PowerPoint Presentation

Separation Connector Improvement for Orbital Sciences CorporationKoll Christianson, Luis Herrera 1College of Engineering, Forestry, and Natural SciencesDepartment of Mechanical EngineeringNorthern Arizona UniversityPresentation Overview Project OverviewProblem Statement Design RequirementsDesign ProposalFirst PrototypeDeflection AnalysisFinal Design ResultsConclusionLuis Herrera2Project OverviewOriginal Separation ConnectorLuis Herrera3

Part # MIL-DTL-38999LDESCIRibe the connector and what it does3Problem StatementThe goal of this project is to design and demonstrate our concept that meets cost goals (DTC), enhances design for manufacturing and assembly (DFM/DFA), and meets or exceeds current reliability.

Luis Herrera4Current DesignLuis Herrera5

12346578910Reduce number of parts to increase reliability, enhance design for manufacturing and assembly, and reduce cost. Design RequirementsMale end cannot be changedPass military environmental requirementsSeparates with10-30 lbf. in tensionStructural integrity to withstand 200 lbf.Easy to manufactureMate and de-mate at least 50 times without failure (cycle reliability)Cannot exceed an increase in size of 25% greater than the original design

Luis Herrera6Design ProposalPreliminary Design Luis Herrera7

Female EndMale EndBall Detent Retention Track7FDM Prototype (Components)Luis Herrera8

Male EndCouplingFemale EndPressure PlateBall Bearing Retention RingFDM Prototype (Assembled) Luis Herrera9

Modifications to FDM DesignCombined:Female EndBall Bearing Retention RingAdded:Spring Retention RingChanged:CouplingRemoved:Pressure plateBall Bearing Retention Ring

Luis Herrera10Deflection Analysis at Full Load

Luis Herrera

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Green arrows are fixtures.11Final Design (Exploded View)Koll Christianson12

Male EndCouplingSpring Retention RingLeash RingFemale EndDesign Assembly AnimationKoll Christianson13

Final Design (Cross-Sectional View)Koll Christianson14

CouplingFemale endBall DetentRetention TrackHelical Grove Wave Spring GroveSpring Retention Ring

Leash RingMetal Prototype (Exploded View) Koll Christianson15

Metal Prototype (Assembled)Koll Christianson16

ManufacturingCreated the ball bearing crimp toolAllows for the removal of the Spring Retention Ring

Koll Christianson17

17ConclusionDesign requirements metDoes not fail after 50 mate/de-matesDe-mates with ~27 lbf.Male end was not changedNew design is approximately 10% larger than the originalMechanically robust

Merits of new designEasy to manufactureInexpensiveMore reliable

Koll Christianson

18AcknowledgmentsMrs. Mary Rogers of Orbital Sciences CorporationDr. Srinivas Kosaraju of Northern Arizona UniversityProfessor Perry Wood of Northern Arizona UniversityTom Kothrin of Northern Arizona Universitys Machine Shop Zheng Lian Team Member

Koll Christianson19Questions?20