AMCOM MK66 Mid-semester report

Project Overview Development of a precision guidance avionics module for the Hydra 70 rocket missile. Development of a precision guidance avionics module for the Hydra 70 rocket missile. M261 MPSM warheadM261 MPSM warhead M round launch platformM round launch platform MK 66 rocket motorMK 66 rocket motor Module will have built in IMU and GPS guidance systems Module will have built in IMU and GPS guidance systems Module will contain 4 canards actuated by servo motors that will perform flight adjustments Module will contain 4 canards actuated by servo motors that will perform flight adjustments Manufacture a mechanical prototype Manufacture a mechanical prototype

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

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

Computation: What’s done Program structure skeleton complete Program structure skeleton complete Exception handling via subroutine returnsException handling via subroutine returns Multi-level structure of function callsMulti-level structure of function calls Static variable allocationStatic variable allocation Direct-mapped I/O ports (232)Direct-mapped I/O ports (232) Initial course plotting development complete Initial course plotting development complete Defined array of directional structuresDefined array of directional structures Axis of travel defines index on array Axis of travel defines index on array Course deviation computation Course deviation computation Function returns difference between intended course and actual courseFunction returns difference between intended course and actual course

Computation (2) Nios CPU core compiled (7.82MB) Nios CPU core compiled (7.82MB) 43%-56% utilization of logic elements on Altera Cyclone FPGA43%-56% utilization of logic elements on Altera Cyclone FPGA Nios development kit interfacing Nios development kit interfacing Protocols for loading Nios core onto FPGAProtocols for loading Nios core onto FPGA Protocols for compiling flight software source code and subsequent upload and executionProtocols for compiling flight software source code and subsequent upload and execution

Computation (3) Decision reached on method of course corrections Decision reached on method of course corrections Method A: Compute required correction from differential, applyMethod A: Compute required correction from differential, apply Method B: Correct incrementally until correct path is reachedMethod B: Correct incrementally until correct path is reached Method B requires least amount of computational power and may be critically damped Method B requires least amount of computational power and may be critically damped

GPS Interfacing Outputs raw data (real-time data) Outputs raw data (real-time data) Binary formatBinary format Transmission ProtocolTransmission Protocol 8 bits 8 bits 1 stop bit 1 stop bit No parity bit No parity bit Output Interval Output Interval Can be set to any time between.05 and 999 secondsCan be set to any time between.05 and 999 seconds

GPS Timing Information Default Settings PPSPeriod 1 second Offset milliseconds Synchronization GPS time synchronized to the rising edge of the pulse

GPS Timing Diagram (for default settings)

Relationship of GPS Time to PBN Output Pulse

To do (embedded) Compile finalized flight software, upload to FPGA Compile finalized flight software, upload to FPGA Complete incremental course correction subroutine Complete incremental course correction subroutine Complete parallel/serial I/O port mappings Complete parallel/serial I/O port mappings Asynchronous interfacing Asynchronous interfacing Line drivers Line drivers

Outer Shell Construction Configuration Tolerance-fit interfaces for both ends of avionics module: Ease of construction Press-fit shear pins around circumference 15in length Components to be made of Alloy 6061

Outer Shell Construction Configuration Male threaded interface: 2.410in OD 6 threads/in pitch.5in tolerance-fit shank 1.5in threaded end 7/32in wall thickness Shoulder machined for positive stop

Outer Shell Construction Configuration Female threaded interface: OD 7/32in wall thickness ID machined to match size/pitch of war head.5in tolerance-fit shank Shoulder machined for positive stop

Outer Shell Construction Configuration

Press-fit Flat-vent Pull-out Pins Internally threaded for ease of removal Allows module to be assembled/disassembled multiple times Reusable

6 Pin Connector (Ocean State Electronics) Multi-Pin Mobile Connectors: Multi-Pin Mobile Connectors: Used in applications that require high reliabilityUsed in applications that require high reliability Economical multi-pin connections, for rugged mobile useEconomical multi-pin connections, for rugged mobile use Positive screw-on retaining ringPositive screw-on retaining ring Built in strain reliefBuilt in strain relief Reliable contact designReliable contact design Keyway matings combine to guarantee permanent contact under extremes of shock and vibration.Keyway matings combine to guarantee permanent contact under extremes of shock and vibration.

Canard Development Current Accomplishments: Current Accomplishments: Canard DimensionsCanard Dimensions Deployment MethodDeployment Method Moment RequirementsMoment Requirements Lift Forces through max angle of attack (=5 o )Lift Forces through max angle of attack (=5 o ) Drag ForcesDrag Forces Deployment ForcesDeployment Forces

Canard Dimensions NACA 0012 Symmetric airfoil CS NACA 0012 Symmetric airfoil CS 1.25 in chord length 1.25 in chord length 3 in span 3 in span.15 in max. thickness.15 in max. thickness

Mission Velocity Profile

Deployment Method Canards deploy towards missile rear Canards deploy towards missile rear “Suicide” type deployment requires little initialization “Suicide” type deployment requires little initialization Inertial and aerodynamic forces open canard Inertial and aerodynamic forces open canard

Deployment Method

Moment Requirements M=.5V 2 ScC m M=.5V 2 ScC m For Small , experiment shows C m =0 at.25*chord For Small , experiment shows C m =0 at.25*chord Place canard link at c/4 Place canard link at c/4 M=0 when actuating M=0 when actuating

Lift Forces Roll Reduction Maneuver – 25 lbs of lift per canard at 5 degree angle Roll Reduction Maneuver – 25 lbs of lift per canard at 5 degree angle 1 st Course Correction - 0 to 25 lbs lift 1 st Course Correction - 0 to 25 lbs lift 2 nd Course Correction - 0 to 27 lbs lift 2 nd Course Correction - 0 to 27 lbs lift 3 rd Course Correction - 0 to 16 lbs lift 3 rd Course Correction - 0 to 16 lbs lift

Lift Force Plots

Deployment Forces Impulsive force on each canard at full deployment = 28 lbs Impulsive force on each canard at full deployment = 28 lbs Due to 79g acceleration and drag at supersonic speeds Due to 79g acceleration and drag at supersonic speeds

Brushless DC Servomotors SL-MTI BL-08-1 SL-MTI BL-08-1 Used in missile fin actuation, and smart bomb Used in missile fin actuation, and smart bomb Interior permanent magnet design Interior permanent magnet design Rated for 50,000 hrs Rated for 50,000 hrs Optional feedback sensors Optional feedback sensors Peak Torque: 5.65 oz-in Peak Torque: 5.65 oz-in Peak Current: 4.71A Peak Current: 4.71A Power Output: 12.51W Power Output: 12.51W Mechanical Response: 4 mS Mechanical Response: 4 mS Max. Power Output: 12.51W Max. Power Output: 12.51W

To Do Finish sourcing outer shell materials Finish sourcing outer shell materials Submit BOM (Bill of Materials) Submit BOM (Bill of Materials) Finalize canard deployment gear set Finalize canard deployment gear set Begin construction Begin construction

References AMCOM AMCOM - Christina Davis - Christina Davis - George Arkoosh - George Arkoosh - Mark Etheridge - Mark Etheridge