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AFATL-TR-74-88, FZU-32 Bomb Fuze Initiator
AFATL-TR-74-88, FZU-32 Bomb Fuze Initiator
AD NUMBER
ADB001308
LIMITATION CHANGES
TO:
Approved for public release; distribution is
unlimited.
FROM:
Distribution authorized to U.S. Gov't. agencies
only; Test and Evaluation; MAY 1974. Other
requests shall be referred to Air Force
Armament Laboratory, Attn: DLJF, Eglin AFB, FL
32542.
AUTHORITY
AFATL ltr, 3 Jan 1977
AFAn-Tt-74-t8
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CO FAItCNllD CAMIIA AMO INSTIUMIHT CO»fOIATIOH
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QQ TICMMICAl »IPOIT Af ATl.TI.74-M
5 MAY 1974
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ABSTRACT
III
(The reverse of this page is blank)
TABLE OF CONTENTS
I INTRODUCTION 1
II TECHNICAL DESCRIPTION 5
2. 1 Installation 9
2.2 Operation 9
2. 3 Maintenance 9
IV TEST PROGRAM 15
5. 1 Conclusions 21
5.2 Recommendations 21
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SECTION I
INTRODUCTION
The design and deve pment of this bomb fuze initiator was under-
taken as part of the development of a proximity fuzing system for gen-
eral purpose bombs. This fuzing system contains a proximity sensor
(MK43 TDD), a fuze, and a bomb fuze initiator. Existing fuzes consi-
dered capable of satisfying the requirements of this fuze system, namely,
reliable safing and arming and above-ground detonation upon receipt of
a signal from a proximity sensor, were those of the U.S. Navy M990
series of electric fuzes and the MK344/376 Electronic Bomb Fuzes.
The baseline device employs an air turbine that rotates the arma-
ture of a four-pole generator. The generator output then passes through
a transformer and rectifier circuit and finally to a regulator that limits
the voltage to 300 VDC. The generator itself is approximately 7/8 inch
in diameter by 1 inch long and is manufactured in Norway by Kongsberg
V&penfabrlkk. The unit is shown in Figure 1 and a schematic of the elec-
tronic circuit is shown in Figure 2. Air is introduced into the turbine
cavity through a 0.44.square inch orifice, ducted through the turbine
■
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ARMING WIRE
REMOVABLE
CAP
AIR TURBINE
INLET ALTERNATOR
ASSEMBLY
RETAINING
NUT AND VOLTAGE
LOCK SCREW DOUBLER
RECTIFIER AND
LIMITER
2
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blades and exhausted downstream from two ports. Turbine velocity is
dependent upon bomb speed and angle of attack. The turbine, generator,
and electronic package are packaged in a metal container 1.9 inches in
diameter by 1.4 inches long. It is sealed against moisture and other
contaminants by O-ringo and epoxy sealants. The plastic cap that closes
the air intake orifice projects 0.625 inch above the bomb surface when
installed in the charging well. :
The contract for this effort specified an effort that encompassed pro-
duction engineering of the FZU-24/B Bomb Fuze Initiator through design,
fabrication, assembly, tests, and evaluation. The final design of the ini-
tiator was designated the FZU-32/B Bomb Fuze Initiator.
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TECHNICAL DESCPIPTION
• •.
AIR INTAKE
TURBINE
WHEEL
LANYARD
FLOW
PARTITION
GENERATOR
LOWER PLATE
CONNECTORS
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There are three connector pins in each of the connector shells. These
are wired so that corresponding pins have identical signals on each con-
I nector. Thus, power can be delivered to fuzes installed in either the nose
or tail fuze wells. (See Figure 5 for the electrical schematic of the unit.)
The bottom cavity of the unit between the connector plate and the genera-
tor is filled with a semi-flexible, epoxy potting compound. The top of the
unit has an O-ring seal between the cover and the housing. The generator
is, therefore, fully sealed from the outside environment.
2.1 INSTALLATION
When the bomb is installed on the aircraft, the swivel D-ring on the
end of the lanyard is inserted into the arming solenoid of the aircraft bomb
rack.
2.2 OPERATION
When a normal armed bomb release occurs, the lanyard D-ring assem-
bly is retained by the bomb rack solenoid, thus pulling ihe tear-off top
from the cover which allows the air intake scoop to rotate upward into
the airstream. The resultant air pressure build-up cauaes the turbine to
rotate and drive the generator. This produces an unregulated alternating
current output of approximately 46 volts and 2 KHz at a calibrated airspeed
of 280 knots into a 3000-ohm load when installed in a MK82 Bomb.
2.3 MAINTENANCE
SECTION III
PROGRAM PERFORMANCE
The objectives of thi« program were to develop a design for the bomb
fuze initiator which wa. economically producible and would be ccmpatible
with the FMU-114/B Fuze, to document the design, build test units, and
evaluate the design by environmental and functional performance testing.
These objectives were accomplished as described in the following para-
graphs.
(1) Removal of the transformer from the unit, with the voltage
step-up function being relegated to a less expensive quad-
rupler network (as opposed to the transformer) which is to
be located within the fuze. This approach allows for more
needed space within the unit. Since the quadrupler is added
to an existing board there is an overall cost savings by in-
cluding this electronics within the fuze.
(2) Change of the protective cap system to one which was less
costly and would not protrude as high above the bomb sur-
face. Accordingly, an inexpensive tear cover approach
was selected. Reduction in protrusion directed the use
of a pop-up type of air scoop. The scoop design includes
sheetmetal parts that are less costly than the baseline
system.
11
The Viking Thorkom Series connector was selected for use in inter-
connecting with other system components. Purchase orders were re-
leased for the initial 60 units. Concurrently, the design of assembly
tooling and a wind tunnel test fixture was started. (Refer paragraph 4. 2
for the details of this test fixture.)
Failure analysis of the item revealed that the generator case had
parted along its seams (the assembly is made with snap-fit parts), and
this had jammed the rotor and turbine. The original Kongsberg instal-
lation for this device employed axial O-ring pressure, which held the
generator case under compression. It was planned to employ a similar
mounting using a snap-ring as the shoulder against the end of the genera-
tor. Unfortunately, the baseline drawing of the generator contained a
dimensional error. To correct this discrepancy, it was necessary to re-
move the shoulder from the housing. Thus, the generator case was not
under compression and the case parted under the shock of the 5-foot drop
test.
The design was corrected with a minimum expenditure of time by
specifying the use of Eccobond 285 epoxy to reinforce the snap joints of
the case.
12
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Copies of the test plan and environmental and performance test re-
ports were submitted. This effectively completed the contractor's part
in the program except for field test support for Air Force testing of the
delivered units and delivery of documentation.
13
(The reverse of this page is blank)
SECTION IV
TEST PROGRAM
The Equipment Test Plan for the FZU-32/B Bomb Fuse Initiator,
Fairchild Document No. 564-001, was prepared to delineate the tests to
be performed during the development phase of the initiator. Tests for
establishing acceptance test levels, life tests, and re liability/environ-
mental demonstration tests were included in this test plan. The Equip-
ment Test Plan included details of the following tests to be perforraed:
4.1.3 Test Plan for FZU-32/B Bomb Fuae Initiator (Final Design)
The Test Plan for the FZU-32/B Bomb Fuae Initiator, Fairchild Document
No. 564-004, was prepared in order to provide a method for evaluating the
final design of the bomb fuze initiator. This document describes the test-
ing procedures, the test equipment, and the test data accumulation methods
15
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to be utilized in the environmental testing of the FZU 32/B Th* T.-*
Plan xncluded details of the following te.f. to be perLmed; *
17
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Ap in equal to the impact pressure, qc, the indicated or calibrated air-
speed can also be determined from standard tables 1.
While this fixture performed well for all testing done, it must be
emphasized that the only control is on the impact pressure. Altitude is
essentially programmed by the nature of the equipment and is not sub-
ject to independent control. For the range of values (of qc) employed,
the tunnel simulated altitudes between 3500 and 5000 feet. For pur- i
poses of duplication of results, it is important that the tixture to be used
have the same characteristics as the one described herein. Impact pres
sure (or Ap) was recorded in centimeters of mercury. (For purposes of
cross reference and to indicate the tunnel operating altitude, refer to
Table I. ) The values in Table I are based on the assumption that room
ambient pressure, po, was standard sea level pressure and that the
total stagnation pressure reaches room ambient pressure in all cases.
Note that the wind tunnel test fixture can only attain a maximum im-
pact pressure of 23 cm Hg.
2750
2^0 8.56 3250
9.98 3850
300 11.54 4500
320 13.22 5200
350 16.00 6400
400 21.34 8850
450 27.66 12.000
500 35.06 16,150
550 43.67 .
21,800
600 53.66 30,200
18
i - - - ■ ■ ---
4.3 TEST RESULTS
Fifty-one units from the final lot were subjected to a number of envi-
ronmental tests at Eglin ' Free Base. Subsequently, these units were
19
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performance tested at the contractor facility in the special purpose wind
tunnel test fixture by Air Force and contractor personnel. A summary
of the data is included in Appendix I under the heading "Post-Environ-
mental Performance, Air Force Applied Environment." One item failed
to perform properly after being exposed to MIL-STD-331, Test 105,
Temperature Humidity. The item failed to start until approximately 400
knots airflow was achieved and then the output was very erratic. This i
failure was attributed to an unidentified form of metal contamination that
caused corrosion of the magnetic rotor in the generator. This failure
was judged to be a random failure and not caused by the environmental
test.
*
. ■
•
•
"
20
5.1 CONCLUSIONS
5.2 RECOMMENDATIONS
The method of mounting the generator into the housing should be changed
to that employed in the later configuration of the initiator fabricated for
another contractor. This method presses the turbine end of the generator
against an O-ring as in a typical Kongsberg installation and eliminates the
necessity to epoxy the generator case together. This also improves assem-
bly efficiency. The unit projects about 0. 025 inch higher above the bomb
surface but this is an acceptable amount for the intended use of the FZU-
32/B.
21
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INITIAL DISTRIBUTION
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TAC/DRAR
TAC/LGNM
SAC/LGW
SAC/NRI
AFWL/SUL
AFWL/SECA
AF Sp Com Ctr/SUR
AUL/AUL/LSE-70-239
57 FIW (DOTH)
USAFTFWC (DR)
Hq OARD/DARD-DDA
Comdr/USN Ord Lab/Code 730
Comdr/USNWC/Code 753
Sandia Lab/Tech Lib
OK
HQUSAFE (LGWHM)
HQUSAFE (DOA)
AFATL/DLOSL
USAFTAWC (TEFA)
AFATL/DL
AFATL/DLOU
AFATL/DLY
AFATL/DLXP
AFATL/DU
USAF/XOON
AFNL/LR
AFAL/TEO
ADTC/XRC
AFATL/DIMP 1
ADTC/SES 1
AFATL/DLJF 8
Condr/USNNC (Code 3354) 1
AMXDO-DA 2
Hq USAF/SAMI 1
TAWC/TRADOCLO 1
Hq 4950 TESTW/M4NOP 2
43
(The reverse of this page is blank)
^ . , ■ ■ - - —- —
m. •<• wi" ^^nmmt*
ITNTTASSTITT F.n
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John Miazza
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May 1974 45
■ COMTKACT OH ««AMT HO. , •M«'NAT*«>t HCVWIT NUMBCniai
F08635.72-C-0152
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