1 K. Prepared for: Naval Surface Weapons Center. 30 June 1975 DISTRIBUTED BY: InfimitiM Strvict U. S. DEPARTMENT OF COMMERCE AD-A

Transcription

1 j j r AD-A THIOVEC(R) TVC NOZZLE WARM GAS ACTUATION Conrad R. Huskey Thokol Corporaton K ' Prepared for: Naval Surface Weapons Center 30 June 975 DISTRIBUTED BY: Um InfmtM Strvct U. S. DEPARTMENT OF COMMERCE

2 59«2906 * THIOKOL CORPORATION ELKTON DIVISION ELKTON, MARYLAND E25-75 FINAL PROGRAM SUMMARY REPORT HIOVEC w TVC NOZZLE WARM GAS ACTUATION CONTRACT N C-038 TTT-- PREPARED FOR: NAVAL SURFACE WEAPONS CENTER WHITE OAK LABORATORY SILVER SPRING, MARYLAND 2090 PREPARED BY: MR. CONRAD HUSKEY SENIOR PROJECT ENGINEER / ~\ n c T\\ JUNE 30, 975 kvprodurd by NATIONAL TECHNICAL INFORMATION SERVICE U 5 Deportment of Commerce Sprng 4»«! VA 225 ' '". *._ Dsrffcullc;; o.j:.-...-"j

3 Unclassfed Securty Classfcaton DOCUMENT CONTROL DATA -R&D (Steurlly claomlcatlon of tltla, body of ammtmcl and Indafjnj wwcwuon mvt km mntatod wnon Iho mvrmu wort It claaalllas) I. OmaMATIN«ACTIVITY (C to author) Thokol Corporaton Elkton Dvson, Elkton, Maryland 292».MKPOftT SBCUWITV CLASSIFICATION Unclassfed t*. CPOUP S. RKPOftT TITL«FINAL PROGRAM SUMMARY REPORT: THIOVEC TVC NOZZLE WARM GAS ACTUATION * EA»CRJPTI v«notes (Tyno otropowt and tnchmlra dato») " AUTHORts» (Flntnama. atltnua Intal, loot romp} Conrad R. Huskey, Senor Project Engneer a«pout OATS June 30, 975 aa. CON- S.SROJCCTNO N C-Ö3S 9a. TOT*' MO. OF PACKS *A aa. cmanator*s RBPORT NUMSKRIS» E25-75 aa. otmss REPORT NOW (Atay maammatq 76. NO. OF WSrt Oswl#a AWWvfff sn#f BSV > A00f^#V ta. ostnauton STATCMKMT p» * II- su IS. ABSTRACT IS. SP >NSORINC MILITARY ACTIVITY ^ü :wj Naval Surface Weapons Center Whte Oak Laboratory Slver Sprng. Maryland 2090 Warm gas actuaton of a THIOVEC TVC nozzle was demonstrated usng a sold propellant gas generator and a solenod operated b-stable flapper-type warm gas valve. The TVC nozzle's dynamc characterstcs were obtaned n a seres of bench tests wth smulated motor chamber pressure producng the resstve torques normally experenced under motor operatng condtons. These bench tests provded frequency response, phase lag, slew rate, and system hysteress data whch proved the system to be a vable canddate for lowmantenance, cost-effectve TVC nozzle system applcatons. DMflsj A "W<* te taw* «473 M»««aa oo roaas tat*, JAM a«. SMfCM IS osaxttfea.aarum. y& «MB UcAty ftaaancattoa ---

4 Scorfy CM«flc»ttot» 4. KIY WORD! LINK A ROLt WT ROLI LINK LINK C ROLI actuaton pneumatc TVC nozzle Ifr Unclassfed Securty Clattlflcaton

5 P.O. Box 24, Elkton. Maryland / ELKTON DIVISION '/ In Reply Refer To: E25-75 June 30, 975 Naval Surface Weapons Center Whte Oak Laboratory Slver Sprng, Maryland 2090 Attenton: Mr. Eugene Eztfon, WR-2 Subject: Fnal Program Summary Report; THIOVEC^TVC Nozzle Warm Gas Actuaton Reference: Contract N C-038 Gentlemen: We are pleased to submt ths fnal program summary report markng the concluson of a successful Warm Gas Actuaton demonstraton program of the THIOVEC TVC nozzle. The enclosed report contans summares of the nozzle calbraton and Warm Gas Actuaton tests whch have verfed the elmnaton of hydraulcs from a thrust vector control nozzle as practcal. If you have any questons concernng ths report, please contact ether Joseph Reardon, Program Manager, or F. I. Ochs, Manager, Contracts Admnstraton. Very truly yours, THIOKOL CORPORATION ELKTON DIVISION JER/cm 7. M. Davs General Manager Ou^ /* A DIVISION OF THIOKOL CORPORATION

6 E25-75 June 30, 975 cc: Naval Surface Weapons Center Slver Sprng, Maryland 2090 Attenton: Code WR-2 (M. Stosz, R. Bardos - copy each) Code WX-2 ( copy) Code WU-06 (P. Fneran - copy) Naval Sea Systems Command Washngton, D. C Attenton: Code 033 (J. Murrn, M. Murphy - copy each) Code 6543B (D. Olsen - copy) Naval Weapons Center Chna Lake, Calforna Attenton: Code 457 (R. Fest - copy) Code 4574 (S. Benson, copy) Chemcal Propulson Informaton Agency Malng Lst Defense Documentaton Center Cameron Staton Arlngton, Vrgna 2234 (2 copes) >t<

7 E25-75 THIOKOL CORPORATION ELKTON DIVISION ELKTON, MARYLAND FINAL PROGRAM SUMMARY REPORT OVEC TVC NOZZLE WARM GAS ACTUATION CONTRACT N C-038 PREPARED FOR: NAVAL SURFACE WEAPONS CENTER WHITE OAK LABORATORY SILVER SPRING, MARYLAND 2090 PREPARED BY: MR. CONRAD HUSKEY SENIOR PROJECT ENGINEER JUNE 30, 975 APPROVED BY: JU. <^~- T. M. Davs General Manager <

8 E25-75 FOREWORD Ths Fnal Report of the THIOVEC TVC Nozzle Warm Gas Actuaton program s submtted to the Naval Surface Weapons Center, Whte Oak Laboratory, Slver Sprng, Maryland, n accordance wth the requrements of Contract N C The followng Thokol personnel contrbuted to ths program: Conrad Huskey Senor Project Engneer Rchard Bourdon Desgn Engneer Carl Gonce Test Engneer Joseph Reardon Program Manager Mr. Conrad Huskey was responsble for the techncal drecton of the program and was the author of ths Fnal Report. Mr. Eugene Elzufon of the Naval Surface Weapons Center was responsble for the techncal coordnaton and montorng of ths Navy-sponsored program.» A

9 E25-75 TABLE OF CONTENTS.0 INTRODUCTION * 2.0 PROGRAM OBJECTIVES DISCUSSION 3 3. General Warm Gas Actuaton System Descrpton of Tests TEST RESULTS 6 4. General Duty Cycle Tests Command Input Versus Nozzle Poston Frequency Response and Phase Lags NOZZLE POST-TEST HARDWARE CONDITION CONCLUSIONS 38 Page APPENDIX A, Nozzle Descrpton

10 E25-75 LIST OF ILLUSTRATIONS PAGE. Pneumatc Control - THIOVEC TVC 4 2. Nozzle Command Duty Cycle 8 3. Test Arrangement 8 4. Nozzle Assembly, Drawng No. E Nozzle Assembly, Test Arrangement 6. Gas-Test Arrangement, Drawng E Nozzle Test Arrangment 3 8. Duty Cycle Test Results 7 9. Duty Cycle, Chamber and Vector Set. Pressure 8 0. Duty Cycle Test, Chamber and Vector Seal Pressure 9. Hysteress Loop Test Result 2 2. Hysteress Test, Chamber and Vector Seal Pressure Hysteress Test, Chamber and Vector Seal Pressure Frequency Response, Test Results Frequency Response Test, Chamber and Vector Seal Pressure Frequency Response Test, Chamber and Vector Seal Pressure Nozzle Frequency Response Post-Test Vector Seal Assembly No Post-Test Vector Seal Assembly No Vector Seal Cover, Post-Test, Seal No Vector Seal Cover, Post-Test, Seal No Vector Seal Components, Post-Test Outer Race, Post-Test 34

11 E INTRODUCTION A two-phase program was conducted to demonstrate warm gas actuaton of the THIOVEC TV C nozzle system. The culmnaton of the effort was warm gas actuaton bench tests whch demonstrated feasblty n Phase I and characterzed nozzle performance n Phase II. Durng the tests, the THIOVEC TVC nozzle was subjected to smulated chamber pressure, duty cycle, and operatng tme smlar to that whch may be experenced aboard a typcal underwater mssle. The nozzle used was refurbshed from the THIOVEC underwater statc test performed under Navy Contract Number N C-2925, Phase I was ntated wth the desgn of the warm gas actuaton system, procurement of the warm gas servocontrol valve, and manufacture of the warm gas generator. Upon completon of the system desgn, the remanng components, such as tubng orfces and fxtures, were fabrcated. After assembly of the system, ntrogen gas was used for system check-out pror to the warm gas feasblty demonstraton test. Phase I was concluded wth the successful warm gas actuaton test wheren all test objectves were met and performance exceeded that requred. The average nozzle slew rate was 20 deg/sec from null to 90% of full deflecton n response to a step command to full nozzle deflecton. The nozzle's 90' phase lag and -3 db response pont, determned usng cold gas, occurred at 20 to 25 Hz. Characterzaton of the warm gas actuaton system, accomplshed n Phase II, provded maxmum and average slew rates, phase lag, response, and nozzle hysteress data. The maxmum slew rate was 300 deg/sec and the average was 65 deg/sec. The 90 phase lag occurred at 20 Hz and the -3 db response was at 25 Hz. The hysteress n the system was measured at ± 0.2 deg over full range of deflecton. /

12 E PROGRAM OBJECTIVES Both the Navy and Thokol are nterested n achevng a low cost, mnmum mantenance TVC nozzle system for use n underwater mssles. Studes have shown that the THIOVEC TVC nozzle s low n cost relatve to the other TVC nozzles, and underwater bench tests and an underwater statc test have demonstrated the feasblty of that TVC system for use n underwater mssles. The program objectve s to further demonstrate features whch permt the realzaton of low cost TVC systems. Specfcally, the feasblty of warm gas actuaton of the THIOVEC nozzle was to be demonstrated. The warm gas actuaton system mnmzes mantenance snce pre launch check-out s not requred because the possblty of hydraulc flud leaks s absent. Of mportance n system cost effectveness studes s the fact that such a warm gas actuaton system permts launchng from stes whch are naccessble for the purpose of performng the mechancal prelaunch check-out ordnarly requred when hydraulc actuaton s used. -2-

13 E DISCUSSION 3. General Work n Phase I was drected toward the verfcaton of test hardware, whch W\B a necessary frst step before characterzaton of the pneumatc actuaton system n Phase II. Electrcal and mechancal hardware was nvolved n buldng the pneumatcally actuated TVC nozzle system. Mechancal hardware ncluded: ) an exstng THIOVEC TVC nozzle; 2) a b-stable warm gas ssrvocontrol valve whch s a modfcaton of an exstng producton valve; and 3) a standard test weght warm gas generator. The electrcal equpment ncluded an electronc servovalve controller, the command sgnal electroncs, and the standard test data acquston equpment to measure and record the pressures, temperatures, and nozzle dynamc characterstcs of nterest. Phase I, therefore, ncluded all work necessary to desgn, fabrcate, and test the TVC system through the frst warm gas actuaton system demonstraton test. Work a Phase II was drected toward characterzng the dynamc response of the THIOVEC TVC nozzle usng a warm gas actuaton system. A total of sx warm gas tests were conducted n ths program: one n Phase I and fve n Phase II. The frst two tests n Phase II were requred to clear an nstrumentaton problem pror to ntatng characterzaton tests. A bref descrpton of the THIOVEC nozzle s presented n Appendx A. 3.2 Warm Gas Actuaton System A schematc show' 4 the test arrangement, desgned for sngle plane moton, s presented n Fgure. OmnaxaJ moton can be acheved usng an addtonal control valve, two addtonal restrctors, and tubng to operate the vector eals n the other ps ne of moton 90 to those shown. The warm gas generator s a standard test vehcle n use at the Elkton Dvson of Thokol and s desgnated TC-. The propellant gran s an end-burnng type 3.75 nches n dameter and 2 nches long. Snce ths standard gran s larger than that requred for supplyng the actuaton gas, a secondary flow orfce was nstalled n the gas generator to bleed off the excess gas supply. The Thokol-developed propellant, TP-Q-300, s a low flame temperature (740 F) propellant whose combuston products are free of sgnfcant partculate matter and toxc or corrosve chemcal speces. The Flow Restrctors permt pressurzaton of one vector seal actuator whle suffcently restrctng flow from the generator nto the ventng sde so as to produce the pressure dfferental necessary to vector the nozzle. The warm gas servocontrol valve s a b-stable flapper type proportonally controlled wth a pulse modulated command sgnal. The THIOVEC nozzle s the same as that used n the prevously mentoned underwater statc test. To permt an economcal test program, brackets were attached to ths omnaxal nozzle so that t vectors n one plane only. Ths reduced the requred number of pneumatc control valves from two to one per test and also reduced test setup tme. -3-

14 THIOVEC TVC Nozzle C) 4) Hü» P' I Rnpp B^w«.I.IHP SA2792A Feed-Back Sgnal TC- Warm Gas Generator Secondary Flo*- Orfce Electronc Controller 4 Command sgnal Command Electroncs Poston Transducer t Ignter Flow Rest ret or L Warm Gas Servocontrol Valve FIGURE. PNEUMATIC CONTROL THIOVEC TVC NOZZLE TEST ARRANGEMENT FOR SINGLE AXIS MOTION

15 E25-75 Cold gas tests were conducted pror to each warm gas test to assure proper functonng of the TVC nozzle and control electroncs. The cold gas, N 2, was ntroduced nto the system through the gas generator chamber, wthout the sold propellant gran nstalled. For warm gas testng, the N2 lne was dsconnected from the gas generator chamber and the propellant gran and gnter nstalled; the TVC system was then ready for the warm gas test. Deftgn calculatons for the warm gas actuaton system were conducted usng the followng assumptons: ) Szng of the system would permt a maxmum gas generator pressure of 2000 psa under condtons of flow through the secondary orfce and one restrctor; the other restrctor was assumed closed by the valve flapper's beng held n the hard-over poston long enough for the gas generator to respond to the change n nozzle flow area. 2) Maxmum pressure dfferental across opposng vector seals was assumed to be 000 psd. 3) The actuaton system was szed to provde a maxmum nozzle slew rate of 200 deg/sec at an assumed gas stagnaton temperature n the vector seals of 660 R. 4) It was assumed that, at the tme maxmum flow rate through the restrctors occurred, the down stream pressure was low enough to permt sonc flow through the restrctors. Maxmum change n vector seal volume of n. occurs when the nozzle travels from the fully deflected poston of 0 degrees vector angle to the null poston. To acheve the maxmum slew rate of 200 deg/sec, the volumetrc rate of flow nto the vector seal causng that deflecton must be 6.86 n. 3/sec. Usng the thermochemcal propertes of the gas generator propellant and the maxmum chamber pressure, the maxmum weght flow rate was calculated to be lbs/sec. Based on ths maxmum flow rate, the gas generator propellant gran, secondary flow orfce, and restrctor orfces were then szed. -5-

16 E25-75.".3 Descrpton of Tests The followng s an outlne summarzng the cold and warm gas testng of the THIOVEC TVC nozzle: ) Szng the Warm Gas System for TC- Generators a) Verfy sze of restrctors and secondary orfces for a 500 psa nomnal generator operatng pressure and measure temperature of exhaust gas and tubng durng generator operaton to assure absence of excessve heatng. b) Equpment: TC- gas generator; stanless steel tubng and fttngs; restrctors; and secondary orfce. 2) Cold Flow Tests a) Cold Gas Control System Checkout. ) Cold gas pressure 500 psg. ) Equpment: (a) servocontroller;. (b) PDM valve; (c) TC- gas generator wthout propellant or gnter; (d) restrctors and tubng to valve and nozzle. b) Nozzle and Control System Tests. ) Cold gas actuaton system supply pressure 500 psg. ) Equpment: (a) servocontroller; (b) PDM valve; (c) TC- gas generator wthout propellant or gnter; (d) tubng, restrctors, and tubng to valve and nozzle, ) Nozzle nternal pressure at 500 psa to smulate motor chamber pressure. v) Nozzle test: system gan adjusted to maxmze response and to elmnate nozzle overshoot pror to data acquston of followng tests: Duty cycle (see Fgure 2). Hysteress loop. Nozzle response (-3 db pont) and phase lag (90 shft pont). -6-

17 E ) Warm Gas Tests a) Operatng pressure of TC- gas generator was 500 psa nomnal. b) Nozzle nternal pressure 500 psa smulatng motor chamber pressure. c) Equpment: same as cold gas except that a propellant gran, gnter, and prmary orfce are used and the cold gas system s dsconnected. d) Tests: ) Duty cycle (see Fgure 2). ) Hysteress loop. ttt) Nozzle response (-3 db pont) and phase lag (90 shft pont). The gas generator used to provde the drvng force to the THIOVEC nozzle s a standard end-burnng generator desgnated TC-. The propellant used was TP-Q-300. The gas generator, whch has a flow rate n excess of that requred, used a secondary flow control orfce to permt bleed-off of excess gas. A test arrangement as shovn n Fgure 3 was made to verfy the orfce szes. The gas generator was assembled n the same manner as that used for the nozzle actuaton tests wth the excepton that the valve was deleted and the gas permtted to dump overboard after passng through the two restrctors. The ntended operatng pressure of the gas generator was to be 500 psa, wth both restrctors and the secondary orlce ventng to atmosphere. The tubng and fttngs used to duct the gas from the generator were of 36-type stanless steel and were standard commercal tems. The secondary and restrctor orf-'ces were made from stanless steel ppe plugs whch were drlled to the proper orfce dameters. The drlled plugs could then be easly assembled as they smply threaded n place. All tubng was reused several tmes wthout damage or rework except for cleanng. Thermocouples were placed on the outsde of the tubng and n the exhaust stream. The temperature of the tubng at TC-.' and -3 locatons was approxmately 500 F. The approxmate statc exhaust gas temperature measured at the dscharge, locatons TC- and -4, was approxmately 00 F. -7-

18 E n "! bß C Ü ; IIM II Tme, seconds FIGURE 2. NOZZLE COMMAND DUTY CYCLE SA347. Prmary Orfce TC- End Burner Reatrlctor No. 2 Reatrlctor No. TC- TC-4 FIGURE 3. TEST ARRANGEMENT -8-

19 E25-75 The THIOVEC nozzle assembly, shown n Fgure 4 (E28478), was assembled wth only two vector seals for sngle plane nozzle moton nstead of the number requred for omnal nozzle moton to smplfy the test arrangement and to control electroncs. A gude bar and rubbng blocks were used on the nozzle to act as a gude to lmt actuaton to only one plane. Ths successfully mnmzes the cost and complexty of the nozzle tests. It should be noted that the same vector seal assembles were used for all the test sequences, ncludng the cold gas actuaton tests, to demonstrate ther compatblty wth the warm gas actuaton system. A photograph of the nozzle assembly s shown n Fgure 5. After assembly the nozzle was checked for adequate clearance by performng an nternal nozzle pressure versus nozzle axal deflecton test to verfy that the grease bearng was assembled properly. After successfully completng the test, the nozzle was placed n a statc test bay where all nozzle testng was conducted. The nozzle was attache J to thr TC- gas generator n accordance wth drawng E27647, presented n F ure 6. A photograph of ths assembly s shown n Fgure 7. The prmary orfce and gnter were removed, the flex lnes and valves from the cold gas source (GN2 bottles) were attached, and the cold gas actuaton testng of the nozzle completed. The pressure from the ON2 bottles was regulated to acheve 500 psa nsde the TC- pressure chamber. The test setup was dentcal for both Phase I and Phase n program. The arrangements for the cold gas tests were the same as those for the warm gas tests except that the prmary orfce, gnter, and propellant gran were not used. The gas exted through a vertcal ppe and was drected by means of a tee to two /4 nch O.D. tanless steel tubes. Two nch dameter restrctors were nstalled n the lne between the gas generator and the valve. The gas flow through each restrctor was drected to the vector seals by means of the warm gas servocontrol valve. The control valve s a b-stable, flapper-type valve whch operates n a pulse duraton modulaton (PDM) mode and provdes proportonal control to the nozzle poston. It s smlar to the sngle stage flapper valves developed at Aeronutronc Dvson, Phlco-Ford Corporaton for the Shllelagh Jet Reacton Control system, and now used for the plot system of the two-stage Mnuteman Roll Control valve whch s currently n producton. The valve has a flexurally-mounted armature (flapper) wthn a cylndrcal body whch ncorporates magnetc pole peces and flow orfces. The only movng part of the control valve s the flexure-mounted flapper. The flapper s made of ferromagnetc alloy, welded to a stanless steel flexure. The flexure suspends the flapper between two sets of magnetc pole peces: gas enters the valve through ether of the two control valve flow orfces, as selected by energzng the approprate solenod col and by movng the flapper to close one of the orfces. Gas enterng the valve then exhausts through the vent port. -9-

20 ff I,.~»«<^x«TOTI^W-*TTO«*N?! ^^ *-*"-.. <a W»WM, EXTENO ~ RETRACT.. Ol* 3 3 : :L,'\.-* (: ^E> :: V N A >-vj^ - /. I.. cfc Mg =*_ :ä* axpraj B NOTES: T>«^r a*(*sto~»"<* * *) r< 'mr**, suewcss ruce TU ss Ifc* yctque s.fms ', '** *a #.) **' -&$ $ S>2» loe&jt SC* *S.ITM+C ly ap-r^v^/htr- T*euo eeußom/c (, * ««r-af o# sctews. 3^=» * utt/caur fl T M AJG-I* TO OVM MC tso* Bf) so y»"9r tf* _rf<*<,.-««*<vm.*«ß+cto ^gz=»vb*t f»7.tc SM**cr% o* fwus >). mack-u* buss', : Tfc /*STMu«ro>/ r Ts» -OS C0t4*4 30** /W -0/ «T00 **0 **» WS I T- J_> -O* <. */"$ **»«# # -<«#«*V *»*> </«'T»A#J / yv<«oct IC oce TDT*t ClC*&* FIGURE 4. NOZZLE ASSEMBL

21 ACT H» A» f... ' n r! >'«% "L EXTEND RfcTHACT rr:,.--^-' ' 9 Jm^p4**; *; : ; * T - 6-' H" v *»'30 2.'/» 5 3»=! gtotyc SJTTQH (fts* uc */.-. *<* mtf*c :- c?'«& / * ' *«<*.;.#; **-J: MtCf-ttS. sort-', >* CS-t?'tH.-.4fl.. %tl70*/*. t*j /* - ' ' /vc" I*» -»»0/ CQNFG fshowu) -S3 CQjf ;S> '» 2 «< 4*4» ;,"* r*",%.u-.' J '" '. " l * * ~* ' ' ".. ^,', * /~J» ; ' -' ee'»«jo " ' -t*. J!l*».,"G,», # f T X». _±oc»0 CUP sere* MMI4M *>Ttu-"0**Tn. ItlOlhQI XCOLCtJ*. sa-nrr toe m> C0*sca*w ~QUTt* *ct sat» m*j5 Q"gl>J6 7-umt> eeumuc. oc»3 CUP sctf-f t**slo-cl SKTtVS*»,, jjfflmg \**ol-*>t'c «M4 th-a eo-nt,»ten* atn. "' c y4 I* 'j? **«S I 'Tll'.!.' «:«ü-rn rygsi " ' j-zfcoa-ct /vocmran **+*, nömrö 4l*T; c : ;»]<>>:,'erct-h \sr»lj tc-rct.uq 4 [4 2 2 '/ g«*»*ro7/7 Mf«rV R^,!* = - fj * I * I *. r< IÖL _! sfttt^-c' sr/h. armm*4# j ##[ *. «I 4«f;* " ^uu.cout ""**-72-0/ <4A/«4 *»cy "" " J/'f-S». «Mf-«*»Lctl "/** *»««*» *»/^ I /*f;'f **<»* 4** : f/l'tw VC!.'. :".. -/.V A.X^-tfZ tc *****:< ' " **!-.j?: -T'lc. / -*<«* * «/ /* 7. 3C/&-.. *' -«."V* «Vtff >tfftuf; *7»«a*.'-?." *«*-.. «ffr. WMors s* «-»< #«#«.. *, «*.»sjrs? JT/f* UUV.'-"«/*, " ^ *. *»*' 2 *J -; ";v /W»»J Hf S KXS '? *». " - T**- '-tea ; BK Cst* :«." *. ' * ' * «uetm; sc *>.< JKMILV, Inwxr. NO »I..

22 ,_._,_,^w..,.. J. Wm ' m»".»-'» ' " "»N.w BB.Uo» FIGURE 5. NOZZLE ASSEMBLY, TEST ARRANGEMENT

23 l 0 p-t/.tet - WF^k 3- CD d QJ ^~ 04^.cos? n*> TM«IJ re«< FIGURE G. GAS-TEST ARRANGER

24 ! a!«. Per- 94 TE^sT ARC*r4<3ej.*C'0T *>*-..? ""^<fc' > r* >-». -.c^r Z 7 XI ' K3:-t*^5V h-z. \9%**r'* s=afc "P7C^7 ' z, to ->PJL. fesfes :2L ' 2.L ö*«^** P»»?»A? h 4s re a y Tue^-b -z UQ» "t* COM M»T on»l.m D'»»M NO Igt MT Bl«""»>"C»O OaMKWTTtM LIST or NATUUL ot nwts LIST - %-->. IWortf-OS». ancncarm h t - %MTO» WgMOII HU». MJHTA THIOVCC GAS TC, T ARRANGEMENT I27C4? ARRANGEMENT, DRAWING E Reproduced from best avalable copy.

25 u w o < < w H W N O o -3-

26 E25-75 One vlave s requred for each control axs. The valve operates n a PDM mode to control the pressure dfferental between the opposng THIOVEC nozzle vector seals as shown n Fgure. Gas flow to the vector seals s ntroduced through a restrctor n the nlet lne and s vented through the control valve. The relatve szes of the valve flow orfces and restrctors are such that wth the flapper held n a hard-over poston, the control valve wll vent all the gas enterng the nlet restrctor as well as ventng the actuator on that sde. All of the gas comng through the other restrctor s retaned so that dfferental pressure s obtaned. Wth the control valve operatng n a pulse duraton modulaton (PDM), the flapper dwell tme on each of the restrctors controls the amount of gas n the vector seals. Ths establshes the dfferental pressure between opposng vector seals, and the resultng net torque s appled to the nozzle as a functon of command. Durng the warm gas tests, the flapper cycled from one flow orfce to the other at a constant cyclc rate of 60 Hz. The dwell tme on ether restrctor was controlled from zero to 00% of the cycle perod. The PDM command s expressed on a scale from -00% to +00%, where -00% represents contnuous dwell on one restrctor, +00% represents contnuous dwell on the other restrctor, and 0 represents a condton where the flapper dwells 50% of the tme on one restrctor and 50% on the other. These commands would correspond respectvely to nozzle poston of hardover one way, hardover the opposte drecton, and null. Intermedate postons for proportonal control are attaned wth PDM commands proportonal to the poston desred. The PDM sgnal to the valve s generated n an ntegrated servoamplfer. A summng amplfer s used to compare the command and feedback sgnals n the ptch and/or yaw axes. The command sgnals are nput to the amplfer module as analog voltages. The feedback sgnal s generated by the poston ndcatng potentometers attached to the nozzle. The command and feedback sgnals are compared n one amplfer and summed wth the PDM waveform. For mproved frequency response a rate compensaton network was ncluded n the summng amplfer. The valve drver energzes one valve col when the summng amplfer output s postve and the opposte col when the output s negatve, thus generatng the percent PDM command at the waveform generator frequency. Only the summng amplfer and drver crcut need be duplcated for the second control axs. The propellant gran used for the warm gas tests was an end-burnng type whch burned for a nomnal acton tme of 6 seconds at 90% of maxmum pressure. The propellant's low flame temperature and combuston products, whch were free of sgnfcant sold partculate and toxc or corrosve elements, proved hghly compatble wth the nozzle and actuaton system hardware. -4-

27 E25-75 Cold gas tests were conducted before the warm gas tests to assure that the TVC nozzle and control system functoned properly pror to testng wth warm gas. Test data acquston ncluded nternal nozzle pressure smulatng motor chamber pressure, nozzle actuaton supply pressure, vector seal (actuator) pressure, nozzle poston, nozzle command, and nozzle bearng lubrcaton pressure. The data was acqured both dgtally and as analog. -5-

28 I E TEST RESULTS 4. General Three types of tests were conducted usng warm gas: ) Typcal duty cycle to determne general response characterstcs and response to step functon command (Fgure 2). 2) Command nput versus nozzle poston at a fnte frequency to determne hysteress loop. 3) Frequency response and phase lag. For the three fnal warm gas tests the nozzle was not dsmantled or cleaned; all tests were completed the same day. The nozzle was checked wth cold gas pror to proceedng to the next warm gas test to verfy proper operaton. The frst two tests were conducted wth a maxmum generator chamber pressure of 680 psa. The last test had the prmary orfce ncreased to provde a slghtly lower (200 psa) pressure and a longer acton tme to ensure suffcent acto: tme to accomplsh the frequency sweep. 4.2 Duty Cycle Tests The average slew rate from tme of command sgnal to 90% of full command deflecton 0 degrees was nomnally 65 deg/sec wth a maxmum slew rate of 297 deg/ sec. In all responses to step command there was an 0.08 to second nterval from the tme of command sgnal to the frst moton of the nozzle. No nozzle overshoot occurred n any of the nozzle's responses to the duty cycle ndcatng that the nozzle had been crtcally damped. Fgure 8 presents the test results showng the commanded duty cycle and the nozzle response. Fgures 9 and 0 present the pressuretme curves of the gas generator (supply) pressure and the vector seal actuaton pressures, The maxmum pressure dfferental across the vector seals occurred as the nozzle was reachng the commanded poston. At the pre?sure spke the dfferental pressure was 685 psg. The spke quckly dropped off to a steady dfferental pressure of 420 psg. Actuaton torque, developed durng the pressure spke, was 063 n.-lbs and at the more steady dfferental pressure condton the torque developed was 650 n.-lbs. -6- I!!

29 '. E25-75 BA j : ^_r_.j:; - ' 8.00 llmf llc.. ' 6.00 '' > 4.00 % c o I 2.00 o» N I 0.00 I n I fr Ir. u» -H r: -- c::! * I : ' ',... _j_. J._. -. J J _4. H ft!! L..! I j - * ". " T II! j!... I...,. I I '. \ -. r x.! -\ -: - l -- -*! M! I! ' ' ' ]. j : 8.00 r - " ' p: f B l! Tme, seconds - ' FIGURE 8. DUTY CYCLE TEST RESULTS -7-

30 ^fl8p«ep»w-«*"'w^»?w!p E25-75 BA3476 f T _ I TC- Chamber Pressure - I, a, f oo r Tme, seconds FIGURE 9. DUTY CYCLE, CHAMBER AND VECTOR SEAL PRESSURE

31 lyrmmmmmrmmvm WPWm m m unwy* «HMJ.funjM J... " "* WWP.m" >»...m«*" j'-pfy. FIGURE 0. DUTY CYCLE TEST, CHAMBER AND VECTOR SEAL PRESSURE E25-75 BA » I I C Tme, seconds

32 E Command Input Versus Nozzle Poston (Hysteress Loop) The nozzle hysteress was determned usng a trangular wave command nput of 0.3 Hz and a full nozzle deflecton command of ±0. The hysteress loop of the nozzle s shown n Fgure. Fgures 2 and 3 present the pressure-tme curves of the gas generator (supply) pressure and the vector seal actuaton pressures. 4.4 Frequency Response and Phase Lags The frequency response and phase lags were measured whle mposng a snusodal frequency sweep of ± 2.5 amplttude. The -3 db pont occurred at 25 Hz wth the 90 phase lag occurrng at approxmately 20 Hz. Fgure 4 presents the test results showng the commanded frequency sweep and nozzle response. Fgures 5 and 6 present the pressure-tme curves of the gas generator (supply) pressure and the vector seal actuaton pressures. Fgure 7 presents a plot of nozzle frequency response, expressed n decbels, versus the snusodal frequency. The nozzle response n decbels s computed usng the followng expresson: decbels = 20 log 0 AR where AR, the ampltude rato, s the rato of nozzle poston to nozzle command. -20-

33 SA A 0 a o g z Nozzle Command, degree«figure. THIOVEC NOZZLE WARM GAS DEFLECTION HYSTERESIS LOOP -2-»

34 Mpll lanv ^PHHHHMPVPMRfMppPM ""W mpuu...-,_.,.. _ -..,,..,;..,,. E25-75 to to BA SP & «I c r M / / ; r - TC Chamber Pressure : ' '! - ( T! J u w VT I 4 J I ] 4.. I t ; l r Tme, seconds ~ :. j.. 4- ~ _ ! I ^m P "... V /ectc!: IT? : -~ - -j «r :..;. j' ---J - -! -!!! j ( j r:*r -r - -"-! - FIGURE 2. HYSTERESIS TEST, CHAMBER AND VECTOR SEAL PRESSURE

35 ! m*m^~>ym v w**^^mrn*rmm** E25-75! CO BA rr / / / / /.-.J L_ tä!:.' TC- Chamber Pressure :.'. - -T~* :"t '" I U [!!. ':' aäb Jh W\. ; L. - I f- 4- "! ^"! --I Press ure r -h ; I '' ' f lt ]]' [ :: : ;': '.. *.; * V t '!' '!; \..." :. '. r. \\\' *! :,! H!I!H ll;. - r- ~ jf H - j:l 7" j -.. r'. : Jl; ll ' ^ j -Tf V Tme, seconds x; '- * '. U.j..., f ' '"' t. n ~" '7 : FIGURE 3. HYSTERESIS TEST, CHAMBER AND VECTOR SEAL PRESSURE

36 I I»» l l.l.!! p e^r- «^"^ * E25-75 ha I BA3479 S * a "«5 6. CO o c w E (S 2.00 L L. - - *'T -, ~.: _... ~ t k V 7n : ~ - :~ III... ' t ffr - - : --j - j MM r~v 7 W H IB Tme, seconds " '" FIGURE 4. FREQUENCY RESPONSE, TEST RESULTS

37 FIGURE 5. FREQUENCY RESPONSE TEST, CHAMBER AND VECTOR SEAL PRESSURE E25-75 BA ( Tme, seconds

38 FIGURE 6. FREQUENCY RESPONSE TEST, CHAMBER AND VECTOR SEAL PRESSURE! '' ' '" - E25-75 BA je & : TC- Chamber Pressure L«r* '.!.4....A. - -' - j ^H. ;. llt Vector Seal Pressure -' Lr..._ '., \ 0.0C C Tme, seconds IT' -~ ;. 4.:: h :!. 00

39 pa w. ' E25-75 I I Frequency, H^ FIGURE 7. NOZZLE FREQUENCY RESPONSE

40 E NOZZLE HARDWARE POST-TEST CONDITION As noted prevously, three consecutve tests were performed on the nozzle wthout dsmantlng and cleanng n between the tests. Fgures 8 and 9 show the condton of the vector seal area and the deposts on the outer race and the seal. Fgures 20 and 2 show the condton of the vector seal cover, ncludng the nlet port through whch the warm gas entered nto the vector seal. Fgure 22 shows the debrs and the condton of the vector seal, O-rng, metal band, and Teflon back-up rng. Fgure 23 shows the condton of the outer race and the ball (nner race) after removal of the resdual grease and debrs. The axal burnsh marks that can be seen on the outer race are normal and are not deleterous to the operaton of the nozzle. It should be noted that there are no marks or scratches on the ball, ndcatng that there was ample clearance durng the seres of cold and warm testng. Inspecton of both the vector seal cover and outer race showed no sgn of heatng or other deleterous effects of any knd from the warm gas actuaton tests. After dsassembly, the nozzle was reassembled wthout rework other than cleanng and relubrcatng the components; n fact, the seal between the ball (nner race) and the outer race was not broken. After reassembly, the breakaway torque and runnng torque was measured at 0 to 5 and 5 to 0" n both the extend and retract poston. The values gven n the followng table were measured at an nternal chamber pressure of 500 psg to smulate motor chamber pressure. TORQUE VERSUS NOZZLE POSITION Breakaway Torque, Runnng Torque, Poston, degrees In./lb n. /lb 0 to 5 Extend to 0 Extend * 0 to 5 Retract to 0 Retract * Ths was the hghest torque measured at the 0 poston and wthn 5% of that predcted. -28-

41 mmmr*m * «. L I HI JUP 'f* vmw m J wj l to to I FIGURE 8. POST-TEST VECTOR SEAL ASSEMBLY NO.

42 ljilumi >» - vm^mmmmmmrm CO o I FIGURE 9. POST-TEST VECTOR SEAL ASSEMBLY NO. 2

43 lujpw.upu jmmnnym. wmmmmt I)»"" ' '«~ <», m*^(w.'"-"f«' - T^ ""ll- :r~ 'BV' rmwtju'.w I r»7."»j2/<nu FIGURE 20. VECTOR SEAL COVER, POST-TEST, SEAL NO.

44 JMNPMMOTI I CO to."»752 ( In FIGURE 2. VECTOR SEAL COVER, POST-TEST, SEAL NO. 2

45 II' Mp.l..luj! n Lj mmmtm I CO V. - -.V«~.l II' n!> FIGURE 22. VECTOR SEAL COMPONENTS, POST-TEST

46 H ^WH '«Ml»»^ BW»»"^W!»^W WP CO FIGURE 23. OUTER RACE, POST-TEST

47 E CONCLUSIONS ) The program objectve was successfully accomplshed n that all test results and the post-test condton of the hardware demonstrated the feasblty of actuatng the THIOVEC nozzle wth warm gas. 2) Snce the nozzle hardware was dentcal to that prevously used wth a hydraulc flud actuaton system, t can be concluded that the nozzle desgn features can reman dentcal and are ndependent of the type of actuaton system, that s, ether pneumatc or hydraulc. 3) Phase n of ths program has successfully characterzed the dynamc response of a warm gas actuated THIOVEC TVC nozzle. 4) Although the nozzle control system was not adjusted or desgned for optmum nozzle dynamc characterstcs, the nozzle response, phase lag, and slew rate are well wthn expected requrements for underwater mssle TVC systems. 5) The warm gas actuaton system produced no nozzle overshoot. 6) Sx repettve warm gas tests usng the same nozzle and actuaton system hardware wth only mnmal clean-up after each test have demonstrated the absence of any adverse effects due to warm gas actuaton of the THIOVEC TVC nozzle. -35-

48 E25-75 APPENDIX A NOZZLE DESCRIPTION.0 GENERAL For descrptve purposes, the THIOVEC TVC nozzle can be consdered as consstng of four basc groups of components: ) THIOVEC Bearng Assembly 2) Actuator Mechansm 3) Actuaton Control System 4) Nozzle Lner (nsulaton, throat, and ext cone) An artst's presentaton of a typcal THIOVEC nozzle wth cutaway vews THIOVEC TVC test are shown n Fgures Al and A2. Only tems ) and 2) above are dscussed n ths appendx. The Actuaton Control Secton, Item 3, s dscussed n the text of ths report. Wth respect to Item 4),Nozzle lner, the THIOVEC nozzle structure, whch nterfaces wth and supports the nozzle lner, s no dfferent from that of other movable TVC nozzles. 2.0 THIOVEC Bearng Assembly The THIOVEC nozzle s bascally a ball-and-socket type TVC nozzle. The operatng chamber pressure of a rocket motor produces a sgnfcant force on the movable ball porton of the nozzle. Ths force s termed "nozzle blow-out load." Ths load s reacted aganst the socket or statonary porton of the nozzle and, n most TVC nozzle desgns, causes hgh frcton at the ball-to-socket nterface. The most sgnfcant feature of the THIOVEC nozzle s the unque method of mnmzng the frctonal forces resstng movement of the ball wthn ts socket. Frctonal forces are low because of the lubrcant between the nner r^re (ball) and outer race (socket) of the nozzle. The lubrcaton seals seal n the lubr ant upon whch the nner race "floats." Therefore, the nner race s n contact wth only the lubrcaton seals and lubrcant, producng a very-low-frcton force resstng rotaton of the nner race. Much of t:e frcton force usually found n ball-and-socket type TVC nozzles s replaced by the lower vscous shear force at the ball-lubrcant nterface. A-l

49 mmm ^^m*wm,,.. p SA 765 BLOW DOWN RESERVOIR OUTER RACE VECTOR SEAL COVER LUBRICATION SEALS to FIGURE Al. UNDERWATER THIOVEC NOZZLE

50 UNDERWATER THIOVEC TVC COMPONENTS VECTOR SEAL COVER - - ACTUATOR RING SOCKET BALL (WITH PLASTICS),,,-...,. j.m WHHflM.-lf^fWWWWI'llWIlL I " n^w. THIOVEC TVC NOZZLE VECTOR SEAL COMPONENTS > GRAPHITE THROAT INSERT \ Y TEFLON WIPER RING BLAST TUBE ADAPTER SECTION FIGURE A2. UNDERWATER THIOVEC TVC COMPONENTS

51 Axal dsplacement of the nner race occurs n the aft drecton at a rate proportonal to nozzle blowout load produced by chamber pressure and the axal load produced by the hydraulc actuaton system. The nozzle blowout load pressurzes the lubrcant, and the subsequent force balance acheved supports the "ball" n ts "socket." Axal dsplacement of the nner race s lmted by the extent to whch the O-rng lubrcaton seals are dsplaced n ther grooves and the outer race deflected by the lubrcaton pressure generated. 3.0 AC TUATION MECHANISM Low resstve torques attanable wth the use of the THIOVEC bearng permt the use of a compact actuaton system n place of conventonal external actuators. The operatng prncple of the THIOVEC nozzle actuaton system s conceptually llustrated by the pston-actuated nozzle shown n Fgure A3. When pston A s extended to maxmum length, the nozzle s ptched downward, smultaneously retractng pston B. To deflect the nozzle upward, pston B s extended whle pston A s retracted. To obtan deflecton n the yaw axs, two addtonal pstons located 90 degrees crcumferentally from pston A and B, respectvely, would be requred. Moton n planes ntermedate to the ptch and yaw planes s accomplshed by proportonate extenson and retracton of adjacent pstons. SA769 Outer Race Vector Seal Cover Pston A Actuator Rng / Pston B FIGURE A3. THIOVEC^ ACTUATION SYSTEM CONCEPT A-4

52 E25-75 In the THIOVEC nozzle, pston functons are performed by four kdney--ahaped flexble vector-seal assembles located between the movable actuator rng and a face on the outer race. Kdney-shaped O-rngs, wth teflon back-up rngs contaned wthn ther steel bands, are used as the vector seals. The four vector seals are spaced 90 degrees apart. They flex, as llustrated n Fgure A4, durng nozzle movement. Fgure A4 shows the approxmate shape of the four seals at the null, maxmum ptch up, and mnmum ptch down postons when each seal s vewed perpendcular to the nozzle longtudnal axs. The vector seals are flled wth hydraulc flud that s contaned by the nner surface of the vector seal cover and the outer surface of the outer race. Thus, when pressure s appled to the hydraulc flud, the vector seal attempts to attan a crcular form. The actuator rng s forced away causng the nozzle to deflect. The vector seal, 80 degrees from the pressurzed seal, s vented to allow nozzle movement. In Fgure A4, note that when the nozzle s vectored n the ptch drecton, the yaw seals assume rregular shapes. Ths produces unbalanced forces tendng to rotate the vector seals about the longtudnal axs. In desgns such as the Harpoon THIOVEC^ nozzle, where the vector seals are not nterconnected but separated, t s necessary to.sstran each vector seal n ts crcumferental poston by mechancally matng t wth the actuator rng and outer race. Rotaton of the nner race s ressted by keys matng wth longtudnal slots n the accuator rng and attached to the outer race. Because the vector seal actuaton mechansm s contaned between the fxed and movable nozzle parts, the nozzle s sad to be nternally actuated as compared to a TVC nozzle wth conventonal external actuators. From the desgn standpont, the retracted (compressed) versus the extended (expanded) poston of the vector seals must be analyzed. When compressed, the vector seal s longer n the crcumferental drecton, resultng n an ncreased effectve pston area. Thus, when hydraulc pressure s appled, a force s appled to the actuator rng, a result whch, n large, restores torque about the nozzle pvot pont. On the other hand, when the vector seal s fully extended, the seal s shorter n the crcumferental drecton, resultng n a decrease n the effectve pston area and provdng a reduced torque. Therefore, the pston area vares wth the nozzle poston. The torque developed s proportonal to the pston area tmes the pressure n the seal. The three basc torques resstng nozzle movement are lubrcaton-seal frcton, vector-seal frcton, and Internal aerodynamc sprng torque. Aerodynamc torque s mnmzed by desgnng the nozzle throat near the nozzle pvot pont. Actuaton flud s suppled to the vector seals through electromechancal se/vocontrol valves. These are connected by a manfold arrangement. Two servocontrol valves are requred for omnaxal nozzle moton. As ether valve permts pressurzaton of one vector seal, t smultaneously vents the opposte vector seal. A-5

53 SA768 Ptch Vector Seals and 2 Yaw Vector Seals 3 and 4 Ptch Vector 8 «Vector Seal Ptch-Up Null Ptch-Down r\ \J KJ r\ Vector Seal 2 Yaw Vector Seele Vector Seal 3 r\ \J \y Vector Seal 4 FIGURE A4. VECTOR SEAL SHAPES VERSUS NOZZLE PITCH POSITION A-6