Case Studies

Missile Tester

Client: Manufacturer of advanced technology systems
(Because of security concerns surrounding this project, we can only discuss this in very general terms.)

Background:
Laser guided training missiles are assembled from multiple sub-component assembles. Each assembly must be manufactured and individually tested, before the final assembly can be started. Everite was contracted to design and build testing machines for two sub-component assemblies. The first assembly housed the guidance system, while the second controlled the missile steering mechanism.

Manufacturing Challenge:
Everite mechanical and electrical teams met with the customer's engineering team to determine the specification details for both of the testing machines. Each part of the sub-assemblies necessitated an evaluation to verify that it was operating within its specifically defined parameters. Two separate testing machines/systems were custom built to suit the unique criteria for the sub-components in question. The ultimate goal was to have two automatic, non-labor intensive testing machines that could speed production, maintain accuracy and reduce overall manufacturing costs while reducing the need for highly trained operators.

The guidance system tester had a dual requirement. Not only must it verify the functionality of the component parts, but also accurately move a lens on the system to a position, which would provide the optimal signal reception. Everite engineers developed a sophisticated feedback algorithm to move the lens in two dimensions, while monitoring the signals of the guidance system. Where previously a highly skilled operator would take at least 10-15 minutes to position the lens, the new automatic system could repeatedly place the lens in 3-5 minutes.

Solution:
The missile steering sub-assembly consisted of multiple electrical, pneumatic, and mechanical parts. As the electrical signals actuate to direct the missile, accurate time plots were created to verify the pneumatic and mechanical displacements were correct and that they occurred within the permissible time frame. By using the latest in non-contact sensor technology, Everite engineers could then develop a self-compensating control scheme thereby eliminating the need for time consuming setup requirements.

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