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Raytheon Seekers 1
Design Review
Raytheon Seekers
Raytheon Seekers 2
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 3
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
Raytheon Seekers 4
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
Raytheon Seekers 5
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
Raytheon Seekers 6
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
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Seeker Device Layout
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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
Raytheon Seekers 9
Launch Conditions
•Set Back: 10,000G
•Balloting: 3,300G
•Set Forward: 2,000G
Flight Conditions
•Lateral: 0-3G
•Vibration: 5G
Shock Response Spectra
Raytheon Seekers 11
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
Raytheon Seekers 12
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
Raytheon Seekers 13
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
Raytheon Seekers 14
Design Evolution
• Design One
– Two solenoids
– Sliding rails
– Return spring
• Design Problems
– Large actuation distance
– Unnecessary parts
– Space limitation
Raytheon Seekers 15
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
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Selected Design
• Design Three
– Solenoid
– Arm
– Mid-arm pin position
– Spring return
– Deflection supports
– Counterweight
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Component Selection
• Solenoid – PO-6 3Volt
• Arm – 7075 T6 Aluminum
• Pin – Stainless Steel with bronze bushing
• Frame –Ti-6A1-4V HT-46
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Selected Solenoid
• Meets necessary criteria:
- Dimensions
- Actuation Length
- Forces
- Power Requirements
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Selected Solenoid (cont.)
Full Arm Swept Angle:53 Degrees
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Arm Design
Raytheon Seekers 21
Pin Connection Design
PIN
BUSHING FRAME PLATE
ARM
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Frame Design
Raytheon Seekers 23
Modeling
• Made actual size
cardboard and CAD
models to assess
the fit of components
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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%
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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
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Analysis (cont.)
Adams – Arm actuation time
Full Arm Swept Angle:53 Degrees
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Future Tasks
• Component FEA analysis
• Pin press fit calculations
• Order materials
• Fabrication
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Remaining Project Plan Spring 2003
• Status Report #3 March 27• Prototype Complete April 12• Test in Rail Gun April 15• Design Presentation April 22• Capstone Conference April 25• Finalize Web Page and Report May 2
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Project Funding
• Raytheon provided $3,000 for project costs– Prototype $1900– Travel Expenses $500– Documentation Material $500– Modeling $100
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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
Raytheon Seekers 31
Time Log
• Aaron Scrignar 71.95• Eric Draves 71.00• Trevor Moody 43.25• Stacy Snyder 32.55• LaTanya Williams 39.75
_________________________
Total Hours: 258.5 hrs
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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
Raytheon Seekers 33
Questions?