1. Compact Integration of Aerodynamic Control and Thrust Vector Control Rich Schroeder General Dynamics, Ordnance and Tactical Systems Healdsburg, California 39 th Annual Gun and Ammunition/Missiles &Rockets Conference April 13 – 16, 2004 Baltimore, MD

2. 1 Introduction l Mission flexibility is critical to meeting cost and logistics objectives for new weapon systems l Three-axis (pitch, yaw, roll) aero control systems inadequate at low Mach and high alpha conditions l Current 3-axis TVC systems (multiple nozzles and jet vanes) are: l Large l Costly l Inefficient l Technology is now mature to integrate aero control with 3-axis TVC for 5 – 13 inch diameter tactical missiles

3. 2 Current State Of The Art SystemAttributes l Standard Missile - Mk72 l Moving NozzlesNo drag / Thrust loss l Separate TVC ActuatorsHigh cost l NETFIRES l Jet TabsDrag losses up to 7% l Separate Actuators for each tabHigh cost l AIM-9X l Jet Vanes2-3 inches added length l Vanes slaved off fin servosLow cost Coupled IATVC System Combines the best Attributes of prior systems

4. 3 Historical Perspective of IATVC 1985 1990 1995 2000 2005 Yoke Plate TVC Developed Patent #4,892,253 6-Axis IATVC Produced 6-Axis IATVC Static Test DifferentialYoke Plate Mechanism Developed Patent #5,566,087 Phase II SBIR (Detail Design/Fab/Test) Static Test on 3 Pulse Motor Apply to Multiple Nozzle Motor (Adds Roll Control)

5. 4 Single Nozzle IATVC l Pitch/Yaw TVC only l Roll component of fin motion de-coupled l Nozzle motion = Algebraic sum of opposite fin motion in pitch/yaw

6. 5 Three Key Enabling Technologies l Compact brushless DC electromechanical actuators l Compact moving nozzles l Yoke plate linkage to couple the motion of 2 nozzles and fins

7. Compact Electromechanical Actuator l Brushless DC Servo motor GD-OTS Lo-J motor l Very high torque to inertia ratio Demonstrated 160 Hz bandwidth 6.1 HP in the size of “D” cell battery l Compact Gearbox Assembly High Ratio (374:1) Spur Gear Reduction l Custom Packaged COTS Electronics Low Cost Commercial IC’s Very Low Resistance FETs Single Axis Fin Gearbox with TVC Power Take-off

8. 7 Power Rate Density – GDOTS Enabling Technology Hi Power Rotary (6, 55) Hi Power Linear (4, 130) x IATVC (2.0, 58) Stinger (0.03, 30) BAT (0.02, 15) x High Speed Linear (0.6, 195) Industry Accepted EMA Limit AIM-9X (1.1, 40) AMRAAM (0.7, 45)

9. 8 Nozzle Considerations l Flex Bearing l Low actuator loads l Moderate – High cost l Largest volume l Trapped ball l High friction torque l Low cost l Compact l Flexible Exit Cone (INOVEC) l Moderate Actuator loads l Lowest cost l Smallest volume l Limited maturity Flex Bearing Nozzles Flexible Exit Cone

10. 9 Dual Nozzle Yoke Plate Mechanism l Two “yoke” plates l Slot limits motion in 1 plane l 1 plate for each axis l Both plates impart roll motion l Rack Gears drive each plate in 1 plane l Racks coupled to fin servos l Resulting nozzle motion l Algebraic sum of pitch, yaw and roll motion of fins

11. 10 Pitch and Yaw Plate / Nozzle Motion Nominal Position Pure Pitch/Yaw Motion Both nozzles move same amount in the same direction Nozzles can only move along one axis since they are constrained by the slots in the other yoke plate (not shown)

12. 11 Roll Plate / Nozzle Motion Pure Roll Motion Pitch and Roll Motion Both nozzles move same amount but in opposite directions

13. System Performance

14. 13 Static Rocket Motor Testing l 7 inch motor l Modified AMRAAM +5 l Demonstrated 3 axis TVC l Aerofin Operation for 60 sec l After motor burn-out l Demonstrate nozzle integrity l Servo performance after nozzle cooling

15. 14 Applications / Benefits Product/ProgramKey Benefit l CLAWSReduce launcher slew requirements l AIM-9XReduce losses due to vane drag Reduce missile length by 2-3 inches l NETFIRESEliminate separate tab servos l JCMIncreased maneuverability

16. 15 Conclusions l GD-OTS has demonstrated all key technologies for a 3-axis IATVC system that is: l Low cost l Lightweight l Compact l High performance l System provides 3-axis control for high-agility air-to-air air-to- ground or ground-to-ground missiles in all flight regimes l Integrated Dual Moveable Nozzle TVC is: l More compact than existing systems l Less parasitic drag loss than jet vanes or tabs l Low cost by leveraging existing Aero-fin servos