Shock Testing Machine Braking Mechanism for Long-Duration High-G Simulation

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Solution Overview

Problem

Current high-G shock testing methods are costly, impractical, and unable to accurately simulate the long-duration high-G acceleration events experienced by munitions and other devices, such as those from large caliber guns and mortars, due to limitations in existing equipment and the high cost of using actual firing systems.

Innovation Solution

A low-cost, reusable shock testing machine capable of imparting a wide range of acceleration magnitudes over long durations, allowing for rapid mounting and dismounting of test components, with adjustable braking force to achieve desired shock loading levels, and featuring a carriage member that travels along rails with a braking mechanism to provide a constant deceleration pulse.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If electro-dynamic shaker is used to simulate shock loading, then measurement precision is improved, but device complexity and cost increase

Engineering Contradiction:

Improveshock response spectrum accuracyVSAvoidequipment complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent creates a simplified mechanical copy of the actual shock environment by using a shock table that can be dropped or impacted to generate shock pulses. Instead of using complex electro-dynamic systems, it copies the essential shock loading characteristics through mechanical means, achieving the required measurement precision with simpler equipment.

Inventive Principle:

Principle #26Copying

2Reliability

If live ordnance with system structure is used for testing, then reliability of test results is improved, but cost increases

Engineering Contradiction:

Improvetest result reliabilityVSAvoidtesting cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent segments the testing system into a reusable shock table (infrastructure) and disposable or replaceable test components. The shock table is built once and reused for multiple tests, while only the specific components being tested need to be prepared for each test, significantly reducing the cost per test while maintaining reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs disposable impactors or drop weights that are replaced between tests, eliminating the need to reuse and maintain expensive live ordnance or complex test structures for each test, thereby reducing overall testing costs while preserving test validity.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of operation

If mechanical impact with mock structure is used, then ease of operation is improved, but duration of action is insufficient

Engineering Contradiction:

Improvetest setup easeVSAvoidshock duration

Core Design Contradiction:

Ease of operationVSDuration of action of moving object

Solution Approach 1:

The patent uses a dynamically adjustable shock table system where the duration and characteristics of the shock pulse can be modified by changing the drop height, impactor mass, or table suspension parameters. This allows the system to adapt to different test requirements, providing both ease of operation and sufficient shock duration by optimizing these dynamic parameters.

Inventive Principle:

Principle #15Dynamics

4Force

If rocket sled is used for high-G testing, then force capability is improved, but loss of time increases

Engineering Contradiction:

Improveacceleration capabilityVSAvoidtesting time

Core Design Contradiction:

ForceVSLoss of time

Solution Approach 1:

The patent replaces the complex rocket sled mechanical system with a simpler gravity-driven drop table mechanism. By substituting rocket propulsion with gravitational acceleration, the system achieves sufficient high-G capability without the time-consuming setup, safety checks, and operational complexity of rocket systems, thereby reducing testing time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables accurate and repeatable simulation of high-G shock loading conditions for various devices, from small electronics to large ordnance, reducing testing time and cost while providing detailed analytical data for component validation and optimization.

Implementation Method 1

a braking mechanism to provide a constant deceleration pulse

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS20230417625A1Long-duration shock testing machine

Publication Date: 2023.12.28 OMNITEK PARTNERS LLC

AI summary

A shock testing machine including: a test platform; a carriage for carrying the test platform; one or more rails movably supporting one or both test platform and the carriage; a stop for stopping the carriage in a testing direction; and a brake for decelerating the carriage after the carriage engages the stop. Wherein the brake includes: a braking member separate from the carriage, the braking member having braking material separated by a gap, the carriage configured to expose the braking member to the stop when the carriage moves past the stop in the testing direction; and an elongated member extending from the carriage, the elongated member extending through the gap, respectively, in the braking member such that a braking pressure is applied from the braking material to the elongated member to decelerate the carriage when a braking surface of the braking member engages a braking surface of the stop.