Projectile Fuze Setback Generator Power Source
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Solution Overview
Problem
Conventional setback generators for projectile fuzes suffer from high unit-to-unit variances, slow response times, and high costs due to complex component parts and inefficient magnetic circuits, as well as inconsistent energy output and packaging limitations.
Innovation Solution
A setback generator power supply with a simplified shearing mechanism using a stator assembly and armature assembly, where a fastener is sheared by launch force to displace the armature and induce current in a coil, employing a magnet with optimized diameter and coil windings for efficient magnetic flux and energy output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a shear disc design is used in conventional setback generators, then the generator can be manufactured with standard components, but the unit-to-unit output variances are high due to unpredictable shearing properties and friction effects
Solution Approach 1:
The patent removes the shear disc component entirely from the setback generator design. Instead of using a shear disc that requires shearing under launch acceleration, the invention uses a resilient element that flexes elastically to drive the magnet relative to the coil. This extraction of the problematic shear disc component eliminates the unpredictable shearing properties and friction effects that caused high unit-to-unit output variances.
Solution Approach 2:
The patent changes the mechanical parameter of the shearing mechanism from brittle shear disc failure to elastic flexing of a resilient element. The resilient element is designed with specific material properties and geometric parameters (thickness, width, length) that allow it to flex elastically under launch acceleration, providing predictable and consistent mechanical drive for the magnet-coil interaction across all units.
2Ease of manufacture
If conventional setback generators use complex component parts, then the magnetic circuit can be designed for specific performance, but the unit product cost is high
Solution Approach 1:
The patent merges multiple components into a simplified integrated structure. The resilient element serves multiple functions: it acts as the drive mechanism, the structural support for the magnet, and the return spring. The magnet is directly attached to the resilient element, eliminating the need for separate shear discs, retainers, and adjustment mechanisms. This merging reduces component count and manufacturing complexity while maintaining energy output through optimized magnet and coil geometry.
Solution Approach 2:
The patent employs inexpensive, easily manufactured components such as a simple resilient element made from common materials (spring steel, beryllium copper, or phosphor bronze) and a basic coil-wound magnet assembly. These components can be mass-produced using standard manufacturing techniques, significantly reducing unit product cost compared to complex conventional designs while maintaining sufficient energy output for fuze operation.
3Speed
If conventional setback generators use shear disc design, then the structure can be simple, but the response time is slow due to plastic deformation and stretching rather than complete shear
Solution Approach 1:
The patent extracts the shear disc component and replaces it with a resilient element that flexes elastically rather than shearing. This eliminates the plastic deformation and stretching delays inherent in shear disc designs. The resilient element responds instantaneously to launch acceleration, flexing to drive the magnet and inducing voltage in the coil without the mechanical delays associated with material yielding and fracture.
4Adaptability or versatility
If conventional setback generators are designed with standard components, then manufacturing is easier, but packaging flexibility within the fuze is limited
Solution Approach 1:
The patent segments the setback generator into modular components: a resilient element, a magnet assembly, and a coil assembly. These modular segments can be independently manufactured and then assembled in various configurations to fit different fuze packaging requirements. The simplified component structure allows for greater adaptability in spatial arrangement within the fuze body compared to integrated conventional designs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design achieves faster response times, more consistent unit-to-unit output, and lower costs by simplifying the shearing mechanism and reducing component complexity, enabling quicker activation of fuze electronics and improved energy output per unit volume.
Implementation Method 1
The armature assembly is displaced upon the shearing of the fastener, responsive to which displacement of the armature assembly a current is induced in a coil of the stator assembly that surrounds the magnet
Implementation Method 2
A magnet with optimized diameter and coil windings for efficient magnetic flux and energy output
Data Source
AI summary
Projectile fuze setback generator power source apparatuses and methods of use and manufacture are disclosed. An explosive projectile contains a fuze with a setback generator and associated fuze electronics. Upon initiation of projectile launch, the setback generator produces a voltage for use by the fuze electronics during flight. The setback generator includes a magnet maintained in place within a surrounding coil by a fastener. When a projectile is fired, rapid acceleration thereof causes the fastener to break and the magnet to be displaced longitudinally within the surrounding coil, which decreases the magnetic field and induces a current in the surrounding coil. The induced current produces a voltage that is stored in a capacitor operably coupled to the setback generators which then is used to power the fuze electronics during flight.