AMCOM MK 66 Missile System Vanderbilt University School of Engineering Fall 2004 Design Review Computer/Electrical Engineers: Ashley Devoto Matt Galante Adrian Lauf Shannon Stonemetz Mechanical Engineers: Jeffrey Kohlhoff Jason Newquist Filiz Genca

Project Overview Development of a precision guidance avionics module for the Hydra 70 rocket missile. –M261 MPSM warhead –M round launch platform –MK 66 rocket motor Module will have built in IMU and GPS guidance systems Module will contain 4 canards actuated by servo motors that will perform flight adjustments Manufacture a mechanical prototype

Customer Requirements Integration: MK 66 rocket motor M261 warhead and launcher Minimal modifications Non-classified, commercially available components Human Factors: Usable with arctic clothing/mittens Minimal training Minimal maintenance Minimal loading time and effort Physical: System Diameter < 2.794” System Length < 79.7” (ideal 71.1”) Weight < 34.4 lbs. per unit Environment: (*) Storage: –System Life: 10 yrs  25 yrs –Temperature: - 65 F  165 F –Humidity: 100% at 75 F Operation: –Temperature: -50 F  150 F –Humidity: 100% at 75 F

System Requirements Performance: Comply with wall-in-space accuracy, temperature, and humidity rqmts. “Ready to fire” Fail safe Max. Velocity: Mach 1.48 Max. Range: ~ 5 km down range Guidance and Control: GPS/IMU Data receiver in war head 4 moveable canards Aerodynamic roll reduction Multidirectional antenna Power/Casing: Thermal Battery Umbilical 1” ACME thread interface Aluminum casing for module Human Factors: No maintenance required Easy integration Ease of transport/storage figuring in space allowances No additional training needed Withstand storage life

Wall-In-Space Requirement

System Definition Block Diagram: System Components Project System Engineering Missile Nose ConeFuse Avionics ModuleMotorWarhead RMS “Black Box” Mech. Interface Umbilical Receiver & Decoder GPS Antenna Launcher Mech. Safety Charge & Wiring GPSProcessorIMUCanardsBatteryServos

System Definition Block Diagram: System Functions Provides guidance aid for missile Provide project breakdown Provides casing for system components Provides electrical entry point Provides missile guidanceProvides propulsionProvides casing for explosives Provides missile with system data Transfers data Provides connection to missile Provides signal processing Provides signal transfer Provides missile launch Provides position data Performs calculations for course corrections Provides acceleration and orientation data Changes trajectoryProvides power Provides power to canards

Simulation Software Pro/Engineering –Core Software ideal for modeling and simulation Aerospace Block Set (MATLAB) –Performs aerospace system design, integration, and simulation: motion equations, gain scheduling, and animation DATCOM –Use of verification data only

Mission Timeline

Module Packaging Module dimensions of 15 in by 2.75 in –Unit will contain : Subassembly Canards Servomotors Actuators GPS, IMU CPU Wiring Efficient space and weight management is crucial

Module Shell/Integration -Shell will be 1/16” thick Aluminum tube with two 7/32” thick Aluminum ends welded on -External threads on module end will interface with internal threads on motor -Mechanical interface with warhead must prevent twisting of wires from antenna and fuse to module -Solution: Spline type interface with serial connector developed -Adapter piece with internal threads and external splines created to connect with warhead threads -Internal splines mate with adapter on warhead

Servomotors Actuation – SL-MTI DC Servomotors Designed for Missile Fin Actuation, MIL Spec Feedback Sensors Specs Weight:.45 lb for 4 servos Size:.8 inch diameter, 1.4 inch length Power: 5 Watts Torque: 2 oz.-in. Voltage: 5V

Canard Design Two Geometries Under Consideration: 1. Rectangular Canards - NACA 0014 Airfoil National Advisory Committee on Aeronautics 2. Triangular Canards - NACA 0020 Airfoil - 3” x 1.25” x.2” square inch surface area - 3” x 1.25” x.2” square inch surface area

Canard Deployment 1.Rectangular Canard Deployment Deploys in direction of travel Impulsive Force of 47N (10 lbs) acts on centroid of each canard 107N (24 lbs) of force required to open each canard Front

Canard Deployment 2.Triangular Canard Deployment Canards fold from body Impulsive force of 18N (4 lbs) acts on centroid of each canard 58N (13 lbs) of force required to open each canard Space conservation

Processor Core (previous implementation) Previous team specified a Motorolla MC68HC11 microcontroller –8-bit 2.456MHz CPU with 256 bytes of onboard RAM and integrated I/O control Why this doesn’t work: –Course corrections require more precision (floating point) –Slow clock rate

Processor Core (new) Nios VHDL processor core (provided, to be used on Altera Cyclone) Capabilities similar to Intel ARM processors (used in routers, PDAs, etc.) 32-bit floating-point precision Code may be written in C with little overhead

M68K – a quick interlude NOT a self-contained solution – requires external memory and I/O control Not suited to military specifications and heat dissipation requirements Ubiquitous, but Nios core has more flexibility, more I/O support

Altera & Nios: complementary components Altera flexibly integrates VHDL virtual processor cores, I/O devices Nios VHDL core provided with Cyclone devel. kit Nios core will reduce CPU development time

Processor State Diagram

Voltage Regulator for Thermal Batteries 24-48V power source from thermal battery LM78M05 3-Terminal Positive Voltage Regulator –Temperature Range – (-40) C  125 C –Min. Input Voltage – 7.20 V –Max. Input Voltage – 35 V –Output Current – 500 mA –Output Voltages – 5V, 12V, 15V –Internal thermal overload protection –Internal short circuit current-limiting

Rocket Management System Current system uses analog line for purposes of charging a timing capacitor Proposed implementation of an RS-232 digital serial interface (12V DB9) Standard 9600bps baud rate will more than likely suffice Data format based on target data: –Current position and elevation –Target position and elevation –Current speed Guidance module returns “target acquired” signal

IMU Selected system: Honeywell GunHard MEMS IMU Serial I/O 5VDC power supply Provides linear and angular acceleration ΔV(x,y,z) ω(θ,φ,ψ) 9600bps data transfer rate

GPS G12-HDMA receiver –4.25’’ tall x 2.3’’ wide –Weight – lb –Power – 1.8 W receiver 0.3 W antenna –Max Acceleration – 23 Gs up to 30 Gs Initialization time – 45 sec cold and 11 sec hot Time-To-First-Fix – 3 sec Reacquisition – 2 sec Operating Temperature - (-30) C to 70C

Cyclone IMU 3 GPS 3 RMS 3 RS232 SDRAM ser. Actuator Control 8 par. Feedback n PC100 ADC 4