How to Remove the Champion Trimmer Block

The utility model of a universal booster block relates to rocket technology, applied to a different class of carriers on cryogenic components, and has a booster control system having a block for matching it with control systems of various carrier rockets, the shell of the tank block is made of a single carbon fiber three-layer construction with a liner, the bottom of the tanks glued into the three-layer shell of the tanks using devices. Manhole covers in the shell are made of a three-layer structure, and the manhole cover on the upper bottoms of the tanks is made of a single-layer structure. A sleeve is screwed onto the tubular flanges of the lower bottoms of the tanks, a ferrule is screwed onto it, to which a flange of a metal pipeline is bolted. Oxygen-hydrogen booster blocks have the same design as applied to the light medium and heavy class of carriers, in each of which the docking fittings of the booster blocks are also made of the same type of carbon fiber. Acceleration block on a pair of oxygen. Kerosene, has the same diameter of the tank block with a universal booster block on a hydrogen-oxygen pair, with the same radii of the bottoms of the tanks in the manhole area and the installation of tubular flanges on them. A device for introducing bottoms into the continuous shell of the tank block and gluing the bottoms consists of a support flange and removable sectors, on which there is a lodgement with an inflatable ring bag with heating plates. This design of the carbon fiber booster block allows its weight to be reduced by 30% compared to the metal booster block mass, which is confirmed by the cryogenic carbon fiber tanks for Sprit and Prospector 6 rockets created in the USA by Microcosm and Garvey Spacecraft Corporation . This allowed them to get the same savings in tank mass.

The utility model of the universal booster block relates to rocket technology and can be used as part of various launch vehicles for launching spacecraft and satellites into their working orbits.

Acceleration blocks are known such as “DM” developed by RSC Energia, “Frigate” developed by NPO named after Lavochkina, working on a pair of oxygen-kerosene, booster block "Breeze", working on a pair of components of rocket fuel amyl and heptyl, as well as oxygen. 12 KHB hydrogen block for India, the last two of which were created at the GKNPTs im. M.V. Khrunicheva. (“Filevsky orbits” Book Two, p. 186, 210, Publishing House “News, 2006)

The disadvantage of these accelerating blocks is that they are individual execution blocks, each attached to its own specific carrier, each type of construction inherent in each of them with its own set of structural materials, contain a different composition of components and require its own production base for manufacturing, which leads to a rise in the cost of their production. All of these accelerating blocks, except for the Indian 12 KRS, have insufficient energy indicators due to the fact that they do not use the most highly efficient oxygen-hydrogen pair of components, which is necessary to have in the future even in the absence of the now and now destroyed hydrogen base in our country at the landfills. The weighted efficiency of the bodies of these accelerating blocks is not up to date, because the design and manufacturing technology of these blocks was based on the previous technical level due to the use of metal alloys inferior in specific strength to modern composite materials.

Known patent 2191720 from 06/01/2000, "Missile unit (options) and the method of its manufacture (options)" made of carbon fiber, the patent holder of which is GKNPTs im. M.V. Khrunicheva (Authors Bakhvalov Yu.O., Kulaga ES, Olenin IG.) The indicated block of tanks has a number of advantages over metal blocks of tanks, including mass characteristics. However, it has a somewhat excessive laboriousness of manufacturing due to the fact that, according to the patent, the tank block is made of half tanks together with bottoms, and with the help of ring connectors in each of the tanks, they are connected along the perimeter, sealed and, thus, form an oxidizer tank and fuel. The number of ring connectors in the tank block is redundant and is due to the need to ensure bonding of the bottoms in the shells of the tanks, carried out directly in the manufacture of tanks simultaneously with the shells of tanks.

A known method of gluing a reinforcing local lining on the bottom of the shell inside it, carried out by astronauts in flight at the Solut-7 orbital station by pressing the lining with an inflatable bag when gluing it with the focus of the inflated bag on the unit located near. (E.S. Kulaga “From Aircraft to Rockets and Space Ships”, p. 156, “Air Transport”, 2001). The disadvantage of this method is that the inflatable bag allows clamping only the local lining and does not allow clamping of glued elements along an annular closed surface in the absence of a supporting surface for the inflated bag, which are necessary if the bottoms are glued into continuous prefabricated tank shells.

The objective of this utility model is to develop a universal carbon fiber booster unit with a uniform body design with a minimum number of ring connectors along the perimeter, having higher weight and energy efficiency with a sufficiently reduced manufacturing complexity, and used as part of various launch vehicles, separately applied for carriers light, medium and heavy classes, to ensure a consistent transition of the same type of blocks working on a pair of oxygen. Kerosene to booster blocks using a purely cryogenic pair of components, manufactured on the same production and technological base with its more efficient technology and to ensure the reliable introduction of prefabricated bottoms into the continuous shell of the tank block with the formation of a supporting surface for gluing them

This problem is solved in that a typical universal booster unit using a cryogenic pair of components, consisting of a propulsion system, a tank unit and a control system, in accordance with a utility model with the achievement of a technical effect consisting in the use of a booster control system in a booster unit consisting of of the same type of functional blocks, containing in its composition a unit for matching it with the corresponding control systems for different classes of launch vehicles, the shell of the oxidizer and fuel tank block is made of a carbon-fiber three-layer construction with a liner in the tank zone, made uniform without ring connectors along the perimeter, docking joints are located at its ends carbon fiber fittings, the shell has hatches with covers between the tanks, the bottoms of the tanks are made of single-layer carbon fiber with a liner on the inner surface, the upper bottoms of the tanks have hatches, the lower bottoms of the tanks have carbon fiber tubular flanges for the output of metal pipes of wires from the tanks, the design of the lower spacer of the booster blocks with the carrier and the upper simplets of the docking with the payload are made integrally with the shell of the block, the bottoms of the tanks are glued into the three-layer shell of the tanks using devices

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This task in providing access to the interbase compartments by using hatches is solved by the fact that the manhole covers in the three-layer shell between the tanks are made of a three-layer structure made of carbon fiber, each of its skins is connected to the corresponding skins of the three-layer shell of the tanks using an outer lining mounted on the glue and the inner lining mounted on anchor nuts.

This task in installing the manhole covers on the upper bottoms is solved by the fact that the manhole cover on the upper bottoms of the tanks is made of a single-layer structure made of carbon fiber, with a liner on its inner surface, mounted on the bottom with anchor bolts screwed on glue into the body of the manhole trim on the bottom.

This task of connecting metal pipelines to tubular flanges installed on the bottom bottoms is solved by the fact that a transition metal sleeve is screwed onto its tubular flanges installed on the bottom bottoms of the tanks, a metal sleeve is screwed onto it on a two barrier ring seal having a flange at its end, to which the flange of a metal pipeline with a planar two barrier seal is drawn by bolts.

This task of unification of booster blocks as applied to the light medium and heavy class of carriers is solved by the fact that oxygen-hydrogen booster blocks have the same design as applied to the light medium and heavy class of carriers using the same materials in the tank block, they have their overall and energy characteristics, in each of which for all three types of booster blocks used in each of the classes of carriers of light, medium and heavy class, the docking fittings of the booster blocks along their docking planes are also made of one type of carbon fiber construction.

This task of unifying the types of booster blocks on a pair of oxygen-kerosene and oxygen-hydrogen components is also solved by the fact that the booster block on a pair of oxygen-kerosene, has the same diameter of the tank block with a universal booster block on a pair of oxygen-kerosene, has its length with the same radii the bottoms of the tanks in the area of ​​the hatches and the installation of tubular flanges on them has the same design of the connecting planes with carriers and payloads in relation to the light, medium and heavy class of carriers.

This task of introducing bottoms into the continuous shell of the tank block and gluing the bottoms inside it is solved using a collapsible device consisting, according to a utility model, of a support flange and removable sectors, the support flange has fixation units for removable sectors attached to the support flange on tubular racks, performed from organoplastics, on the supporting surface of which there is a lodgement with catchers for fixing the end of the bottom and putting it into a three-layer shell with removable covers placed on its rear end, an inflatable ring bag with polymer heating plates is located in the lodgement

Video: How to Remove the Champion Trimmer Block


The design of a universal booster unit and a device for inserting and gluing bottoms into the shell of the tank unit is further explained using the figures in FIG. 11. Figure 1 presents a structural diagram of a universal booster unit, Figure 2 (Node 1 in Figure 1) shows a fitting installed at the ends of the three-layer shell of the tank block, Figure 3 (Node 2 in Figure 1) shows a manhole cover in a three-layer the casing of the inter-tank space, Fig. 4 (Node 3 in Fig. 1) shows a manhole cover on the upper bottoms, Fig. 5 (Node 4 in Fig. 1) shows a tubular flange on the lower bottoms, Figs. 6 and 7 show a general view of the device for input and gluing the bottom into the shell of the tank block, on Fig-11 presents a diagram illustrating the process of using the device for gluing the bottoms, as well as an enlarged process diagram illustrating the manufacturing process of a universal booster block according to this utility model using a device for input and gluing the bottoms.

Figure 1, presents a universal booster unit, consisting of a propulsion system 1, a tank unit 2 and a control system 3, a typical control system for the booster unit, comprises a unit 4 for matching it with corresponding control systems for various classes of launch vehicles, the shell of the unit tanks 5 of oxidizer and fuel, at its ends has docking fittings 6 made of carbon fiber, used in patent 2399016 from 03/18/2009. Patent holder, which is GKNPC them. M.V. Khrunicheva (Author E.S. Kulaga et al.), There are 7 hatches between the tanks in the shell, inside the shell there are upper bottoms of 8 tanks and lower bottoms of 9 tanks, which form oxygen and hydrogen tanks, which have cylindrical straight sections around the perimeter 10, the upper bottoms of the tanks 8 have hatches 11, the lower bottoms have tubular flanges 12 for the withdrawal of metal pipelines from the tank, used by the patent holder, which is GKNPC them. M.V. Khrunicheva (Author E. S. Kulag and DR).

Figure 2, shows the docking fitting 6, installed at the ends of the three-layer shell 5, by gluing it to the skin of the three-layer shell of the tank block using the corners 13 available on the fittings.

Figure 3 shows the hatch covers 7 in the three-layer shell of the tank block 5, the inner lining of which 14 is connected to the inner lining 15 of the tank shell using the lining 16 mounted on the anchor nuts 17, the outer lining of the manhole cover 18 is connected to the outer lining of the tank shell 19 by gluing pads 20.

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Fig. 4 shows a hatch 11 with a cover 21 on the upper bottoms 8, attached to the bezel 22, using anchor bolts 23 on the adhesive

Figure 5 shows a tubular flange 12 onto which the adapter sleeve 24 is screwed over its external thread, a ferrule 25 is screwed on it on a two barrier O-ring seal 26, having a flange 27 at its end, to which the flange 28 of the metal pipe 29 with a plane two barrier seal 30.

Figures 6 and 7 show a collapsible device for inserting and gluing the bottom 8 in the shell of the tank block 5, consisting of a support flange 31 and removable sectors 32, in which the flange has grooves 33 for fixing the removable sectors attached to the support flange on the tubular posts 34 made of organoplastics, on the supporting surface of the sectors there is a lodgement 35, in which there is an inflatable annular bag 37 with polymer heating plates 38, on the front of the lodgement there are catchers 39 for fixing the end face 40 of the tank bottom and entering it into the three-layer shell of the tank block, at the rear end cradle placed removable cover 41.

The process of using the device for introducing bottoms into the shell of the tank block is carried out by the fact that outside the three-layer shell of the tank block, the bottom 8 is mounted on the rod 42, which is supported by the rest 43 using the flange 44, and removable sectors 32 are mounted on the support flange 31 onto which the inflatable ring bag 37, the rear removable covers 41 are closed and the assembled device 45 is inserted into the cylindrical part 10 of the bottom and fixed at the end 40 of the bottom of the tank, the bottom thus assembled together with the device 45 installed in it is inserted, using the mechanism 46, according to the catchers 39 available on the removable sectors 32, to the desired location in the three-layer shell of the tank block 5, then pressure is applied to the inflatable annular bag, which presses the horizontal part of the bottom to the tank block shell, voltage is applied to the heaters and the bottom is glued.

On Fig-11 presents a diagram illustrating the manufacturing process of the block of tanks of the upper stage of the carbon fiber autoclave molding, according to this model using a device for input and gluing bottoms in the shell of the tank block.

Single-layer bottoms 8 and 9 are preliminarily laid out and molded together with the liner on the upper part 47 of the common mandrel (Fig. 8), while gluing the tubular flange 12 at the same time, then, without removing the molded lower bottom 9 of the hydrogen tank from the upper part of the mandrel, the lower removable bottom is docked to it part 48 of the common mandrel, based on the limit stop 49 mounted on the bottom 9. On the assembled common mandrel, lay out and form a continuous inner lining 50 of the three-layer shell of the tank block 5 with the liner (Fig. 9).

Aluminum honeycomb blocks 51 are laid on it, (FIG. 10), fittings 6 are installed along the connecting planes, the package is split, the outer skin 52 with adhesive film made in advance on a common mandrel, the patch plates 53 are mounted on it and the assembled assembly is autoclaved (FIG. .10). After that, the three-layer shell of the tanks is removed from the common mandrel and into the shell, together with the lower bottom 9 of the hydrogen tank, glued its upper bottom 8 using the mounting device 45, introduced using the mechanism 46, perform internal installations in the hydrogen tank, close its hatch with screws 23 screwed on the sealant into the carbon-plastic thickening of the bottom 6 according to FIG. 4, (Unit 3) and then the bottom of the oxidizing tank is glued sequentially using the same mounting device (FIG. 11), after which inter-tank hatches according to FIG. 3 will be made in the shell of the tank block (Node 2)

If there is a production need for one reason or another, you can cut the three-layer shell of the tank block in the inter-tank spacer and thereby divide the universal booster block into separate tanks and then connect them, as shown in Figure 3, Unit 2, the technology of which has been worked out with the manufacture of the mentioned experimental tanks.

The mass characteristics of the tank block of the universal booster block according to this utility model will be higher than that of the tank block according to the aforementioned patent 2191720 from 01.06.2000. In this patent, the total number of annular joints of the tank block is reduced by one joint compared to traditional booster blocks, and in the universal booster block, their number is reduced by four joints compared to traditional booster blocks by introducing a continuous three-layer shell and gluing the bottoms of tanks into it using the corresponding device shown in Fig.6 and 7, and its use is illustrated in Fig.8-11.

How to Remove the Champion Trimmer Block

The reliability of the technology for manufacturing three-layer shells made of carbon fiber has been tested in the manufacture of head fairings of various sizes at various enterprises in the rocket industry.

In the manufacture of GKNPTS them. MV Khrunichev by the vacuum method of experimental carbon fiber tanks on the subject of "Lener". “Development of technological processes for the manufacture of rocket tanks and carbon fiber booster blocks with a polymer liner” included in the “Federal Space Program for 2006-20015”, the joint of the upper and lower mandrels has been worked out. The design and method for manufacturing docking fittings and tubular flanges from carbon fiber have been developed, for which the mentioned patents have been obtained.

The manufacturing technology of the polymer liner and bottoms, among the other six technological processes worked out in the manufacture of the mentioned experimental tanks, was recognized by the expert council of the company as “know-how” of the enterprise and were not put up for patenting.

In the process of developing technological processes on the topic “Leiner”, I’ll remove and then put on the fiberglass mandrel of the manufactured inner skin with the bottom made of carbon fiber reinforced plastic without any difficulties even in the absence of catchers. Their presence in this device will allow you to guarantee to enter the assembled device with bottoms into the shell of the tank unit with a possible slightly deformed input section, which can occur under the influence of its own weight when it is in a horizontal position.

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The tightness of carbon fiber from 6 layers of prepreg with a polymer liner during the implementation of the theme "Leiner", during vacuum molding, was one order less than required. The tightness of the samples with the liner during compression molding, which corresponds to autoclave molding, was even higher than required. The ability to provide the necessary tightness of carbon fiber tanks is confirmed by the experience of US experts.

To date, Microcosm has developed three-layer honeycomb carbon fiber tanks for the Sprit rocket in the United States, and Garvey Spacecraft Corporation has developed similar carbon fiber fuel tanks for the Prospector 6 launch vehicle, which allowed them to save up to 30% in weight. These tanks were used as a hydrogen tank as part of this carrier rocket during its successful demonstration flight. In the design of these tanks with a diameter of 1 m. The lining of the shell of the tanks was made of 12 layers of prepreg. In their manufacture, US experts have shown that the manufacture of carbon fiber tanks with the necessary tightness can also be carried out during vacuum molding with ultrasonic sealing of the cured material instead of using conventional autoclave curing.

The technical feasibility of the design according to this utility model is confirmed by the fact that, for example, for the maximum possible diameter of the universal unit for heavy carriers, equal to 4 m, the characteristic dimensions of some elements of this device will be of the following order.

The number of sectors according to Fig.6 will be equal to 16 with the diameter of the hatch on the bottom equal to 800 mm. In this case, the characteristic dimensions will be R1= 2000 mm, R2= 390 mm, a = 160 mm, b = 360 mm, d = 80 mm, h1= 40 mm, h2= 1.2 mm, h 3= 10 mm. The given values ​​show the full practical feasibility of the technical implementation of this device

1. A universal booster unit can be used as part of various launch vehicles for launching spacecraft and satellites into their working orbits, consisting of a propulsion system on a cryogenic pair of components, a tank unit and a control system, characterized in that it has a booster control system, containing in its composition a unit for its coordination with the corresponding control systems of various launch vehicles, the shell of the oxidizer and fuel tank unit is made unified without circular connectors along the perimeter from a carbon fiber three-layer construction with a liner in the tank area, with hatches between the tanks, docking fittings are located at its ends made of carbon fiber, the bottoms of the tanks made in advance are glued to the three-layer shell of the tanks using devices for gluing the bottoms and are made of a single-layer structure of carbon fiber with a liner on the inner surface, as well as carbon-fiber tubular flanges containing metal pipelines from tanks.

2. The universal booster block according to claim 1 can be used as part of various missiles, characterized in that the manhole covers in the three-layer shell between the tanks are made of a three-layer structure made of carbon fiber, each of its skins is connected to the corresponding skins of the three-layer shell of the tanks using an outer lining installed on glue, and the inner lining mounted on anchor nuts.

3. The universal booster block according to claim 1 for various missiles, characterized in that the manhole cover on the upper bottoms of the tanks is made of a single-layer structure made of carbon fiber with a liner on its inner surface, mounted on the bottom with anchor bolts screwed on glue into the body of the manhole trim on the bottom.

4. The universal booster block according to claim 1 for various missiles, characterized in that a transitional metal sleeve is screwed onto its tubular flanges installed on the lower bottoms of the tanks, a metal sleeve is screwed onto it on a double-barrier ring seal, having a flange on its an end to which a flange of a metal pipeline with a planar double-barrier seal is drawn by bolts.

5. The universal booster block according to claim 1 as applied to different classes of carriers, characterized in that the oxygen-hydrogen booster blocks have the same design as for light medium and heavy classes of carriers using the same materials in the tank block, have their overall and energy characteristics , in each of which for all three types of booster blocks used in each of the classes of carriers of light, medium and heavy classes, the docking fittings of the booster blocks along their docking planes are also made of the same type of carbon fiber construction.

6. The universal booster unit according to claims 1 and 4 as applied to various classes of carriers, characterized in that the booster unit is oxygen coupled. Kerosene has the same diameter of the block of tanks with a universal booster block on a pair of hydrogen. Oxygen, has its length with the same radii of the bottoms of the tanks in the area of ​​the hatches and the installation of tubular flanges on them, has the same design of the connecting planes with carriers and payloads in relation to light, medium and heavy classes of carriers.

7. The device for gluing bottoms into the shell of the tank block of universal booster blocks according to claim 1, consisting of a support flange and removable sectors, characterized in that the support flange has fixation units for removable sectors attached to the support flange on tubular posts made of organoplastics, on the supporting surface of which there is a lodgement with catchers for fixing the end of the bottom and putting it into a three-layer shell with removable covers placed on its rear end, an inflatable ring bag with polymer heating plates is located in the lodgement.