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C R E A T I V E E N G I N E E R I N G F O R T H E S P A C E A G E

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A D I V I S I O N O F T H E B O R G - W A R N E R C O R P O R A T I O N

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C O R P O R A T I O N

O h i o ( 4 4 0 1 4 )

aerospaceequipment WARNER

History .

Corporate Heritage

Management

Organization

Geographical Significance

Borg-Warner Research

Pesco Products.

Manufacturing

Test Facilities

Clean-Environment Facilities

Quality Control

Reliability

Training and Service

Provisioning

Technical Publications

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A rrlerraberof the

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TEAMsirace 1933

Pesco Products Division of the Borg-WarnerCorporation is a leading supplier of fluid han-dling components and systems for all types ofair cr aft, missiles, and ground support equipment.

Pesco's many product lines include high-reliability fuel and fuel booster pumps, hydraulicpumps and power supply systems, electric andhydraulic motors, cryogenic fluid handlingsystems, including cryogenic motors and pump-

ing systems, axial-flow fans, thermoelectriccoolers, and electronic cooling packages.

Organized in 1933 as the Pump EngineeringService Corporation, Pesco began as a modestmanufacturer of vacuum pumps and fuel andhydraulic pumps. Now entering its fourth de-cade, Pesco has produced more than one millionpumps and hundreds of thousands of otherhydraulic and electrical components.

Pesco is known for the variety of dependablecomponents it has developed for the aircraftand aerospace industries. One of the company'sfirst products was the Model 194 vacuum pump,

which is still finding wide application on air-

craft instrumentation.Vacuum pumps were only the beginning. In

1935, Pesco introduced its fuel and hydraulicpumps. When the famed "China Clipper" took

to the air in 1939, it was supported by installa-

tions of Pesco fuel, hydraulic, and vacuumpumps. After this first venture into commercialaircraft components, Pesco sought to apply its

technical knowledge and specialized manufac-

turing skills to still more products. In 1943, for

instance, the company built its first engine-driven centrifugal fuel pump for the Hughes

Aircraft Company.

Pesco supplied advanced systems and com-ponents to the nation's fighting planes duringWorld War II. Pesco's patented "pressure load-ing" feature first appeared in pumps installedon the famed P-5L Mustang. Completely sub-merged fuel booster pumps were used on theP-39 and B-24. Pilots of Douglas F-4s woreflight suits surrounded by an envelope of coolingair cireulated by Pesco pumps.

In L944, Pesco began producing its ownelectric motors, since commercially-availablemotors did not meet Pesco's exacting require-ments for performance and reliability. The firstmodels were used to drive an emergency hy-draulic pump. Shortly after this, Pesco devel-oped an electric motor-driven fuel vane pumpto pressurize gasoline cabin heaters on bombers.

Commercial aircraft adopted many of Pesco'swartime-developed products for new passengercomfort and operating dependability. The Lock-heed Constellation, for example, used Pescofuel and hydraulic pumps. In 1945 and 1946,two-stage compressors for cabin pressurizationmade their appearance.

With the rapid changeover to jet-powered

military aircraft during the first postwar years,Pesco applied its vast engineering experienceand product knowledge to this important newfield. In 1945, the company developed for theF-80 a two-stage unloading pump which waslater adopted by the Swedish Air Force. In1946, Pesco delivered the nation's first turbine-driven afterburner pump. Weighing 9 poundsand delivering 25 horsepower, it was the fore-runner of afterburner pumps used today.

Pesco has demonstrated a unique ability to

convert anticipated requirements into depend-able devices with sustained performance capa-bilities. This is affirmed by the fact that Pescopumps and equipment are installed on virtuallyall of today's major afuuBft, and by Pesco'scontinuing record of association with "mile-

stone" flight vehicles.Pesco has also kept pace with the expanding

needs of national defense and man's far-reach-ing probes into space. When the United Statesmodified the German V-2 rocket as its firstmajor operational vehicle of the missile age, aPesco motor-driven hydraulie pump was spe-cifled. Today, Pesco pumps and power equip-ment are being used on all versions of thePolaris, the Pershing, the Minuteman, andother missiles.

Airframe, engine, missile and space vehiclemanufacturers depend upon Pesco's extensivetechnical knowledge and practical manufac-turing experience to translate new performanceand reliability requirements intd precisioncomponents and systems with advanced capa-bilities for powering or guiding flight.

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MANAGEMENTThe strength of Pesco Products Division lies in the

competence of its management team. Each member

contributes specialized knowledge and experience to the

operation of the business. Individual skill and judgment

are backed by corporate direction and consultation on

matters of finance, capital investment, subsidiary

activity, and operating policy.

Each of the individuals charged with divisional

responsibitity has a broad background of experience in

his particular area of activity. Thus, he contributes to

the successful operation of the division not only as a

member of the management team, but as a practitioner

in his specialized field of interest, as well.

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Presideneral _M

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Measurement& Controls

Engi neeri ng

Evaluation

Prod uctEngineering

EngineeringAdministration

ProductReliability

Thermoelectr ics

LaborRelat ions& Security

Person nel

Engin eeringMan ufacturing

PlantEngineering

Product Planni& Control

Vice-PresidentSales

General SalesEngineered Products

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West CoastSa les

Vice PresidentEngineeri ng

Director

Secretary &Legal Counsel

Vice PresidentT reasu rer

DirectorI ndustri alRelations

Employment

DirectorManufacturing

ManagerMan ufacturing

Advertising

& Publications

Planning &Sales Administrat ion

ServiceEngi neering

As a division of Borg-Warner Corporation, Pesco

operates as an independent activity with full responsi-

bility for all phases of business including marketing,engineering, manufacturing, and finance.

Pesco's management is organized horizontally throughthe staff level and vertically within individual depart-ments. Overall operations are directed by the divisionpresident, with each key management function assigned

Miss i le

Projects

to an executive with broad experience in the area ofhis particular responsibility. A specific breakdown ofthese various elements of the management structure isindicated by the organLzation chart above.

The financial statement of Pesco Products Divisionis a part of the Borg-Warner Corporation annual re-port, a copy of which is available on request.

ManagerQuality -Control

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The main plant of Pesco Products Division is locatedon a 30-acre site in Bedford Heights, Ohio, a south-eastern suburb of Cleveland.

The plant is ideally located with respect to trans-portation for raw materials and finished prodttcts aswell as for personal travel. There are five major rail-roads, 150 truck i ines and 11 airl ines serving Cleveiand.The St. Lawrence Seaway provides a gateway to oceanshipping, and the Ohio Turnpike and the Federal inter-state highway system serve the area.

A rail spur is located near the property and numeroustruck l ines have terminais located within minutes of

the plant. Major highways l ink the facil i ty with boththe Cleveland and Akron municipal airports. The plant

can be quickiy reached from a nearby interchange of theOhio Turnpike.

Included in the main plant are 302,000 square feet ofproduction area plus ample space for development andtest laboratories, warehousing, and service facilities.Modern offices within the plant house admrnistrativeand engineering personnel.

Proximity to suppliers of raw materials and manu-facturers of components and semi-finished products isanother significant advantage of Pesco's Clevelzrndlocation.

[}raws TheTopWorkers

From A SkilledLahor Pool

Three-quarters of the nation's production facilities andhaif its popuiation are located within a 500 mile radiusof Clevelancl. In the greater Cleveland area alone are3500 manufacturing firms employing 325,000 people. Alocation in this ayea offers many advantages to anaircraft,"missile-oriented company such as Pesco. Thearea provides one of the country's largest skilled laborpools. Included in this tremendous potential are 35,000people employed directly in the production of aircraftand missile components.

In all, there are more than 310 types of production

activity accounting for the manufacture of more than2000 separate product classiflcations.

The public schools of the area are highly rated andprovide a substantial nucleus of high school graduatesqualified to flll job vacancies. Many excellent tradeschools permit Pesco to choose well-trained youngpeople who are adequately prepared for a career inprecision manufacturing.

Two top-ranking engineering colleges( two universities,and four colieges of liberal arts provide many of theprofessional and administrative people who work atPesco.

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Elorg-Wa,rrrer Resea,rctr Cerrter

Bxtending Pesco's engineering development facilities isBorg-Warner's Roy C. Ingersoll Research Center atDes Plaines, Ill inois, a pioneer in advanced designconcepts and basic product development.

This multi-million doilar faciiity is staffed with morethan 150 well-qualified scientists, engineers, andtechnicians, and is equipped with precision instrumenta-tion to translate theory into mechanics, ideas into hard-ware.

Functionally, the Borg-Warner Research Centeroperates within clearly-deflned research parameters tofulfill the technical requirements of the various Borg-Warner divisions.

Activity at the Research Center includes basic workin the chemical, mechanical, physical, electronic,electrical and metallurgical sciences. Materials researchand analysis are also prime functions.

From these efforts come many significant contribu-tions to America's aerospace technology.

Thermal and electr ical analyzing equipment. Thermoelectr ic test ing apparal

Research Center analog computer. Laboratory instrumentation in a typical set-up.

Exceptional liaison among engineering groups has beena traditional characteristic of the Pesco operation, anda significant influence in the company's manufacturingconcept.

Close communication and personal contact insurecomplete integration of the design and developmentfunctions-and earry over into the production phase,as well.

Pesco attacks complex problems with group thinking.For example, a metallurgist, a mechanical designer, ahydraulic engineer, a thermodynamics expert, and aproject manager may combine to form a syntheticall-around proficiency; and the cumulative knowledgeof this proficiency is available to the person assignedprimary responsibility for the project.

Historically, this concept has proved to be of tangiblevalue to Pesco customers. It has stimulated designingenuity, minimized development time, increasedproduct reliability, and stabilized the transition fromengineering to production.

The integrated engineering function at Pesco isadministered by a vice president, with a Director ofEngineering assisting in a staff capacity and exercisingline supervision over Design & Drafting, DevelopmentEngineering, and Test & Evaluation.

Basically, products originate in Pesco's DevelopmentEngineering Department, with the company's ChiefEngineer as immediate supervisor. Available for day-to-day contact and participation are groups specializing

in dynamic devices, positive displacement pumps,cryogenics, and eiectric motors.

Supporting-and sharing responsibility with-theDevelopment Engineering Department are the Test &Evaluation and the Design & Drafting Sections. Theformer provides significant laboratory services inmetallurgy and chemicals, fuels and pneumatics,hydraulics, and electricity. Incorporated in the latterfunction are specialists in standards and specifications.

The Development Engineering group and its as-sociated departments are staffed for complete capabilityfrom design concept to pilot model, and exercise totalcontrol over prototype production.

Once manufacturing has begun, cognizance and re-sponsibility shift to Pesco's Product Engineering group.Duties of this organtzation consist of design changes toreflect new application requirements, and liaison withcustomers is a vital function contributing to productionefficiency and customer satisfaction.

Pesco's orientation toward engineering is apparentthroughout the production sequence. In the PurchasingDepartment engineering buyers are alert to engineeringessentials, and engineering schedulers in productioncontroi assure optimum coordination among operations.

The capability and technical imagination of Pescoengineering are best evidenced by the products whichappear on the pages that foilow. Some have advancedthe state of the art. All have achieved specific objectives-efficiently and dependably.

Pesco liquid hydrogen pump with turbine drive.

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P E S C O P I T O D { ] C T S

On these pages are listed some of the basic productsand systems developed and currently manufactured byPesco Products Division.

Although the concepts they represent are becomingconventionai through acceptance and use, designcharacteristics invite modification of the items to meetindividual application requirements. Many of theproducts, in fact, have been developed specifically aselements of a fully-integrated system or power package.

And through its advanced research program, Pescohas developed important, often highly-sophisticated,

CRYOGENIC SYSTEM COMPONENTS

concepts from theory into the realm of practicabilityeven before the products have been in field demand.This program, too, has provided preliminary informa-tion on feasibility and cost, and has been a definitefactor in reducing project lead time.

Current production programs for these componentsillustrate the broad range of development and manu-facturing capabilities at Pesco. Every product has beendesigned and produced by Pesco's own team of manage-ment, engineering, and production specialists.

Cryogenic Ch illdown PumpsSingle-stage, volute type centrifugal pumps for pre-operation chilldown of cryogenic liquid systems havebeen developed and produced by Pesco ProductsDivision. Incorporating a centrifugal impelier and anaxial flow inducer for improved vapor handling abilityand suction performance, Pesco chilldown pumps arebuilt to eliminate problems of lubrication, wear, andextra weight by having both impeller and inducermounted directly on the electric motor drive shaft.Hydraulic axial loads from the pump impeller on thebearings are hydraulicaliy balanced so that bearingoperation, even under conditions of iow lubricity ofcryogenic fluids, is reiiable during extended periods ofhigh speed operation.

HYDRAULIC PUMPS AND MOTORS

Variable Displacement Piston PumpsPesco variable displacement pumps combine uniformflow rates with high volumetric and torque efficiencies.By reversal of hydraulic connections, these componentsserve as high-power-output hydraulic motors.

The units are available either with stationary orrotating cylinder barrels. Models with rotating barrelsfeature pistons of unique spherical design whicheliminate piston-bore galling; prevent piston seizureunder thermal shock, cylinder distortion or fluid con-tamination; and eliminate side-load wear, maintainingpeak efficiency during unit l i fe.

Pump or motor speeds range to 24,000 rpffi, andoperating temperatures as high as 700'F are permis-sible. A design advantage of Pesco units is their fastresponse to flow variations, which can be as low as 0.02seconds from zero to full flow.

Positive 0isplacement Gear pumpsPesco positive displ:icement hydraulic gear pumps as-sure uniform flow rates, sustained operating efficiencyover extended periods, and high volumetric and torqueefficiencl'

cl iaracteristics include sucLion capabil it ies for re-i iabil i tr; up to 50,000 feet without pressurization,operating pressures in excess of b000 psi, speeds to24,A00 rpm and flow ratings from 0.2 to 50 gpm.

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Multi-Element G ear PumpsPesco mult i -e lement gear pumps are designed for fa i l -safe operal ion in rr i rborne lubr icat ion, scavenging,h.t 'draulic-power and liquid-transfer systems. An.u*combination of these functions can be built into onehousing designed to meet specified space, weight arndt l r ive requirements. Engineered to perform rel i rLbly upto 50,000 feet wi thout pressur izat ion, they operuLe intemperature ranges from *65' to 600"F and have dis-placements of .004 to 3 cubic inches per revolut ion.

N T E G R A T E DH Y D R A U L I C P O W E R P A C I ( A G E S

Pesco integrated hydraulic power packages are devel-oped and manufactured to meet specific environmentaland performance conditions. Units have been built toproduce pressures in excess of 5000 psi, and flow ratesup to 50 gpm.

A typical Pesco hydraulic power package consists ofan appropriate drive-electric motor, hydrarilic motor,or turbin Pesco variable displacement piston pumpor a Pesco fixed displacement gear pump, a reservoir,and necessary filters, controls, valves, connectors, andother auxiliary equipment to meet the system specifica-tions. All components are carefully selected and cus-tom-engineered into a compact unit meeting the spaceand weight limitations, while assuring optimurn systemperformance.

The drive used on a particular power package isselected on the basis of the type of power available, theduty cycle of the hydraulic power system, the outputrequired, and weight-versus-horsepower considerations.For most missiles, small hydraulic pumps are driven byDC motors. Depending upon the application, an air-eraft power package may employ a turbine drive, ahydraulic motor, or an electric motor as the systemprime mover.

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Pressure loading is a unique principle developedand patented by Pesco. Two of four bearings"ffoat" in the housing, and are directed towardthe gears by discharge pressure. pressure in thegear cavity counter-balances the ,,pressure_

loading" force to maintain end clearance. Thisunique design provides extra-long life, highoperating efficiency, uniform flow rates withvolumetric efficiency to 97 % and torque effi_ciency to 92/r.

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F U E L P U M P S

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Fuel Gear PumpsSpecified on almost every operation military and com-mercial aircraft in service todal', pesco gear-type fuelpumps have been performance-proved uncler the mostsevere oper:rt ing conditions. cap:icit ies range from 1.gto 186 gpm with discharge pressures up to 1b00 psig.speeds range to 7000 rpm. These pllmps are capable ofhandling ali commercial and militarrr fuels.

Fuel Booster PumpsLightweight, vane-type Pesco fuel booster pumps :rredesigned to deliver pressurized fuel to engines i it allalt itudes. Both the pump and the electric motor whichdrives the unit :rre designed, developed, qu:rl if ieci anclm:rnr-rfactured b)' Pesco to assure single-source re-sponsibi l i t l - . Tank-mounted and l ine-mounted mori t lsare available, with oper:rt ing speeds to 24,A00 rpm;pressures to 40 psi; and flows to 1,000 pph.

Centrifugal Fuel PumpsIncrc'ased emphasis on contaminants in fuer systems hasdictated the need for examin:lf ion of new pump con-cepts. \ rar ious t -vpes of centr i fugal pumps, both in- l ineand tank-mounted, are being investigated at, pesco.Alreadl, ' developed is the after-burner pump for theF-111 aircraf t and booster pumps for the c-180 anclC-141 aircraf t . The F-111 :r f terburner pump is one ofthe largest centrifugal t1'pes ever designed.

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T H E R M O E L E C T R I C C O O L E R S

P A C K A G E D E L E C T R O N I C C O O L E R S

Pesco thermoelectric coolers can be used wherever spotcooling is required to increase sensitivity and life ininfrared detectors, semiconductors, electric componentsand special instrumentation. Cascaded cooling elementsup to four stages give heat-pumping capacities from-35'C to -99'C under no-load conditions, and from-30"C to -78'C with loads to 15 mw.

Their miniature size and rugged construction makesthermoelectric coolers ideally suited for applicationswhere space limitations and operating conditions aresevere. A variety of types and sizes is available asbasic hardware or in evacuated Kovar, glass or sap-phire window-type enclosures.

New cooler designs emphasize rugged, uniquely-cascaded 2-, 3- and 4-stage units with low power-consumption requirements.

Completely-integrated heat-dissipation systems forcooling electronic equipment aye products of Pesco.These high-performance cooling systems feature ex-ceptional light weight, small size, integral constructionand the reliability resulting from Pesco's single-sourceresponsibility. Systems for liquid-to-air, liquid-to-liquidand air-to-air are available, with capacities rangingfrom 30 to 600 BTU/min.

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A X I A L F L O W F A N S

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Pesco axial flow fans are designed for a wide variety ofindustrial and military applications where a rugged,integral, air-moving source is required in a compactpackage. Flow rates range from 20 to 45,000 cfm, andspecially-designed "anti-stall" impellers eliminate dipin the stall range. Other features include reducedoperating speeds and noise level, high blade loading,and exceptional weight-to-airflow ratios. A wide rangeof models-direct, geared, belted-with Pesco-builtelectric motors are available.

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E L E C T R I C M O T O R S

High Frequency ACDesigned to meet aircraft and space-industry require-ments, these small, highly-reliable electric motors aresuited to continuous-duty service under the most severeoperating conditions. Designed for 400 eyele, singleor 3-phase, 115-, 200- or 416-volt operation, they areavailable in six frame sizes with capacities from .01-8 to16 HP. Speeds range up to 23,000 rpm.

Iiglttweight 0CPesco DC electric motors are designed to meet thedemand of both military and industrial service. Highlyefficient and completely reliable, they feature lightweight and minimum size. Five frame sizes meet powerrequirements from .005 to 15 hp, with speeds rangingup to 15,000 rpm. Series, shunt or compound windingsare available for 6- to 112-volt operation.

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MANf]F- 'ACTT.]F| , ING

Precision is the watchword of Pesco production fa-cilities, just as performance and reliability are inherentin all of Pesco products.

At Pesco, manufacturing is divided into groupsaccording to the type of machine-chuckers, drills,gear cutters, millers, grinders and the like-by specificfunctions of departments, such as heat treating,anodizing and plating, receiving inspection, serviceinspection, assembly, testing or shipping, to name a few.

With each department functioning as an integral,though specialized section of the manufacturing com-plex, Pesco achieves the versatility and flexibility sovital in meeting each customer's most exacting require-ments while assuring on-time delivery.

The factory organizational plan not only permitssmooth well-ordered flow of materials and components,but is conducive to quality workmanship. Each depart-ment is manned with highly specialized personnel whoare given an opportunity to operate extensively withintheir fields of training. Thus, they are able to increasetheir specialized skills and abilities consistently.

In addition to a full complement of standard machinetools-including engine lathes, turret lathes, automaticchuckers and bar machines, internal and externalgrinders, drill presses, and milling machines-Pesco isequipped with a wide range of close-tolerance specialmachines. Two precision jig mills, for example, assureproduction of parts with 0.0002" accuracy. A specialgrinder is capable of accuracies to 0.000020" on flats and0.000010" roundness.

Three departments are devoted to precision gearcutting and grinding. One of these is in an atmospher-ically-controlled room where superfinishing and honingoperations are performed.

Here, surface finishes of less than 1 microinch areobtained and gears are matched to within 0.000050".

Sixteen automatic boring mills and twenty automaticscrew machines are available for handling stock up to3r,4" diameter. A complete heat-treating departmentwith fourteen furnaces assures close supervision of metalcharacteristics. Anodizing and plating, along withauxiliary cleaning equipment, is provided in the plant.

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Mi l l ing a cryogenic pump shaf t .

Bor ing operat ions on a fue l pump us ing a L inderj ig borer .

Gr ind ing gear set journa ls on a Cinc innat i angularhead gr inder .

A complete, fully-equipped experimental model shopfor the production of experimental models and proto-types is also provided. A completely-equipped toolmaking department produces many of the toois used atPesco.

In Pesco's gage crib are precision and ultra-precisionfacilities for calibrating all master and working gages inaccordance with military specifications MIL-Q-9858(Quality Control) and MIL-q-45662 (Gage CalibrationSystem Requirements). In addition, there are Pescofacilities to meet or exceed all requirements of MIL-Q-5923 pertaining to general quality control practices.

B inocu la r m ic roscope used t o debu r r p rec i s i on pumppa rts.

A battery of automatic turret lathes.

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Machining operation on an lngersol l-Matson electr icaldischarge machine.

Bor ing operat ions on a fue l pump us ing a L inderj ig borer .

Gr ind ing gear set journa ls on a Cinc innat i angularhead gr inder .

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A complete, fully-equipped experimental model shopfor the production of experimental models and proto-types is also provided. A completely-equipped toolmaking department produces many of the tools used atPesco.

In Pesco's gage crib are precision and ultra-precisionfacilities for calibrating all master and working gages inaccordance with military specifications MIL-Q-9858(Quality Control) and MIL-Q-45662 (Gage CalibrationSystem Requirements). In addition, there are Pescofacilities to meet or exceed all requirements of MIL-Q-5923 pertaining to generai quality control practices.

B inocu la r m ic roscope used t o debu r r p rec i s i on pumppa rts.

A battery of automatic turret lathes.

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A DeVl ieg J ig Mi l is used to bore pump body por ts .

The heat t reat ing depar tment is a par t o f Pesco in tegrated produc-t ion fac i l i t ies .

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Machining operation on an Ingersol l-Matson electr icaldischarge machine.

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TestFa,cil i t ies

Because of Pesco's traditional emphasis on quality andproduct performance, test facilities play a significantrole in plant operations.

The company maintains special laboratories forevaluation studies in metallurgical, electrical, chemical,hydraulic, fuel, and cryogenic applications, each equip-ped with full-range instrumentation and staffed byknowledgeable technical personnel.

A complete hydraulic and electrical test area forqualif ication and performance testing is also available.

Pesco's test facilities are capable of verifying productconformance to all applicable customer or militaryspecification, and are prepared to document all data forcustomer review and analysis.

With aerospace goals demanding I00% reliabil ity,Pesco test facil i t ies assume a vital role in the company'sintegrated production program.

C R Y O G E N I C L A B O R A T O R Y

Located near Perry, Ohio, (30 miles northeast of themain plant) the Pesco Cryogenics Laboratory tests andevaluates system components developed to handle alltypes of cryogenic fluids efficiently and safely.

The cryogenics laboratory features special liquidhydrogen and liquid oxygen dewars and test cells, pluscompiete recording instrumentation and remote con-trols for measuring, calibrating, and controlling com-ponent performance.

A 7000-galion vacuum insulated test dewar for high-flow liquid hydrogen pumps is a major installation.Smaller dewars are available for related projects.

The 51-acre instaliation is one of the few completecryogenic iaboratories maintained by a company for itsown programming-typical of Pesco's concern withproduct quality and dependability.

1600 gal lon Dewar for test ing in l iquid oxygen.

Centra l ins t rument and cont ro l panels for a l l tes t bu i ld ings at thecryogenic center.

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Aerial view of the cryogenic test faci l i t ies.

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To insure performance dependabil ity, pesco maintainsa ciean-room complex for inspection, cieaning, as-sembly, and testing of high-performance hydraulicpower supplies for missile applications. variable- andfixed-displacement units are processed in the area.

conditions are closely controlled within the spacious,

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Clean - Env i ronrnent Fac i l i t iesFor Assembiy And Test ing

well-lighted facility. Filters installed in the air-con-ditioning system remove gs% of airborne particleslarger than 5 mierons (5 millionths of a meter). Tem-perature is maintained at 72oF with a permissible dif-ferential of plus/minus 2o; and relative humidity isapproximately 45% (52o maximum dew point).

Walls, floors, and bench tops inside the area are vinylcovered to facilitate cleaning and to eliminate flaking,scaling and powdering. Rooms in whieh the highestcleanliness standards are maintained are pressurized toa greater degree than adjacent areas, with a pressurevariable ranging from .25 to.025 inches (water).

In the "white" atea (where closest control is main-tained), the atmosphere contains not more than 200particles larger than 5 microns in each cubic foot of air.In secondary areas, the count is not more than b005-micron particles; in tertiary a.reas, not more than 10005-micron particles. In no areacan there be more than 10particles measuring 65 microns in any dimension.

Although electric motor drives for the units aremanufactured, assembled, tested, and cleaned else-wherein the Pesco plant, all hydraulic-pump componentsare cleaned, assembled, and tested in the clean room.Each hydraulic power supply unit undergoes from 60 to120 hours of intensive testing before it is delivered tothe customer.

Cleaning equipment includes a high-velocity jetsystem for flushing components with recondensedtrichloroethylene; facilities for nitrogen drying; astainless steel ultrasonic degreaser; and bagging/sealingequipment for cleaned parts.

Assembled units are normally subjected to static

Equipment available for calibration and patch testingincludes 7 variable-speed dynamometers with opera-tional ranges of 300 to 20,000 rpm. In the unit TestRoom are Pesco-built consoles with closedJoop systemssimulating missile-flight conditions, and oscillographicinstruments to record the performance of each po*.tsupply unit.

Adjacent to the clean room is an electro-interferenceroom providing RF shielding and complete instrumen-tation for checking against GM specifications for bothconducted and radiated frequencies.

_ Pesco is prepared to compile and submit a compre-hensive performance-data package with each hydraulicpower supply unit-documentary proof of pesco crafts-manship and Pesco quality.

24

-r-

Pure-Ai re cont ro l led env i ronmenta l assemblv s ta t ion.

E L E C T R I C A L T A B O R A T O R Y

Components and circuitry are evaluated under oper-ational conditions in Pesco's 5000-square-foot electricallaboratory.

Equipment includes a 10- to 2000-cps vibration tabieand an environmental chamber capable of simulatingaltitudes to 60,000 feet and testing performance at bothhigh and low temperatures.

A high-speed dynamometer rated at 12,000 rpm and15 hp; an explosion test chamber; a 12-KVA, 3-phase,400-cycle load bank for alternator tests; high-speedrecording potentiometers and string oscillographs arealso available.

Power service includes 27- and 120-volt DC andll5 i200 400 volt, 320-510-cvcle AC.

H Y D B A U T I C T A B O R A T O R Y

A full range of equipment is installed jn the 7500-square-foot area comprising Pesco's hydraulic laboratory.

Dynamometer facilities include: eight dynamometersranging in size from 15 to 150 horsepower; one high-speed unit rated at 80 horseporver at 18,000 rpm; and aLink gear-drive dynarnometer attachment for speeds to27,000 rpm. Related equipment: six constant-speedendurance stands ranging from 10 to 25 horsepower andfour variable-speed run-in stands.

Instrumentation includes DuMont dual-beam andBendix single-beam oscilloscopes; Ellis strain-gageampiifiers; DuMont Type 2g7 oscillographs and Type32i high-speed oscillograph record cameras; SorensonAC voltage regulators; Baldwin-Lima SR-4 torquepick-ups; assorted pressure and flow transducers andmiscellaneous pressure and temperature recorders.

A six-channel Model 1b0 Sanborn recording oscil-lograph is atrso a significant part of the test equipment.

Torque

Six channel model 15d

M E T A L L U R G I C A T A N D

C H E M I C A T T A B O R A T O R I E S

Pesco's 2700-square-foot metallurgicai and chemicalfacility is capable of thorough analysis and evaluationof both metaliic and non-metallic materials.

The laboratory is equipped with such special devicesas an emission spectrograph for chemical analyses offerrous and non-ferrous metals; a Norelco X-ray dif-fraction unit to determine the crystalline structure ofchemical and metallurgical specimens; and a Jarrel-Ashspectrograph for qualitative and quantitative analyses.

In the physical test area are installed a Tinius-Olsentensile tester and a Krouse torsional fatigue tester.Adapters are available for tensile testing at temperaturesto 1500'F and for fatigue testing at temperatures to800'F.

trquipment for metallographic and physical testing offuels, lubricants, and elastomers is available in thechemical laboratory. The facility is also equipped forheat-treating and nitriding.

F U E t T A B O R A T O R Y

Performance testing of components utilizing all aircraftfuels is a function of the fuel laboratory, a 13,000-square-foot area completely equipped for full-rangeevaluation.

Equipment includes: seven dynamometers varyingfrom 1 to 150 horsepower; seven endurance standsfrom 25 to 150 horsepower; eight booster-pump en-durance stands; and one 2O0-horsepower dynamometercapable of testing high-speed centrifugal pumps atspeeds to 30,000 rpm.

Norelco X-ray dif fract ion unit.

Ja rrel-Ash spectrogra ph.

200 HP dynamomete r f o r f ue l pump tes t s .

Endurance test s tand for fue l pumps.

Qua,lity Coratrol

In Pesco's production philosophy, quality control iscognizant of all phases of manufacturing. In practice,quality control is "materials control," assuring con-sistency and acceptability through all processing stepsfrom receiving inspection to final approval.

The program is supervised by the quality controlmanager, who formulates, outlines and directs overallactivity. He and his department are responsible fortracing all materials, acting to correct defects, monitor-ing vendors, and reporting to customers.

The statistical section of the department analyzesdata from the floor, including process quality charts,checkoff cards, scrap reports, rework reports, andprocess warning cards.

Checkoff cards used in receiving, zone, final, and

shipping inspection are correlated by the analystsection. This form is a medium of instruction for allinspectors checking detail or assembled parts to thecorrect A.Q.L., and are frequently revised to tighten orloosen inspection procedures to reflect the history orqualifications of the vendor.

The supervisors of quality controi are responsible fordimensional checks on all assemblies, sub-assemblies,and detail parts-whether supplied by vendors orprocessed at Pesco. They function under the directionof the general foreman of quality control (chief inspector).

To show the scope and emphasis on quality controlrelating to every Pesco-built item, procedures are out-lined in the following paragraphs.

27

Qua,Iity Control

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B E C E I V I N G I N S P E C T I O NAll raw materials, castings, and finished or semi-finishedparts purchased by pesco are inspected upon delivery.No production order of casting. i* u..uptud withoutspecific approvar from the casting rayout alpa.tmurrt.Samples of bar stock, castings, ,rLb.., and piastics aresubmitted to the chemicar and metailurgical raboratoryfor acceptance before the items are released to pro-duction. checkoff cards detail fuil i.r.t.r.tior* forinspection, and include information pertinent to thehistory of the item and the vendor.

I N - P B O C E S S I N S P E C T I O NResponsibility for acceptability of work in process isshared by two groups: process inspection lnd zoneinspection.

Process inspectors give first-piece approvars on allnew setups. The group also checks dimensions andphysical characteristics of parts being pro....ud.

. For purposes of quality control, the prant is dividedinto four zones. when machining is compi.t"a in onezone' the pieces must pass inspection ny ine cognizantzone unit.If acceptable, they progress into a subseque nt zone

for further processing. unacceptable pieces must bescreened, and either reworked or scrapped.The system has been instituted to remove discrepantparts from the production rine as soon as expedient toprevent expenditure of time or money on urtimate

rejects.

F I N A T I N S P E C T I O N

All Pesco parts undergo comprehensive final in_spection after compretion of machining or speciarprocessing. Engineering drawings and checkoff cardslisting the requirements of applicabre ,p..#.utionufunction as yardsticks to assist personner in checkingat the proper level of inspection for each characteristic.

Materials and components found acceptable are so28

indicated on the checkoff cards. Issue of stock ticketssignifies approval.

Items accepted by Pesco procedures are submitted toAir Force quality control personnel for a subsequentinspection. Parts can be moved to stock only after AirForce approval is stamped on stock tickets.

T E S TFunctional testing is a 100/6 program to assure con-formance to specification established jointly betweenPesco's engineering department and the customer.

All units are serial numbered at this time, and re-corded data of all tests is delivered with the product.Daily, weekly, and monthl5r reports advise the manu-facturing and quality control groups of trend ordeviations from the production pattern.

S H I P P I N G I N S P E C T I O NAt Pesco, shipping inspection is a two-station sequence.Station 1 receives units after test acceptance and

checks them against outline and assembly drawings.The group also inspects for damage which may haveresulted from mounting of parts in test rigs.

Station 2, located at the end of the shipping line, isthe last checkpoint prior to packaging. Here, serialnumbers and model numbers are verified and comparedwith the customer order.

Because all units processed and assembled requiremilitary dpproval, each product is then submitted to anAir Force quality control team stationed permanentlyat Pesco. Only when paperwork caruies the Air Forcestamp of approval are the units shipped.

As further certification of Pesco quality, pescofacilities undergo periodic surveys in accordance withMIL-Q-5923, General Qua,litA Control Requirements.Pesco facilities and operations meet all appropriatemilitary standards.

Functionally, Pesco's quality control department isinherently flexible. In this w&y, product modificationsand diverse contractual requirements can be assimilatedinto an over-all plan with minimum deviation from thebasic production program.

29

Flelia,bility

Quality and rel'iabi,Ii,ty have different meanings.

Quali,ty is the ability of a part to meet its specificationsat any point of reference. Rel,iabilita is the probabilitythat a device will perform its intended function for agiven length of time. It has also been designated as"mean time between failures" (MTBF).

Because of its significance in aerospace applications,reliability gets day-to-day emphasis at Pesco. Materialsare consistent, manufacturing processes are identicallyrepetitive, and records are comprehensive-three con-ditions which are essential to reliabilitv control. Normal

deviations are traceable direetly to a vendor or aproduction operation.

Reliability, of course, is an engineering function atPesco, too. Design analysis by reliability engineerseliminates most sources of failure, and mathematicalmodels can be utilized to predict the service life of Pescoproducts. Periodic tests verify the accuracy of predictions.

Pesco personnel throughout the production structureare oriented in the reliability concept. They take a vitalinterest in producing devices which will perform de-pendably at realistic cost to the customer.

30

Service Engirreerihg,Tra,irring And Prowisiorring

Training and technical service functions are theresponsibility of Pesco's service engineering department.

The service engineering department is responsible foroverhaul and repair service, service publicatidns, fieldservice, and service engineering.

Where appropriate, the department assigns its fieldservice repairman and engineering consultants to visitcustomer facilities to repair Pesco units or assist in theinstallation of Peseo equipment in airframes or engines.

The department also maintains a bonded stockroomand inventory control system to support overhaulprograms for which the government furnishes parts.

Each distributor of Pesco products for commercialaircraft maintains comprehensive service facilities foraccessory repair and parts distribution. Personnel havereceived factory training at Pesco and are competenttechnicians qualified for expert service and field over-haul.

6

3 1

P R O V I S I O N I N G

Pesco's provisioning section, organized in 1949 as oneof the first in the industry, is a team of service engineers,designers, and specialized technical personnel. Thegroup is capable of determining at ariy stage-frominitial design to actual service-the spare parts requiredfor Pesco units.

Pesco is an acknowledged pioneer in the "kit,, con-cept of provisioning for military requirements. pescoengineers work in close conjunction with militaryspecialists in determining overhaul and replacementschedules for Pesco-built units, and supplies integrated"kits" for preventive maintenance and simplified repair.

Provisioning at Pesco is a flexible program, permittinga procedure for procurement of spares and follow-upengineering changes to be developed to each customer'sspecifications.

T E C H N I C A T P U B T I C A T I O N S

All data and illustrations pertinent to maintenance,overhaul, and repair required by military or commercialcontracts are prepared and produced by the publicationsdepartment.

The department functions as a self-sufficient activitydirectly responsible to the sales department. It isstaffed with technical writers, illustrators, photo-graphers, and printers experienced in publishing ATAmanuals, military handbooks, Pesco Serviscripts, andservice bulletins.

Complementing the publications department is afully-equipped print shop with offset and letterpressfacilities for production of handbooks, manuals, andservice bulletins. trquipment for process photographyand plate making is also available.

Data required by all general and specific militaryspecifications appropriate to the customer are compiledby department personnel. The material is inspected byAir Force handbook inspectors in residence at Pesco.

Pesco Pub l i ca t i ons Depa r tmen t has a p r i n t shop f u l l y equ ipped w ithree of fset and one le t terpress for the product ion o f handboomanua l s and se rv i ce bu l l e t i ns .

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32

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