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TARLight PDR 3 Oct ‘01 F.1.1 Rashid STARLight STARLight STARLight Mechanical Tahir Rashid STARLight Mechanical Engineer (734) 764-7210 [email protected]

STARLight PDR 3 Oct ‘01 F.1.1 Rashid STARLight STARLight Mechanical Tahir Rashid STARLight Mechanical Engineer (734) 764-7210 [email protected]

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STARLight PDR 3 Oct ‘01 F.1.1 Rashid

STARLightSTARLight

STARLight Mechanical

Tahir Rashid

STARLight Mechanical Engineer

(734) 764-7210

[email protected]

STARLight PDR 3 Oct ‘01 F.1.2 Rashid

STARLightSTARLightMechanical Requirements

• Mechanical Requirements– Instrument to be used on Husky A-1B aircraft (or similar)

– Low weight (Must be within allowable aircraft weight & c.g balance)

– Structural integrity

– Maintainability (Easy field replacements)

– Antenna dipoles must point in the same direction and be placed in a Y-arrangement

– Antenna spacing must be 0.68 = 5.6”

– Height of sensor module < 9” to avoid interference with ground and excessive aerodynamic drag

– Minimal interference between aircraft structure and antenna FOV

– Material selection with appropriate heat transfer properties

– Moisture control

– Simple and cost-effective

STARLight PDR 3 Oct ‘01 F.1.3 Rashid

STARLightSTARLightSensor Module Design & Structure

STARLight PDR 3 Oct ‘01 F.1.4 Rashid

STARLightSTARLightSensor Module Design & Structure

• Dwg#: 086-0045 X5

STARLight PDR 3 Oct ‘01 F.1.5 Rashid

STARLightSTARLightSensor Module Section

• Dwg#: 086-0046 X5 (Exploded View)

STARLight PDR 3 Oct ‘01 F.1.6 Rashid

STARLightSTARLightSensor Module Section

• Dwg#: 086-0046 X5 (Top & Side View)

STARLight PDR 3 Oct ‘01 F.1.7 Rashid

STARLightSTARLightSensor Module Section

• Dwg#: 086-0046 X5 (Side View)

STARLight PDR 3 Oct ‘01 F.1.8 Rashid

STARLightSTARLightY-Thermal Plate / Manifold

• Dwg#: 086-0078 X1

STARLight PDR 3 Oct ‘01 F.1.9 Rashid

STARLightSTARLightControl Module Design & Structure

• Dwg#: 086-0050 X2

STARLight PDR 3 Oct ‘01 F.1.10 Rashid

STARLightSTARLightStructural Analysis Plans

• Preliminary aerodynamic load analysis (Doc#: 086-0067X1)

• Results indicate profile drag force of 130lbf (500N) with sensor height=5.7” (7° tilt w.r.t ground)

0 2 4 6 8 100

50

100

150

200

Sensor Height (in)

Pro

file

Dra

g (

lbf)

D h( )

lbf

h

in

D h( )

lbf

STARLight PDR 3 Oct ‘01 F.1.11 Rashid

STARLightSTARLightStructural Analysis Plans

• Perform a complete finite-element structural analysis using FEMAP

• Static analysis will provide– Confidence in structural design

– Confidence in material selection

– High stress concentration areas

– Undesirable structural deflections

– Areas of improvement (if necessary)

• Vibration analysis will provide– Fundamental frequencies of structure.

STARLight PDR 3 Oct ‘01 F.1.12 Rashid

STARLightSTARLightWeight Estimate Summary

• Doc# 086-0068X2 (10% Margin)Description

Unit Mass[lb]

Quantity

Sub-Assembly

Mass[lb]

Total Mass

[lb]

Sensor Module73.620

Receiver Module 1.516 10 15.160

DA Module 0.500 10 5.000

Antenna 0.507 10 5.070

Sensor Board Components 5.290 1 5.290

Dewar & IR Profiler 0.950 1 0.950

Y-Thermal Plate 33.900 1 33.900

Hex Rings 0.440 10 4.400

Other Structure 4.050 1 4.050

Control Module 63.400

Microprocessor Assembly 5.510 1 5.510

Power Supply 4.410 1 4.410

Refrigeration Kit 38.000 1 38.000

Thermal Control System (Plumbing, valves, etc)

11.000 1 11.000

Pilot Control Box4.410 1 4.410

Total 137.120

STARLight PDR 3 Oct ‘01 F.1.13 Rashid

STARLightSTARLightWeight Estimate Summary

Allowable Weights

50

100

150

200

250

45 55 65 75 85 95 105

Sensor Weight (lbs)

Co

ntr

ol M

od

We

igh

t (l

bs

)

X

STARLight PDR 3 Oct ‘01 F.1.14 Rashid

STARLightSTARLightSchedule (Efforts to CDR)

• Prototype design of Receiver/DA assembly (Mechanical parts only)

– Complete detail level drawings for 2-channel prototype (10/26/01)

– In-house manufacturing of assemblies (11/09/01)

• Detail level drawings for complete sensor assembly (flight hardware)

– Will depend upon: Receiver component layout A/D component layout Antenna design details Dewar assembly configuration

– Can be completed 4 weeks after above items have been finalized

STARLight PDR 3 Oct ‘01 F.1.15 Rashid

STARLightSTARLightSchedule (Efforts to CDR)

• Mechanical detail level drawings for :

– Control Module (01/11/01)

– Pilot Control Box (01/31/01)

– Mechanical GSE (02/08/01)

• Complete Structural Analysis (12/14/01)

• Update Mechanical ICD (Doc#: 086-0003) (02/08/01)

• Update Weight Report (Doc#: 086-0068) (02/08/01)