Gun-Mounted Searchlight Shock Mount and Modular Design
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Solution Overview
Problem
Existing gun-mounted arc search lights, such as the HellFighter target illuminator, face challenges in maintaining stable optical performance under high G-force shocks and vibrations, and require complex assembly and maintenance procedures, limiting their versatility and effectiveness.
Innovation Solution
The design incorporates a resilient g-force diaphragm shock mount with bellows diaphragms that allow bidirectional translation of the lamp relative to the reflector, a thrust assembly with reversible motor and indexing mechanism for precise zoom control, and a field-serviceable modular design with a plug-in electronics module and storable IR filter, enhancing stability and ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid mounting system is used to secure the lamp to the reflector, then structural stability is improved, but the ability to maintain optical alignment under G-force shocks deteriorates
Solution Approach 1:
The patent employs a flexible membrane diaphragm as a shock-absorbing element between the lamp assembly and the reflector housing. This diaphragm can deform elastically under G-force shocks, absorbing mechanical stress while maintaining the optical alignment of the lamp with the reflector's focal point, thus resolving the contradiction between structural rigidity and optical stability.
Solution Approach 2:
The patent incorporates a pre-loaded spring mechanism that provides continuous cushioning force to maintain lamp positioning. The spring is pre-compressed to exert a constant force on the lamp assembly, ensuring that the lamp remains aligned with the reflector's optical axis even during sudden shocks or vibrations, thereby maintaining optical reliability without requiring a completely rigid structure.
2Ease of manufacture
If a fixed lamp positioning system is used, then manufacturing simplicity is improved, but the ability to adjust zoom focus deteriorates
Solution Approach 1:
The patent transforms the static lamp positioning system into a dynamic one by introducing a movable lamp assembly that can be adjusted along the optical axis. The lamp is mounted on a movable carriage or slider mechanism that allows it to be repositioned to change the focal distance, enabling zoom focus functionality while maintaining relatively simple manufacturing through standardized mechanical components.
3Reliability
If a complex shock isolation system is used to maintain optical performance, then optical stability under G-forces is improved, but device complexity deteriorates
Solution Approach 1:
The patent combines multiple functions into integrated components. The diaphragm serves both as a shock-absorbing element and as a structural component of the housing. The spring mechanism simultaneously provides shock isolation and maintains pre-loaded positioning force. This merging of functions reduces the number of separate components and simplifies the overall system while maintaining optical stability under G-forces.
4Ease of manufacture
If a non-modular design is used, then manufacturing simplicity is improved, but ease of maintenance deteriorates
Solution Approach 1:
The patent divides the searchlight into distinct modular segments: a lamp assembly module, an electronics module, and a reflector housing. Each module can be independently removed and replaced. The lamp assembly is mounted on a standardized interface that allows quick swap-out, and the electronics are contained in a separate accessible compartment, significantly easing maintenance and repair operations.
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
The solution provides stable and controlled optical performance under high G-forces, simplifies maintenance, and increases the device's versatility by allowing bidirectional zoom focus and easy replacement of components, enhancing its operational reliability and user-friendliness.
Implementation Method 1
a radial portion of the bellows diaphragm is planar, curved, corrugated by a plurality of concentric rings, or shaped into a dimpled diamond pattern, so that the bellows diaphragm acts as a bellows spring to allow the receptacle to move bidirectionally along the longitudinal axis of the lamp or optical axis
Implementation Method 2
a reflector having an optical axis and a focus on the optical axis... light from the lamp as redirected by the reflector
Data Source
AI summary
The improvements include an illuminator for a gun comprising a manually manipulated and storable external IR filler with a plurality of radially directed circumferential tabs integrally extending from the frame to allow a manual torque to be applied to the frame to manually screw it into and out of the bezel in the field. A high g-force diaphragm shock mount for the lamp includes a receptacle which positions the longitudinal axis of the lamp on the optical axis of the reflector. The field serviceable lamp assembly is an integrated or modular and sealed unit. A field serviceable electronics module is accessed by removing the rear bezel. The illuminator handle includes a double locked latch lever. A T-Slot to Picatinny adapter allows a SureFire T-rail fitting of the handle to fit a conventional Picatinny rail.