Enhancing Dispenser System Function Using Electronic ...Electronics Development Corporation...
Transcript of Enhancing Dispenser System Function Using Electronic ...Electronics Development Corporation...
Electronics Development Corporation
Enhancing Dispenser System Function Using Electronic Safety and Arming
Technology
Rick Farris, KDI/L-3 CommunicationsRobert N. Johnson, Electronics Development
CorporationKen Yates, Area Attack System Program Office, Air Armament Center (AAC/YH)
NDIA 48th Annual Fuze Conference26-28 April 2004
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Outline
• Background• Requirements• Design Approach• Revised Design
– System– Safety– Electronics– Packaging
• Initial Results
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Existing TMD Fuze
• Photo slide from Ken Yates presentation at 3 April 2003 industry day
ClevisBattery
Safe & Arm
G-switchesSpin switches
(Not used by SFW)
Electronics
Option Switch
Pitot Tube
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Motivation for Fuze Modification
• Cost and price reduction– 20% increase had been projected for FY05
• Eliminate obsolete parts– 30 year old technology
• Improve reliability– 20 year life, cold temperature performance
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SFW TMD Fuze Modification Program
• Contract awarded 15 August 2003 by Air Armaments Center, Eglin AFB, Florida
• Prime contractor KDI/L-3 Communications– Electronics Development Corporation subcontractor for
design and development support
• Original plan to introduce in FRP-11 (FY06) production, since moved up to FRP-10 (FY05)
• Aggressive schedule:– Qual Tests 1Q05– Flight Tests 2Q05
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Requirements
• Functionally and physically interchangeable with the current fuze
• Producible and sustainable• Lower cost• Improved Reliability• Non-Nuclear Munitions Safety Board approval
(Systems Safety)
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Specification Summary
• SUU-64/B, SUU-65/B, and SUU-66/B• Optional FZU-39/B proximity sensor• Four modes:
– Time spin– Time non-spin– Proximity spin– Proximity non-spin
• Work if proximity selected but sensor not installed• Varied release conditions
– 200 – 40,000 feet– 120 KCAS no-arm, 195 KCAS all-arm with pitch and yaw
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Technical Approach
• Maintain existing interfaces to TMD, aircraft, and armaments technicians
• Replace obsolete and unreliable portions with current technology:– Electronic S&A Device (ESAD)– Pulse Generator– MEMS Accelerometer– MEMS Pressure Sensor
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Existing System Operation
OptionLanyard
ArmingLanyard
InitiateBattery
Remove 1stBarrier
Deploy Pitot
2.7 s ProxInhibit
Prox Sensor
ArmingDelay
DynamicPressure
Differential
2nd BarrierSpring
Fire BoltCutter
Release 2ndBarrier
Wait forSpin
Wait for Arm
FireDetonator
Committo Arm
23 ms max.(non-spin)
Pressurewithin 1 s
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Technical Uncertainties
• Simply replacing the mechanical timer with an electronic timer raises technical issues:– Thermal battery startup time for electronic timer– Safety / Arming environment sensing without power
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System Design Approach
• Retain– External configuration and interfaces– Thermal battery– Arming lanyard, battery striker, and Pitot deployment
hardware
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System Design Approach, con’t.
• Add– Tailored version of ESAD from SDB– LEEFI / stripline cable– Electromagnetic pulse generator to capture lanyard pull time
(launch environment)– Low power timer to provide accurate time indication until
battery power is available (timer T0)– Electronic pressure sensor for differential pressure (post-
launch environment)– Miniature solenoid valve to allow zero-compensating of the
pressure sensor once battery power is available– MEMS accelerometer for the spin sensor
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Block Diagram
Crystal Controlled IC
Sequential Verification LogicError Detection Logic
Dynamic Clock Driver LogicArm Delay Logic
RC Oscillator Controlled IC
Sequential Verification LogicError Detection Logic
Dynamic Clock Driver LogicArm Delay Logic
Serial A/DConverter 2
OptionSwitchOption Lanyard
PulseGenerator CounterArming Lanyard
(1st Environment)
Battery Power Filter
Arm Time Settings
Spin Settings
DifferentialPressureSensor
Total PressureStatic Pressure
Valve
Acceleration(Spin) Sensor
HighVoltageFlyback
DynamicSwitch
StaticSwitch 2
StaticSwitch 1
HighVoltage
Capacitor
HighVoltageSwitch
LEEFI
OutputLead
High Voltage Feedback
Fire Signal
Bolt FiringCircuit
ExplosiveBolts
ProxSensor
Interface
ProxSensor
Arm TimeSwitch
Spin Switch
ESAD
Regulation
Serial A/DConverter 1
SolenoidControl
DC/DCConverter
Serial A/DConverter
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Fuze Connector Pin AssignmentsJ1 Fuze Connector
Pin Old Function Proposed Function A Ground Ground B Test Point Bolt Capacitance Test Point Bolt Capacitance C Test Point Det Capacitance Test Point HV Monitor D Explosive Bolt Return (Ground) Explosive Bolt Return (Ground) E Explosive Bolt Return (Ground) Explosive Bolt Return (Ground) F Sensor Identification Sensor Identification G PROX Fire Signal PROX Fire Signal H Test Point P.A. Capacitance Test Point FCH J Test Point Option Switch Test Point FCL K + BAT V + BAT V L - BAT V - PROX V M + BAT V + PROX V N Test Point RPM Sensors Test Point Acceleration Input P Test Point S&A Arm Switch S11 Test Point Pressure Sensor R Explosive Bolt Output Explosive Bolt Output S Explosive Bolt Output Explosive Bolt Output T Test Point Function Switch S10 Test Point FSH U Test Point Barrier Enable Switch S8 Test Point FSL V Not Used Test Point Release Sensor
RED – Explosive Bolt BLUE – Prox Sensor
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Packaging Concept
• Surface mount ESAD components in hermetic package
• Pressure sensor, solenoid valve, and pulse generator in sealed fuze housing
• Flex circuit to interconnect between ESAD and:– fuze connector– arm time, spin, and option switches– release sensor– solenoid valve and pressure sensor
• LEEFI flex circuit
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Release Sensor
• Lack of power hampers transition detection• Must capture sequence and timing of release events• Must establish time zero for arming delay timers in
both ESAD ICs• Proper operation verified by both ESAD ICs
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Release Sensor
Q12 1
Q13 2
Q14 3
Q6 4Q5 5
Q7 6
Q4 7
GN
D8
Q1 9CLK10
RST11
Q9 12Q8 13
Q10 14
Q11 15
VD
D16
U254HC4020
TRA1
TRB2
CLR3 Q 4
Q 13
CTC14
RC COM15U1A
54HC123
Q 5
CTC6
RC COM7
TRA9
TRB10
CLR11 Q 12
U1B54HC123
C3 C4
L1
1
2
3
4
D1
C1
Vdeploy
Vdeploy
Vdeploy
R1 R2
Vdeploy
Vdeploy
R8
C5
Q1
Q2
Q3
Q4
Q5
C2R3
D2R4 R5 R6 R7
VCC
TIMER1
TIMER2
TIMER3
TIMER4
D3 R9
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Airspeed Sensor
• Retain current mechanism to deploy Pitot• Use solenoid valve to calibrate zero point
– Both ESAD ICs participate in valve operation
• Require correct change in ∆P with valve actuation– Both ESAD ICs validate pressure signal
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Airspeed Sensor “Plumbing”
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Air Speed Sensor Characteristics
• No-arm/All-arm taken from TMD Fuze Performance Specification:– 200 to 40,000 feet– No arm for release airspeeds below 120 KCAS– All arm for release airspeed above 195 KCAS– Above 300 KCAS release, pitch -30° to +10°, yaw ±30°– Below 300 KCAS release, initial transient AoA -25° to +10°
pitch, yaw ±25°– Must sense within 1 second or dud
• Using identical pressure probe and go/no-go limits as existing fuze
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Air Speed Sensor Pressure Limits
• No-arm/All-arm from TMD Fuze Item Specification:– Must not arm for sensed pressure less than 0.8 PSI (55
bar)– Must arm if the pressure is above 1.3 PSI (90 bar) for
longer than 10 ms
• Reset characteristics from 1980 Honeywell TMD Development Report:– Must remain armed unless the pressure falls below 0.4 PSI.– Must reset (disarm) if pressure falls below 0.3 PSI for more
than 10 ms
• Anticipate changing all-arm pressure to 1.0 PSI
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Pressure from 1980 TMD Report
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Revised System Operation
OptionLanyard
ArmingLanyard
InitiateBattery
PulseGenerator/
Counter
Deploy Pitot
Prox Sensor
2.7 s ProxInhibit
ArmingDelay
DynamicPressure
Differential
Pressurewithin 1 s/
2nd environ
Close valveZero sensorOpen valve
POST andVerify 1st
EnvironmentFire BoltCutter
ChargeFiring
Capacitor
Wait forSpin
Wait for Arm
Fire LEEFIDetonator
Committo Arm
23 ms max.(non-spin)
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Timing Diagram (non-spin)Separation
Impulse Generator
First Environment Counter
Battery Power
Electronics Reset and POST
Arming Delay
Verify 1st Environment
Actuate Pitot Valve
Differential Pressure
Static Switch 1
Static Switch 2
Dynamic Switch
High Voltage
High Voltage Detector
Fire Signal/LEEFI Detonated
T0 0.63 s
195 kcas within 1 s from T0
23 ms maximim
ArmTime
Arm Time+23 ms max
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Fuze Packaging
• Use as much of the current design as possible• Remove mechanical S&A and electronics• Add Electronics Assembly• Modify Arming Actuator Assembly
– Environmental Sensor Assembly• Pressure Sensor• Release Sensor (Pulse Generator)
– Solenoid valve– Anti-rotation feature added to Slide and Tip / Probe Base
Assembly
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Fuze Packaging
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Fuze Packaging
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Arming Actuator Assembly
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Explosive Train
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Explosive Train Comparison
• Current– 425 mg PBXN-5 output– output is part of detonator cord– initiated by HNS transition charge from HNS detonating cord
• Proposed– extend PBXN-5 output to fill Lead Holder– ~700 mg, same diameter as current output lead– swage in place– initiated by LEEFI output across small gap ~80mg PBXN-5
• Increased length not expected to increase output– dent data from current fuze needed to compare
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Prototype Arming Actuator Assembly
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Solenoid Valve Testing
• 3 solenoids tested from -65 ºF to 160ºF (3 steps)• ~1 psi input pressure• Valve actuation circuit per schematic• Measure
– Turn-on delay (Ton)– Stabilization time (Son)– Turn-off delay (Toff)– Stabilization time (Soff)
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Solenoid Activation
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Release Sensor
• Current Pulse Generator– 2100 +/- 200 turns of 44 AWG– Produces 4.4 V on 8 µF– output marginal for .5 second timer circuit requirement
• Modified Pulse Generator– 350 +/- 50 turns of 36 AWG– produces 7.7 V on 8 µF– produces 5.1 V on 16 µF– output adequate for more than 1 second of operation
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Release Sensor
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High Voltage Charge (+18 V supply)
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High Voltage Charge (+23 V supply)
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Program Status
• Building and testing Design Verification Test Units• Next major milestone CDR this summer• Flight tests Dec-Jan timeframe