Abstract: An actuator includes an actuator housing, a ball screw, and an axial soft stop assembly. The ball screw extends through the actuator housing and has a first end and a second end. The ball screw is coupled to receive a drive force and is configured, upon receipt of the drive force, to selectively move in a retract direction and an extend direction. The axial soft stop assembly is disposed within the actuator housing. The axial soft stop assembly is configured to be selectively engaged by the ball screw and, upon being engaged thereby, to translate, with compliance, a predetermined distance in the extend direction, and to prevent further movement of the ball screw upon translating the predetermined distance.

Abstract: An actuator includes an actuator housing, a ball screw, and an axial soft stop assembly. The ball screw extends through the actuator housing and has a first end and a second end. The ball screw is coupled to receive a drive force and is configured, upon receipt of the drive force, to selectively move in a retract direction and an extend direction. The axial soft stop assembly is disposed within the actuator housing. The axial soft stop assembly is configured to be selectively engaged by the ball screw and, upon being engaged thereby, to translate, with compliance, a predetermined distance in the extend direction, and to prevent further movement of the ball screw upon translating the predetermined distance.

Abstract: Systems and methods of controlling solid propellant gas pressure and vehicle thrust are provided. Propellant gas pressure and a vehicle inertial characteristic are sensed. Propellant gas pressure commands and vehicle thrust commands are generated. A propellant gas pressure error is determined based on the propellant gas pressure commands and the sensed propellant gas pressure, and vehicle thrust error is determined based on the vehicle thrust commands and the sensed vehicle inertial characteristic. Reaction control valves are moved between closed and full-open positions based on the determined propellant gas pressure error and on the determined vehicle thrust error. The system and method allow the reaction control valves to operate at variable frequencies or at fixed frequencies. The system and method also allows propellant pressure to be commanded to follow a predetermined pressure profile or commanded to vary “on-the-fly.

Abstract: A modular electromechanical actuation system assembly is provided that includes an electronic control unit housing having a plurality of motor receptacles and a plurality of battery receptacles formed in an outer surface thereof. Each of the motor receptacles has an associated motor electrical interface, and each of the battery receptacles has an associated battery electrical interface. An electronic control unit is disposed within the electronic control unit housing and is electrically coupled to each of the motor electrical interfaces and each of the battery electrical interfaces. A plurality of motors are supported, one each, within one of the motor receptacles, and a plurality of batteries are supported, one each, within one of the battery receptacles.

Abstract: Systems and methods of controlling solid propellant gas pressure and vehicle thrust are provided. Propellant gas pressure and a vehicle inertial characteristic are sensed. Propellant gas pressure commands and vehicle thrust commands are generated. A propellant gas pressure error is determined based on the propellant gas pressure commands and the sensed propellant gas pressure, and vehicle thrust error is determined based on the vehicle thrust commands and the sensed vehicle inertial characteristic. Reaction control valves are moved between closed and full-open positions based on the determined propellant gas pressure error and on the determined vehicle thrust error. The system and method allow the reaction control valves to operate at variable frequencies or at fixed frequencies. The system and method also allows propellant pressure to be commanded to follow a predetermined pressure profile or commanded to vary “on-the-fly.

Abstract: A modular electromechanical actuation system assembly is provided that includes an electronic control unit housing having a plurality of motor receptacles and a plurality of battery receptacles formed in an outer surface thereof. Each of the motor receptacles has an associated motor electrical interface, and each of the battery receptacles has an associated battery electrical interface. An electronic control unit is disposed within the electronic control unit housing and is electrically coupled to each of the motor electrical interfaces and each of the battery electrical interfaces. A plurality of motors are supported, one each, within one of the motor receptacles, and a plurality of batteries are supported, one each, within one of the battery receptacles.

Abstract: The present invention provides methods of manufacturing a hot gas valve for a divert and attitude control system in a propelled craft. The methods include the steps of building a valve, or a plurality of separate valve components or segments using a solid free-form fabrication process, and assembling the plurality of separate valve components or segments if necessary to produce the hot gas valve. The solid free-form fabrication process comprises the steps of forming successive feedstock layers by depositing the feedstock material into a predetermined region, the feedstock layers representing successive cross-sectional component slices, and modifying the feedstock by directing an energy source to the predetermined region and thereby creating modified regions in the successive feedstock layers, the combined modified regions defining the hot gas valve or an at least partially-formed valve component or segment.

Abstract: A solid rocket motor including a combustion chamber, in which propellant is ignited to produce combustion gas, and a nozzle having a throat with an effective flow area, implements a system and method to inject gas into the nozzle throat to control its effective cross sectional flow area. Controlling the effective cross sectional flow area of the nozzle throat in turn controls combustion chamber pressure, thus the burn rate of the propellant in the combustion chamber, and thus the thrust generated thereby.

Abstract: A method is provided for manufacturing a missile component for use in a high temperature environment, where the missile component has a flow passage therethrough and the flow passage has a shape. An apparatus manufactured by the inventive method is provided as well. The method includes the steps of depositing a first metal onto a mandrel having the shape of the flow passage to create a first metal layer, applying an insulating material on to the first metal layer to create an insulating layer, machining a predetermined shape into at least a portion of the insulating layer, and applying a second metal onto the machined insulating layer to create an outer shell layer.

Abstract: A method and apparatus for producing gas, for example for propulsion. Propellant grains are segmented, preferably in symmetrically arranged pairs and preferably about a central channel extending longitudinally between the ends of the grains. Longitudinally extending grains may be ignited at one end only of each grain, at both ends, and/or at one or both ends along with at an interior portion of a grain. In order to maintain a relatively constant center of gravity, symmetrically arranged pairs of grains can be ignited simultaneously. In order to produce a desired pressure versus time profile, the number of ignition points on a grain can be varied.