APPARATUS AND METHODS FOR PUSHING OUT AND DRILLING AN AERIAL FLARE
Provided are systems, apparatus, and methods for pushing out and drilling a flare grain in an aerial flare. The system includes at least three stands including a first stand holding a first electric linear actuator positioned to interface with the aerial flare and push out a flare grain of the flare. The second stand holds the aerial flare and is positioned relative to the first stand to facilitate interface of the flare with the first electric linear actuator. The third stand includes a drill and is movable relative to the second stand for drilling a hole in the flare grain. A second electric linear actuator is coupled to the third stand device moves the third stand device relative the second stand to enable the drill to engage with the flare grain. The system also includes a controller/processor automating the pushing and drilling operations by controlling the electric linear actuators.
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The invention described herein was made in the performance of official duties by employees of the Department of the Navy and may be manufactured, used and licensed by or for the United States Government for any governmental purpose without payment of any royalties thereon. This invention (Navy Case 200629US01) is assigned to the United States Government and is available for licensing for commercial purposes. Licensing and technical inquiries may be directed to the Technology Transfer Office, Naval Surface Warfare Center Crane, email: Crane_T2@navy.mil.
FIELDThe field of the present disclosure relates generally to apparatus and methods for pushing out and drilling an aerial flare, and more particularly to automated apparatus or methods for pushing out and drilling an aerial decoy flare grain including electrical actuation.
BACKGROUNDFor devices such as aerial decoy flares, testing of the flare grain involves pushing the flare grain or similar pyrotechnic substance used in flares out of a flare housing (also referred to herein as a unit under test (UUT)) and then drilling a shallow hole in the flare grain for further testing. This testing is typically for ordnance assessment or life cycle testing of in-service flare grains where items are taken out of inventory and evaluated. Known procedures for testing aerial decoy flares involve fully pushing the flare grain out of the flare housing with a pneumatically operated fixture. The pushed out flare grain is then transported to another fixture for drilling a shallow hole in the flare grain, which may be performed by another pneumatically operated fixture. Since these procedures are typically performed outdoors at ordnance test areas or ranges during cold weather conditions, for example, the moisture in the pneumatic lines tends to freeze causing safety concerns and production delays.
SUMMARYThe present disclosure provides a flare grain push out and drilling apparatus that does not rely on pneumatics, but rather electro-mechanical actuators, and also affords a singular apparatus such that flare grains do not need to be transported after being pushed out from a flare housing. In one aspect, the apparatus includes a base and three stands, of which two are stationary and one movable stand with a drill attached that is moved forward and reverse using a first linear actuator. One of the stands is a center stand that holds an encased test sample using a fixture designed to keep the sample stationary while the flare grain or composition is pushed by another second linear actuator towards the drill. Both linear actuators may be implemented with electro-mechanical devices that are controllable with a programmable controller (or similar microprocessor based controller) affording quicker and safer testing of flare grains.
Additional features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrative embodiments.
The detailed description of the drawings particularly refers to the accompanying figures in which:
The examples described herein are not intended to be exhaustive or to limit the invention to precise forms disclosed. Rather, the embodiments selected for description have been chosen to enable one skilled in the art to practice the invention.
The present disclosure provides an apparatus that affords the ability to push a flare grain composition of an aerial decoy flare out of the flare case, and also drill a shallow hole in the end of the flare grain composition to facilitate attachment of a base or other stand thereto for further testing. This present apparatus utilizes electric linear actuators (i.e., electromechanical linear actuators) rather than other mechanical devices such as pneumatic actuators, which affords at least the ability to operate the apparatus in the field even when temperatures are lower, such as below freezing (0° C.).
Apparatus 100 also includes a second stand 116 (also termed herein as a “center stand” as stand 116 is positioned between the first stand 104 and a third stand 120 to be discussed below) disposed or affixed on the base 102. The center or second stand 116, which is also termed a UUT stand, includes a UUT test holding fixture 118 disposed or affixed to a top portion of the UUT stand 116. The UUT test holding fixture 118 is configured to receive and hold an aerial decoy flare (or UUT), which is not illustrated in
Apparatus 100 further includes a moveable third stand 120, which is configured to be movable with respect to the base 102 and, in turn, with respect to the second or center stand 116. In one example, the third stand 120 may be mounted on a complementary rail, conveyor, or track 122 affixed to the base 102 allowing the third stand 120 to move along the rail 122 lateral or parallel relative to the base 102 as indicated by direction arrow 124. The third stand 120 is mechanically coupled with a second linear actuator 126 (LA 2) via the actuator rod 128 of linear actuator 126, which moves the third stand 120 laterally in the directions indicated by arrow 124. It is noted that in the embodiment illustrated in
The movable third stand 120 includes a drilling device 130 disposed on or affixed to a top portion 131 thereof. The drilling device includes a drill bit 132 or equivalent rotary cutting apparatus that is positioned to engage a second end portion of a flare grain (located at 134 but not specifically illustrated as the aerial flare is located in and held by holding fixture 118). When operated, the drilling device 130 and the drill bit 132, in particular, is brought into contact with the flare grain and drills a hole therein of a predetermined diameter and length dependent on the drill bit size and the distance linear actuator 126 moves the moveable third stand 120. In one embodiment, the drilling device 130 may be implemented with a Milwaukee magnetic drill press motor model number 6Z293, but is not limited to such.
According to still further aspects, the moveable third stand 120 may also include a fixed catch tray 136 having a proximate end affixed to a side 138 of the stand 120 and extending therefrom. The catch tray 136 is configured to catch an end cap of the flare that is located at end 134 of the flare and is initially pushed off by the force exerted on the flare grain at end 112 by the push rod 110 that is, in turn, transferred to end 134 since the flare grain is relatively solid. Furthermore, the catch tray 136 is configured to catch a sample (i.e., the flare grain after a hole is drilled therein by the drill device 130) and any explosive composition shavings created during the drilling process. As illustrated in
In yet further aspects, apparatus 100 may include a drill shield 142 that encloses or surrounds the drill device 130. The drill shield 142 helps to shield the explosive compositions of the flare grain from sparks that may occur in the electric motor of the drill device 130.
As shown in
Furthermore, the apparatus 200 includes a third movable stand 220 that is mounted on a rail or track 222 allowing movement of the stand 220 along or parallel with the longitudinal axis 250 of the base 202 toward or away from the second or center stand 216. Although not shown, a drilling device (and an accompanying drilling device shield) may be mounted on a top portion of the third movable stand 220 for engaging with and drilling a hole within a flare grain being held on the second stand 216. Similar to apparatus 100, the third movable stand 220 may be moved using a second electric linear actuator 226, which is coupled to the third movable stand with a push rod or throw 228 (not shown coupled to the third movable stand 220 in this illustration). Furthermore, the third movable stand 220 may include a catch tray 236 affixed thereto.
In aspects, the second or center stand 216 may be constructed such that at least a portion of the second electric linear actuator 226 is housed or enclosed by the stand 216 as shown in the example of
As further illustrated, the controller 502 is coupled to the linear electric actuators 506 and 508 (e.g., LA 1 and LA 2 corresponding to actuators 106, 206 and 116, 226, respectively) to control the operation thereof. In particular, the controller is configured in some embodiments to operate the linear electric actuators 506 and 508 in specific directions and at specific times/sequences. Additionally, circuitry 500 may further include optional key switches 510 and 512 in series with the electrical couplings between eh controller 502 and the linear actuators 506, 508 as safety locks to prevent the pushing/drilling operation unless authorized and/or a safety check of the area has been performed. In particular, it is noted that safety necessitates the removal of power to the controller while an unprotected operator is in the proximity of the fixture. Removal of power from the controller 502, however, may negate the programming function of the controller depending on the type of controller used. Accordingly, the use of keyed switches 510, 512 at least on the positive voltage wires between the controller and the linear actuators ensures that the linear electric actuators 506, 508 are inoperable. Thus, in some aspects an operator can be required to turn off the switches 510, 512, remove the keys, and then perform whatever operation is required near the fixture, re-insert the keys to close the switches 510, 512, and then continue operations.
In other aspects, it is noted that power supply 504 may be embodied as an AC and/or DC power supply that is powered by either an external source of power such as AC power from a generator or from stored energy sources such as one or more DC batteries. The power supply may include inverters to convert DC sources to AC, as well as converters to convert AC to DC. Furthermore, the power supply 504 may include current rectifiers and/or voltage regulators or converters to convert AC voltages/currents to DC voltages/currents or the increase/reduce DC to DC voltages. In still further aspects, the drill device may be configured as a DC device (e.g., 12 Volts DC powered).
The power supply 504 may also power the drilling device 514. Furthermore, the drilling device 514 may be turned on or off manually with a switch 516, which may be a single pole/single throw switch rated for the voltage/current of the drilling device 514 in one embodiment. In other embodiments, switch 516 may be a controllable power switch, such as with a power field effect transistor (FET) as one example, which is switchable by a supplied input voltage or current. In yet further embodiments, if the switch 516 is controllable, the controller 502 may selectively control operation of switch 516 as illustrated by the dashed connection between controller 502 and switch 516. For example, the control operation of the drilling device 514 by controller 502 via switch 516 may be implemented according to a predetermined drilling process coordinated with operation of the second electric linear actuator 508 (or 126 or 226) that moves the third stand holding the drilling device 514. In a further example, the drilling device 514 may be turned on after the second linear actuator (e.g., 126, 226, 508) has moved the third stand (and drilling device) into close proximity of the flare grain to be drilled. Additionally, the controller 508 may be configured to run the drilling device for a predetermined period of time as the second linear actuator continues to move the third stand toward the second stand and, hence, the flare grain, in order to drill a hole of a predetermined length.
In further aspects, easy transportation of the controller/processor 502, power supply 504, switches 510, 512, and 516 and associated wiring between these elements may be desirable. Accordingly, these components may be contained within a housing or case illustrated by dashed line 518. In one embodiment, a hard case may be employed such as a Pelican™ case. In yet further embodiments, the controller and electrical box may be attached or affixed to inner surfaces of the case. In still further aspects, the case 518 may be configured with apertures or access ports to allow access to internal components (e.g., key switches 510, 512 and controller 502) without opening of the case 518.
Turning to
Next, method 700 includes initiating a drilling sequence wherein drilling device (e.g., 130 or 514) is started and a second linear actuator (e.g., LA 2 (126, 226, or 508)) moves the third stand (e.g., 120 or 220) to engage with a second end of the flare (and flare grain) and drill a hole in the flare grain of a predetermined depth and diameter as shown in block 706. The processes of block 706 may include implementing a predetermined drilling process, such as via controller 502, the process including operating the drilling device for a predetermined time period and operating the second electric linear actuator to cause the third movable stand to move toward the second stand at a predetermined rate and distance in order to drill a hole in the flare grain. Furthermore, the processes of block 706 may also include maintaining the push rod (110 or 210) in position at the other end of the aerial flare to maintain an opposing force to the force of the third stand applied by the second linear actuator and drilling device such that the flare grain is held immobile during drilling. After the processes of block 706, the third movable stand may be retracted to then allow operation of the first linear actuator and associated throw rod (110, 210) to continue or resume applying pushing force to then fully push the now drilled flare grain out of the case of the aerial flare, such as into the catch tray (136, 236) as shown by block 710.
Finally, the controller (e.g., 502) may be programmed to cease operation, which may also include retraction of the push rod of the first linear actuator, shutting off the drilling device, moving the third stand back to an original position away from the second stand, and shutting off power/voltage to all electrical devices as shown in block 710. This then allows an operator to the safely retrieve and remove the flare grain from the UUT stand (or catch tray 136 or 236) for further testing as shown in block 712.
As those skilled in the art will appreciate, the present apparatus and methods allow for pushing out the flare grain and drilling a hole using solely electrical actuators and automation outdoors during cold weather conditions when moisture in other systems using pneumatic lines, for example, tends to freeze causing safety concerns and production delays. In addition, the present apparatus affords for both pushing out of the flare grain and drilling as opposed to the flare grain simply pushed out of the case requiring an operator to pick up the flare grain and, in turn, then have to set it up to be drilled. Accordingly, the disclosed combination of the two processes (pushout/drilling) eliminates the hazards inherent with hands on repositioning of raw explosive compositions between the push-out machine and the drilling operation.
Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the spirit and scope of the invention as described and defined in the following claims.
Claims
1. A system for pushing out and drilling of a flare grain in an aerial flare comprising:
- a first stand mounted to a base and configured to hold a first electric linear actuator with a throw rod positioned to interface with a first end of an aerial flare and exert a force on a first end of a flare grain within the aerial flare to cause the flare grain to move relative to a case of the aerial flare;
- a second stand mounted to the base and configured to receive and fixedly hold the aerial flare;
- a third stand mounted to the base and configured to be movable relative to at least the second stand and the aerial flare and further including a drilling device attached thereto;
- a second electric linear actuator coupled to the third stand and configured to move the third stand and the attached drilling device relative to a second end of the flare grain to engage the drilling device with the second end of the flare grain for drilling a hole in at least one portion of the flare grain; and
- a controller electrically coupled to the first and second electric linear actuators and configured to control the first and second electric linear actuators according to a predetermined sequence of operation.
2. The system of claim 1, wherein the third stand further includes a catch tray affixed thereto and configured to be located under at least the second end of the aerial flare when the third stand is moved toward the second stand for drilling the hole in the at least one portion of the flare grain
3. The system of claim 2, wherein the second stand is configured with an opening allowing the catch tray to pass through the second stand and be positioned under at least the second end of the aerial flare.
4. The system of claim 1, wherein the predetermined sequence includes:
- operating the first electric linear actuator by the controller to exert the force on first end of the flare grain to cause an end cap of the aerial decoy located at the second end of the flare grain to be pushed off and expose the flare grain and also cause the flare grain to be at least partially pushed out of the case of the aerial flare at the second end of the aerial flare; and
- operating the second electric linear actuator after operating the first electric linear actuator to cause the drilling device to contact the flare grain at the second end of the aerial flare and to drill the hole in the at least one portion of the flare grain.
5. The system of claim 4, further comprising:
- operating the first linear actuator after operating the second linear actuator and the drilling device to fully push the flair grain out of the case of the aerial flare.
6. The system of claim 1, wherein the controller is further configured to control operation of the drilling device according to a predetermined drilling process coordinated with operation of the second electric linear actuator.
7. The system of claim 6, wherein the predetermined drilling process includes operating the drilling device for a predetermined time period and operating the second electric linear actuator to cause the third movable stand to move toward the second stand at a predetermined rate and distance.
8. The system of claim 1, wherein the third stand further comprises a rail disposed between an upper portion of the third stand and the base and configured to allow the third stand to move relative to the base.
9. An apparatus configured for pushing out and drilling a flare grain in an aerial flare, the apparatus comprising:
- a base;
- a first stand mounted to the base and including a first electric linear actuator with a throw rod positioned to interface with a first end of an aerial flare and exert a force on a first end of a flare grain within the aerial flare to cause the flare grain to move relative to a case of the aerial flare;
- a second stand mounted to the base and configured to receive and fixedly hold the aerial flare;
- a third stand mounted to the base and movable relative to at least the second stand, the third stand further including a drilling device attached to a top portion thereof;
- a second electric linear actuator coupled to the third stand and configured to move the third stand and the attached drilling device relative to a second end of the flare grain to engage the drilling device with the second end of the flare grain for drilling a hole in at least one portion of the flare grain; and
- a processor communicatively coupled to the first and second electric linear actuators and configured to control the first and second electric linear actuators according to a pre-programmed sequence of operation.
10. The apparatus of claim 9, wherein the third stand further includes a catch tray orthogonally affixed to a vertical wall portion of the third stand and configured to be located under at least the second end of the aerial flare when the third stand is moved toward the second stand for drilling the hole in the at least one portion of the flare grain.
11. The apparatus of claim 10, wherein the second stand is configured with an opening allowing the catch tray to pass through the second stand and be positioned under at least the second end of the aerial flare.
12. The apparatus of claim 9, wherein the predetermined sequence includes the processor:
- operating the first electric linear actuator by the controller to exert the force on first end of the flare grain to cause an end cap of the aerial decoy located at the second end of the flare grain to be pushed off and expose the flare grain and also cause the flare grain to be at least partially pushed out of the case of the aerial flare at the second end of the aerial flare; and
- operating the second electric linear actuator after operating the first electric linear actuator to cause the drilling device to contact the flare grain at the second end of the aerial flare and to drill the hole in the at least one portion of the flare grain.
13. The apparatus of claim 12, further comprising:
- operating the first linear actuator after operating the second linear actuator and the drilling device to fully push the flair grain out of the case of the aerial flare.
14. The apparatus of claim 9, wherein the processor is further configured to control operation of the drilling device according to a predetermined drilling process coordinated with operation of the second electric linear actuator.
15. The apparatus of claim 14, wherein the predetermined drilling process includes the processor operating the drilling device for a predetermined time period and operating the second electric linear actuator to cause the third movable stand to move toward the second stand at a predetermined rate and distance.
16. The apparatus of claim 9, further comprising a shield mounted to the third stand and configured to encompass the drilling device to shield the flare grain from electric arcs or sparks that occur in the drilling device.
17. A method for pushing out and drilling of a flare pyrotechnic substance of an aerial flare comprising:
- mounting an aerial decoy flare to a unit under test (UUT) stand;
- initiating a push out sequence wherein a first electric linear actuator is operated to cause a push rod of the first electric linear actuator to exert a pushing force on a first end of the flare to push out an end cap of flare, as well as push at least a portion of the flare pyrotechnic substance of a casing of the flare;
- initiating a drilling sequence wherein a drilling device is started and a second linear electric actuator is operated to move a movable stand holding the drilling device to engage with a second end of the flare and the flare pyrotechnic substance to drill a hole in the flare pyrotechnic substance of a predetermined depth and diameter; and
- ceasing powering of all electrical devices including the first and second electric linear actuators and the drilling device to allow retrieval of the drilled flare pyrotechnic substance.
18. The method of claim 17, further comprising:
- operating the first linear actuator after operating the second linear actuator and the drilling device to fully push the flair grain out of the case of the aerial flare.
19. The method of claim 17, further comprising:
- operating the drilling device for a predetermined time period and operating the second electric linear actuator to cause the movable stand to move toward the UUT stand at a predetermined rate and distance in order to drill the hole in the flare pyrotechnic substance.
20. The method of claim 17, wherein ceasing powering of all electrical devices further includes retraction of the push rod of the first linear actuator and moving the movable stand back to an original position away from the UUT stand prior to shutting off power or voltage to all the electrical devices.
Type: Application
Filed: May 3, 2023
Publication Date: Nov 7, 2024
Applicant: The United States of America, as represented by the Secretary of the Navy (Arlington, VA)
Inventors: Paul Fries (Owensburg, IN), Nicholas Uebelhor (Jasper, IN), Austin D. Schulte (Bloomfield, IN), Michael C. Jones (Loogootee, IN)
Application Number: 18/142,609