Adjunct Missile Seeker Deployment Mechanism Design Review.

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


OutlineOutline

• Introduction• Requirements• Design Overview• Trade Studies• Software Subsystem Design• Interfaces• Analysis• Requirements Review


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


Concept of OperationConcept of Operation

• The IR seeker will only be deployed during the terminal phase of flight


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


RequirementsRequirements

• System must adhere to these specific requirements. – Physical Properties– Dome Properties– Environmental Concerns– Electrical Constraints – Performance


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 %


Design OverviewDesign Overview

Our mechanism will be located near the front of the missile and fit into the allotted space specified by the customer.


Design Overview (cont)Design Overview (cont)

• Our design is a spring driven slide rail system


SubsystemsSubsystems

• Assembly: Seeker deployment mechanism– Three Main Subsystems

• Door Mechanism• Deployment Mechanism• Electronics


Door MechanismDoor Mechanism

• Shape and size of door


Door MechanismDoor Mechanism


Deployment Mechanism Deployment Mechanism ComponentsComponents

Driving SpringDampener


Slide TrackSlider

Deployment Mechanism Deployment Mechanism ComponentsComponents

Mounting Bracket


Mechanism AssemblyMechanism Assembly

Allotted space for design



Sliding rail



Slider



Seeker mountedto slider



Brace for spring and dampener



Damping unit



Spring Driver


Deployed StateDeployed State


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


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


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


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


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)


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


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


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


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


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


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


Internal Structural AnalysisInternal Structural Analysis

• Finite element computer modeling is used to ensure assemblies will support loading requirements

• Goal: Factor of Safety > 1.5


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


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


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


Future OutlookFuture Outlook

• Further development of– Seeker shroud– Indexing feature– Spring release mechanism– Door release mechanism

• Maintain focus on– High risk areas


Questions?Questions?


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


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


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


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


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


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

John Doe

TJ's input...


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

John Doe

TJ's input...


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

John Doe

TJ's inserts...


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


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


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


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


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.)


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



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


Adjunct Missile Seeker Deployment Mechanism Design Review.

Documents

Transcript of Adjunct Missile Seeker Deployment Mechanism Design Review.