Post on 30-Dec-2015
STARLight PDR 3 Oct ‘01 F.1.1 Rashid
STARLightSTARLight
STARLight Mechanical
Tahir Rashid
STARLight Mechanical Engineer
(734) 764-7210
trashid@umich.edu
STARLight PDR 3 Oct ‘01 F.1.2 Rashid
STARLightSTARLightMechanical Requirements
• Mechanical Requirements– Instrument to be used on Husky A-1B aircraft (or similar)
– Low weight (Must be within allowable aircraft weight & c.g balance)
– Structural integrity
– Maintainability (Easy field replacements)
– Antenna dipoles must point in the same direction and be placed in a Y-arrangement
– Antenna spacing must be 0.68 = 5.6”
– Height of sensor module < 9” to avoid interference with ground and excessive aerodynamic drag
– Minimal interference between aircraft structure and antenna FOV
– Material selection with appropriate heat transfer properties
– Moisture control
– Simple and cost-effective
STARLight PDR 3 Oct ‘01 F.1.4 Rashid
STARLightSTARLightSensor Module Design & Structure
• Dwg#: 086-0045 X5
STARLight PDR 3 Oct ‘01 F.1.5 Rashid
STARLightSTARLightSensor Module Section
• Dwg#: 086-0046 X5 (Exploded View)
STARLight PDR 3 Oct ‘01 F.1.6 Rashid
STARLightSTARLightSensor Module Section
• Dwg#: 086-0046 X5 (Top & Side View)
STARLight PDR 3 Oct ‘01 F.1.7 Rashid
STARLightSTARLightSensor Module Section
• Dwg#: 086-0046 X5 (Side View)
STARLight PDR 3 Oct ‘01 F.1.8 Rashid
STARLightSTARLightY-Thermal Plate / Manifold
• Dwg#: 086-0078 X1
STARLight PDR 3 Oct ‘01 F.1.9 Rashid
STARLightSTARLightControl Module Design & Structure
• Dwg#: 086-0050 X2
STARLight PDR 3 Oct ‘01 F.1.10 Rashid
STARLightSTARLightStructural Analysis Plans
• Preliminary aerodynamic load analysis (Doc#: 086-0067X1)
• Results indicate profile drag force of 130lbf (500N) with sensor height=5.7” (7° tilt w.r.t ground)
0 2 4 6 8 100
50
100
150
200
Sensor Height (in)
Pro
file
Dra
g (
lbf)
D h( )
lbf
h
in
D h( )
lbf
STARLight PDR 3 Oct ‘01 F.1.11 Rashid
STARLightSTARLightStructural Analysis Plans
• Perform a complete finite-element structural analysis using FEMAP
• Static analysis will provide– Confidence in structural design
– Confidence in material selection
– High stress concentration areas
– Undesirable structural deflections
– Areas of improvement (if necessary)
• Vibration analysis will provide– Fundamental frequencies of structure.
STARLight PDR 3 Oct ‘01 F.1.12 Rashid
STARLightSTARLightWeight Estimate Summary
• Doc# 086-0068X2 (10% Margin)Description
Unit Mass[lb]
Quantity
Sub-Assembly
Mass[lb]
Total Mass
[lb]
Sensor Module73.620
Receiver Module 1.516 10 15.160
DA Module 0.500 10 5.000
Antenna 0.507 10 5.070
Sensor Board Components 5.290 1 5.290
Dewar & IR Profiler 0.950 1 0.950
Y-Thermal Plate 33.900 1 33.900
Hex Rings 0.440 10 4.400
Other Structure 4.050 1 4.050
Control Module 63.400
Microprocessor Assembly 5.510 1 5.510
Power Supply 4.410 1 4.410
Refrigeration Kit 38.000 1 38.000
Thermal Control System (Plumbing, valves, etc)
11.000 1 11.000
Pilot Control Box4.410 1 4.410
Total 137.120
STARLight PDR 3 Oct ‘01 F.1.13 Rashid
STARLightSTARLightWeight Estimate Summary
Allowable Weights
50
100
150
200
250
45 55 65 75 85 95 105
Sensor Weight (lbs)
Co
ntr
ol M
od
We
igh
t (l
bs
)
X
STARLight PDR 3 Oct ‘01 F.1.14 Rashid
STARLightSTARLightSchedule (Efforts to CDR)
• Prototype design of Receiver/DA assembly (Mechanical parts only)
– Complete detail level drawings for 2-channel prototype (10/26/01)
– In-house manufacturing of assemblies (11/09/01)
• Detail level drawings for complete sensor assembly (flight hardware)
– Will depend upon: Receiver component layout A/D component layout Antenna design details Dewar assembly configuration
– Can be completed 4 weeks after above items have been finalized
STARLight PDR 3 Oct ‘01 F.1.15 Rashid
STARLightSTARLightSchedule (Efforts to CDR)
• Mechanical detail level drawings for :
– Control Module (01/11/01)
– Pilot Control Box (01/31/01)
– Mechanical GSE (02/08/01)
• Complete Structural Analysis (12/14/01)
• Update Mechanical ICD (Doc#: 086-0003) (02/08/01)
• Update Weight Report (Doc#: 086-0068) (02/08/01)