
• Goal: Factor of Safety > 1.5
Adjunct Missile Seeker Deployment Mechanism 36
Requirements ReviewRequirements ReviewProperty Value Unit RiskLength 4 inches moderateDiameter 8 inches lowWeight 1 lbs highOperational Temperature ITAR moderateFlight Speed ITAR moderateStorage Life ITAR lowAvailable power ITAR moderateDeployment Time ITAR moderateDeployed Time ITAR lowDeployment Shock ITAR highReliability 99.99967 % moderate
Adjunct Missile Seeker Deployment Mechanism 37
Risk MitigationRisk Mitigation
• Weight– Parametric design using removal of material
while maintaining structural integrity– Possibly using chassis design of another
team to save weight– If necessary use higher cost materials with
higher specific strength
Adjunct Missile Seeker Deployment Mechanism 38
Risk MitigationRisk Mitigation
• Deployment Shock– Addition of dampeners
• Damping materials• Dashpot• Eddy current dampener
– Additional EM field issues
– Shock isolator• Increases deployment time
– Optimize spring coefficient
Adjunct Missile Seeker Deployment Mechanism 39
Future OutlookFuture Outlook
• Further development of– Seeker shroud– Indexing feature– Spring release mechanism– Door release mechanism
• Maintain focus on– High risk areas
Adjunct Missile Seeker Deployment Mechanism 40
Questions?Questions?
Adjunct Missile Seeker Deployment Mechanism 41
Physical PropertiesPhysical Properties
Ex: The outer missile body diameter is 8 in.
ID Metric Maximum Desired Units1 System Weight 2.5 <2.5 lbs2 - Seeker Weight 1 1 lbs3 - Cryogenics Weight 0.5 0.5 lbs4 - Dome Weight 5 3.5 oz5 - Structure Weight TBD TBD lbs6 - Motive Weight TBD TBD lbs7 Length 4 + Δ 4 in8 Diameter 8 8 in9 Available X-section hemisphere
ITA
R
Adjunct Missile Seeker Deployment Mechanism 42
Dome PropertiesDome Properties
E.g. The dome must be transparent to EM radiation with a
wavelength (λ) between 3 to 6 microns.
ID Metric Maximum Desired Units1 Defocus ?2 Transparency 3-6 μm3 FOR ±35 deg4 Thermal Loading C5 Mechanical Loading psiIT
AR
Adjunct Missile Seeker Deployment Mechanism 43
Environmental ConcernsEnvironmental Concerns
Ex: The system may be stored for up to a maximum of 10 yrs., or may be used immediately.
ID Metric Maximum Minimum Units1 Storage Life 10 0 year2 Launch Temperature 60 -45 C3 Storage Temperature 85 -65 C4 Stagnation Temp. C5 Atmospheric Temp. C6 Atmospheric Pressure atms.7 Altitude ft.8 Humidity %9 Climate, Dry n/a10 Distance of Flight ft.11 Visibility %12 Velocity 1875 1777 mph
35025
105,600100
1.0020,0000.00
const.ITA
R
Adjunct Missile Seeker Deployment Mechanism 44
Electrical ConstraintsElectrical Constraints
Ex: The system shall use less than 100 Watts max of power during deployment.
ID Metric Maximum Desired Units1 Deployment Wattage 100 90 W2 Static Wattage 3 to 4 3 W3 Voltage 28 28 V4 Input Signal5 Feedback Signal
TBDTBDIT
AR
Adjunct Missile Seeker Deployment Mechanism 45
PerformancePerformance
Ex: The seeker must survive deployed flight conditions for maximum of 25 sec.
ID Metric Maximum Desired Units1 Deployed Time 25 25 sec2 Deployment Time 500 400 ms3 Deployment Shock 40 <40 g4 Shock Duration 3 ms5 Shock Type6 Flight Speed 3 Mach
1/2 sine pulseITA
R
Adjunct Missile Seeker Deployment Mechanism 46
Dome Materials Con’tDome Materials Con’t
• Ex: Weight Characteristic Matching of Materials
Strength Thermal Expansion Poisson's Ratio "of strain rate"
10% 5% 10%
Material(s) (MPa) Rank Wtd. (1/K) Rank Wtd. Unitless # Rank Wtd.
Sapphire 400 5 0.50 5.30E-06 5 0.25 0.27 5 0.50
ALON 300 4 0.40 7.80E-06 3 0.15 0.24 3 0.30
Y2O3 125 2 0.20 7.10E-06 4 0.20 0.29 6 0.60
MgAl2O4 190 3 0.30 8.00E-06 2 0.10 0.26 1 0.10
MgF2 52 1 0.10 1.37E-05 1 0.05 0.27 4 0.40
Diamond 1000 6 0.60 1.00E-06 6 0.30 0.16 2 0.20
Adjunct Missile Seeker Deployment Mechanism 47
Dome Materials Con’tDome Materials Con’tThermal Conductivity Elastic Modulus Hardness Refractive Index Total:
10% 20% 10% 35% 100%
(W/mK) Rank Wtd. (GPa) Rank Wtd. (kg/mm2) Rank Wtd. n Rank Wtd.
34 2 0.20 380 5 1.00 1800 4 0.4 1.7 4 1.4 4.25
11 5 0.50 317 4 0.80 1970 5 0.5 1.6 5 1.75 4.40
14 4 0.40 164 1 0.20 650 2 0.2 1.9 2 0.7 2.50
15 3 0.30 193 3 0.60 1645 3 0.3 1.7 3 1.05 2.75
0.25 6 0.60 139 2 0.40 415 1 0.1 1.3 6 2.1 3.75
2000 1 0.10 1050 6 1.20 9000 6 0.6 2.4 1 0.35 3.35
Note:In the tables you will see that colors green, yellow, and red. Red denotes high risk material to use for application.Yellow denotes border line risk material.Green denotes least possible risk material.
Chosen material: Sapphire due to widespread use by industry
Adjunct Missile Seeker Deployment Mechanism 48
Door Ejection Method Con’tDoor Ejection Method Con’t
• Requirement– Use dead bolt locking system to hold down door during flight
before acquire phase.Fig. 2: Side View of Door
Adjunct Missile Seeker Deployment Mechanism 49
Microcontroller TypeMicrocontroller TypeCriterionWeight
Signal Generator Yes/No Rank Wtd. [kb] Rank Wtd. [MHz] Rank Wtd. Yes/No Rank Wtd.TI MSP430F167 Yes 1 0.1 32 1 0.1 8 1 0.1 Yes 1 0.15NS CR16MCS9VJE7 Yes 1 0.1 64 2 0.2 16 2 0.2 Yes 1 0.15CriterionWeight
Signal Generator [W] Rank Wtd. Yes/No Rank Wtd. [$] Rank Wtd. [°C] Rank Wtd.MP430F167 1.1m 1 0.1 Yes 2 0.2 11.28 2 0.1 -40-85 1 0.15NS CR16MCS9VJE7 1.1m 1 0.1 No 1 0.1 15 1 0.05 -40-125 2 0.3Criterion TotalWeight 100%
Signal Generator [oz] Rank Wtd.MP430F167 < 2 0.3 1.3NS CR16MCS9VJE7 > 1 0.15 1.35
15%
15%
10% 10% 5% 15%
Weight
10% 10% 10%
Power Consumed TI Device Cost Operating Temperature
ADC Converter Memory Size Speed External Devices
• Chosen Microcontroller: TI MSP430F167– Based on overall ranking and secondary requirements
Adjunct Missile Seeker Deployment Mechanism 50
Position SensorPosition Sensor
• Chosen position sensor: Honeywell SS46– Highest decision matrix overall rating
CriterionWeight
Sensor [in] Rank Wtd. [in 3̂] Rank Wtd. [oz] Rank Wtd. [°C] Rank Wtd.Honeywell SS46 0.002 2 0.4 4.7m 3 0.45 <1 3 0.6 -55 - 150 3 0.45Honeywell LTS04N04KB5C 0.008 1 0.2 1.08 2 0.3 1.52 2 0.4 -40 - 80 1 0.15Macro Sensors PR 750-2000 with LVC-2500 0.001 3 0.6 6.72 1 0.15 11.1 1 0.2 -55 - 105 2 0.3Criterion TotalWeight 100%
Sensor [W] Rank Wtd. Yes/NoRank Wtd. [$] Rank Wtd.Honeywell SS46 478m 2 0.3 No 1 0.1 2.16 3 0.15 2.45Honeywell LTS04N04KB5C 7.56m 3 0.45 No 1 0.1 20 2 0.1 1.7Macro Sensors PR 750-2000 with LVC-2500 1.6 1 0.15 No 1 0.1 120 1 0.05 1.55
Cost5%
Power Consumed15%
TI Device10%
20% 15% 20% 15%Accuracy Total Volume Weight Operating Temperature
Adjunct Missile Seeker Deployment Mechanism 51
Temperature SensorTemperature Sensor
CriterionWeight
Signal Generator Yes/No Rank Wtd. [sec] Rank Wtd. [°C] Rank Wtd. [oz] Rank Wtd.TI TMP123 Yes 1 0.1 0.5 1 0.1 2 1 0.1 = 1 0.15MAXIM DS620 Yes 1 0.1 0.2 2 0.2 0.5 2 0.2 = 1 0.15Criterion TotalWeight 100%
Signal Generator [W] Rank Wtd. Yes/No Rank Wtd. [$] Rank Wtd. [°C] Rank Wtd.TI TMP123 0.2m 2 0.2 Yes 2 0.2 2.48 1 0.05 -40-125 2 0.3 1.2MAXIM DS620 3.2m 1 0.1 No 1 0.1 1.66 2 0.1 0-70 1 0.15 1.1
Digital Interface Conversion Speed Accuracy Weight
Power Consumed TI Device Cost Operating Temperature
15%
10% 10% 5% 15%
10% 10% 10%
• Chosen Temperature Sensor: TI TMP123– Highest overall ranking
Adjunct Missile Seeker Deployment Mechanism 52
Drive / Actuation DevicesDrive / Actuation DevicesCriterionWeight
Mechanism [lb] Rank Wtd. [in^3] Rank Wtd. [lb] Rank Wtd.0.5" Diameter Spring* 36.2594 3 0.45 0.05 5 0.5 0.01 5 2.75Nema 14 Motor: part # [5014-820] 1 1 0.15 4.5 4 0.4 2.5 4 2.2Nema 17 Motor: part # [HT17-068] 1.5 2 0.3 5 2 0.2 3 2 1.1EN Series Pnumatic Actuator: part # [E-X0EQK-02l1B-ASA0]**106 4 0.6 5 2 0.2 3 2 1.1Hydraulic Actuator: part # [LH-NFPA]***1000 5 0.75 5.5 1 0.1 4 1 0.55
Criterion TotalWeight 80%
Mechanism [in/sec] Rank Wtd. [$] Rank Wtd.0.5" Diameter Spring* 90 4 0.4 0.05 5 0.5 4.6Nema 14 Motor: part # [5014-820] 1 1 0.1 100 4 0.4 3.25Nema 17 Motor: part # [HT17-068] 1 1 0.1 140 2 0.2 1.9EN Series Pnumatic Actuator: part # [E-X0EQK-02l1B-ASA0]**107 2 0.2 105.4 3 0.3 3.8Hydraulic Actuator: part # [LH-NFPA]***1 1 0.1 143 1 0.1 1.6
Deployment Speed Cost*10% 10%
Total Linear Force Volume (condensed.) Weight15% 10% 55%
• Chosen drive device: Spring– Highest overall ranking
Adjunct Missile Seeker Deployment Mechanism 53
TSMTemperature Sensor Module
Receive Activation from PDM
Activate Chip
Select on TMP123
Start Temperature
Sensing
Missile Power Applied
Output on SO pin
Determine Calibration
Data to Load from ROM
Ouput to PDM
Read Data on μC I/O
Port
Software Flow Diagram (Cont.)Software Flow Diagram (Cont.)
Adjunct Missile Seeker Deployment Mechanism 54
DAMDoor Actuation Module
Receive Sequence Start from
PDM
Produce Actuator Drive
Signal
Door Ejected
Yes
Door Indicate Change
Door IntactNo
Door Status
output to PDM
Load Calibration
Data
# Times Module Failed
EED Fire 1EED 1
DetonatedYes
EED 2 Detonated
No
Disable Squib 2
Software Flow Diagram (Cont.)Software Flow Diagram (Cont.)
Adjunct Missile Seeker Deployment Mechanism 55
SAMSeeker Actuation Module
Receive Sequence Start from
PDM
Produce Actuator Drive
Signal
Seeker Indexed
Yes
Seeker Indicate Change
Seeker Misaligned
No
Seeker Status
output to PDM
Load Calibration
Data
# Times Module Failed
EED Fire 1EED 1
DetonatedYes
EED 2 Detonated
No
Disable Squib 2
Software Flow Diagram (Cont.)Software Flow Diagram (Cont.)