CONTRACT (SANITIZED)

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78-03330A004200090015-6
• Release Decision: RIPPUB
• Original Classification: S
• Document Page Count: 9
• Document Creation Date: December 23, 2016
• Document Release Date: April 3, 2014
• Sequence Number: 15
• Publication Date: September 23, 1959
• Content Type: MEMO

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461#16
CONFIDENTIAL
Ezo FC:. To
[
2 5 SEP 1959
Chief,
Contrae
50X1
eat
50X1
under tb
is fabricating
11, prototnes.
2. Under thete
to the cozxtractor one
this task the overnment shall furnish
electronic switching circuit sub.Kasassably
fOr incorporation in each at the fabricated under this
task, thab-assesblies, maibers 12k through 1401 sere hind
carried to the contractor C)O2I September 1959. The =eject engineer
on this task is
Distribution:
Original + 1 - Addressee
Subject File
1 - OC-E Chrono
? 1 - R+D Chrono
1\413 - EP Chrono
OC-E/R+DI-2P/ :gjb (18 Sept. 1959)
DOC REV DATE 12 irsiO 13Y406
onto COMP ..P.LA,..3 DPI TYPE 0 2--
ORIG CLASS PAGES 'e-TIEV CLASS
JUST RCP"' NEXT REV C94'/0 AUTHt HO 104
ON
4--Ftt-17
50X1
50X1
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CONFIDDi I IHL
PROJECT DISCIU:IOF WITH cusToy7,a ENGINR
November 5-6, 1959
Project #163 (TEMA)
Project #160 (15 TEM)
Project #183 (15 SAD)
1. The two purposes of this discussion were (1) to resolve apparent differ-
ences in observations in connection with operation of SAD from electronic
circuitry other than that supplied originally under Project 74B, and
(2) to arrive at details of application of a desiccant to the SAD Project
#183 based on work now being done in connection with application of a
desiccant to TEM-A under Project #1630
2. Bi-stable multivibrator for operation of SAD. It was pointed out that the
electronics package requirements had been changed so that we should not
expect the same type of operation as the specification to which we were
working originally. The new requirements are that the unit should not
trigger from a single pulse but from a succession of pulses between 6 and
10. Our specification was that the unit should operate from a single pulse.
We had found in our tests that the new unit would operate from a ragged
pulse such as striking two wires together but apparently did not operate
from a single "clean" pulse which was to be expected of course under the
new specification.
3.
It was found on tests here after this explanation was made that if a suc-
cession of pulses 'subh as 25 per second was fed t9 the unit it would operate.
No study was made while the customer engineer was here to determine just
how many pulses did produce operation of the unit. The results of the test
described next indicate that we should determine this.
4. Tests made on Nevembm76 showed that the energization to the SAD solenoid
occurs in two steps, the first of which applies approximately 3 volts to the
resistor-condenser combination and the solenoid. This is later folloved by
the full pulse of 5.7 volts. The time for this first plateau is the same as
the distance between pulses.
5. The only logical explanation we see for this operation is that one palse does
not put the proper bias on the ba-e of the output transistor to cause full
switching action and that a later pulse then gives full switching action.
6. This type of operation is very poor for the resistor-condenser type of
operation of the solenoid. The first plateau will partially charge the con-
denser but not operate the solenoid. The energization level is too low to
provide sufficient amperes turns to operate the solenoid although the length
of the pulse may be several times that required to operate the solenoid when
it has proper voltage. In this particular case, the time is approximately
3 times that required.
7. This pulse then charges the condenser appreciably so that when the later full
height comes through there will not be any appreciable current developed
through the solenoid. The amount of useable energy delivered to the solenoid
is rather unpredicable.
CONFIDENTIAL
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uulirilit.11 I IAL
8. The result is to raise the voltage requirement for the solenoid above
that required with full switching of tie output solenoid in one step as
was done with the previous electronic circuitry.
It was noted that the circuit provided by the vendor for his electronic
vpackage did not show any resistor-condenser combination in cnnection with
Thathe solenoid. This may mean that the effect of the resistor-condenser com-
taeY-4bination upon the voltage which would be supplied to the sotbnoid was not
considered.
10. It was found here that when the electronic system was triggered the SAD
unit we had recently supplied did not work. Examination of the circuit
shows that in addition to the resistance of the Emitter-Collector portion
of the transistor circuit there has been a 100 ohm resistor introduced in
this circuit.
11. Calculation shows that this will reduce the energization from the line voltage
by a minimum of 27%. The word minimum is used because this resistor is also
the return path for the Emitter-Collector circuit of the transistor used in
this package for resetting the multivibrator and' releasing the solenoid.
There will be an additional drop through this resistor, therefore, caused by
the steady state leakage. This value will be quite low at normal temperature
but might increase radically when the temperature goes up.
12. It was pointed out by our customer engineer that two other units worked satis-
factorily with this electronics and this one did not, and the sugestion made
that there must be something wrong with this solenoid. However, tests showed
that this solenoid operated satisfactorily with 3.9 volts'on the solenoid
direct17 and 4.9 volts on the resistor-condenser-solenoid combination at room
temperature. Apparently, the other units must have had a lol.er operating
,:oltage than this one although this one is lower than would ordinarily have
Peen required.
.b) 4?orA
'cul
ttit
13. There was a considerable discussion of factors leading to variations in solen,id
operation, pointed out approximately 10 things in the nianufactur50X1
a solenoid which might cause variations in operation of a particular solenoid.
There are others. Some of these are:
A. Variation in actual diameter of the wire used for winding
a solenoid.
B. Variation in the magnetic permeability of a particular piece
of iron used.
C. Slight variation in the air gap of the solenoid at time of
pick-up.
D. Variation in thickness of springs used for the spring portion
of this device (1/10 thousandth difference can man as much
as 30% variation in spring pressure).
E. Variation in adjuStment of contacts such as opening and com-
pression when contac-ix, are closed.
F. Changes in friction of the various parts operated by the solenoid
and by the plunger in its housing as well.
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CONFIDFNTIM
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G. Slight movement in the point of attack of the contact
driving part upon the contacts themselves.
H, Tolerances in the actual stiffness of the contact spring
material even when the thickness does not change.
I. Variations in the eccentricity of the solenoid plunger in
its upper air gap. (This causes larWvariation in side
pull and consequently in the friction, and resulting re-
f quired ampere turns.)
J. Differences in mounting of the hack operating arm with
respect to the axis of the plunger are very critical.
lii.. In the manufacture of very large solenoids, these factors can-be more readily
controlled than in small ones. In small ones, even the control of many
dimensions to a very few ten-thousandths of an inch permits a measurable
variation in most of the factors outlined.
15. There is no attempt made in manufacturing solenoids of this t-pe to keep all
solenoids at a definite operating point. Neither is it possible (because
of economic and time considerations) to build a large batch of solenoids and
select out of these only the ones which are close to one operating value.
16. Consequently, a particular solenoid is calculated and built and a study made
of its characteristics. Then some practical estimates are made of the likelihood
of other solenoids having different characteristics,
17. Aft-r this first solenoid has been built, the ones built for use will in most
cases be given a different winding resistance to bring their operating point
and force possibilities (as shown by the 'tests on the first model) within the
force requirements of the load.
18. If a particular solenoid made later turns out to have a much better operating
voltne than is actually needed, it is net altered to have its characteristics
come out the same as other solenoids but is left as having a larger margin for
operation than the average would have.
19. It appears likely that the vendor built his circuit around a solenoid which is
better than would be required for the circuit it was originally designed to
work with. Consequently, the introduction of the 100 ohms in series with the
solenoid he has testing did not cause trouble even though the operation may
have been somewhat marginal.
20. ae do not have data on the actual operating point of the original SAD which
was apparently used in designing this electronic package. It passed a 4.5 volt
test which seemed to be all that was necessary for its use in connection with
the electronic package designed for it originally.
21. At the suggestion of our customer engineer, tests will be made to determine
what voltage must be supplied by the vendor to the resistor-condenser-solenoid
combination for operation. Incidental observations on tee operation of the
electronic package will also be submitted .
22. It should bernoted that when we are operating a resistor-condenser-solenoid
combination the transient solution is rather complex and changes in any of
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the parameters do not produce obvious and readily determined effects.
A complete or 'definitive classical mathematical solution of the apparent
transient problem is made impractical by ordinary means because of (1)
variation in inductance with enertization.(2) similar variation of in-
ductance with air gap.(3) inertia effects changing the load-air gap plot.
(4) changes in the force required curve.(5) non-linear changes in the
transistor part of the circuit, and probably others.
23. It was noted that the unit supplied to us has 13 milliamperes stand by
current--compared to less than 2 ma, for the unit supplied under 74B.
24.* It wes found that the SAD unit had been damaged. The hack wire was badly
bent near Its support and was not adjusted properly to cause the balance
wheel to hack on the proper screw when the solenoid was released. The
back-up support for this hack wire had been broken off and was now attached
near the support by a glob of some type of adhesive and was not in posit-Ion
to engage the hack wire itself but was down near the pillar plate of the
watch asseMbly. WO also found a spoteof the adhesive, on the balance wheel.
25. This total hack assembly was replaced and the defective :as given to our
customer engineer for his further investigation. It Will then be returned
to Us for replacement of springs and for use in a later unit which will be
supplied on Project #183.
26. " e requested that we supply him 5 copies of the up-to-date circuits
on i 1 (Project #160) and SAD (Project 1i183) as he feel his are not the
latest after addition of testing wires to 160 and addition of sensithity
adjustment to 183. We should similarily supply 5 copies of the latest
circuit drawing on TEM-A as (Project 1/163) as some wires have been added
to this as well.
27, It was suggested that we cement the gaskets used for closing up TEM and
SAD. It was pointed out the disadvantage of this is that you do not have as
smooth a surface to apply the gasket to when you use cement as you do when
there is no cement and, therefore, have a tendency to get a poorer seal.
This will be investigated further for some type of light cement which can
be applied more evenly.
28. It was suggested that "Seel Skrews" be used for the two screws on the back of
the TE-A unit. This will be investigated as to feasibility and used if
possible.
29. It is agreed that we will not use potting on the electronic package of the 163
unit unless vibration tests show that it is not possible to hold the units
properly without it. Potting is being omitted to facilitate any repairs or
replacements which might later be needed on the electronic circuit board.
30. Desiccant application. Our customer engineer was shown a unit we have made
up using a small desiccant package supplied by Culligan to Bell & Howell for
aerial cameras and a commercial unit just obtained from a company in Connecticut.
The Culligan unit was decided upon.
31. The general system plan is to have a desiccant'package which is mounted in
a threaded hex assembly screwed into the back end of the TEM-A. This hex
unit has a window in it thru which a blue blotting paper indicator can be
observed. In case moisture is detected this total unit would be removed
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C
and the JAYI-A purged with dry nitrogen as described below:
32. An adaptor would be screwed into the threaded hole used for the desiccant
package. A small bottle of nitrogen at approximately 1500 lbs. pressure
is used. This unit is similar in size and shape to the carbon dioxide
units used in seltzer bottles, but has a threaded end.
1;3. The adaptor would have a hollow piercing pin so that when the nitrogen bottle
is screwed down,into the thread the piercing pin would pierce the end of the
nitrogen bottle releasing the pressure.
34. The threads of the adapter receiving the bottle would have a semifluid tT.e
compound so that the 1500 lbs. pressure would not be exhausted along the
threads of the adapter to the outside of the case.
35. The adapter itself would have a very small thread (48 per inch). The one
shown our customer engineer has a cross hole from the piercing pin out to
these threads. From the
point of exit of this hole the threads on the adapter were truncated about
.009" to nrovide in effect a long capillary from this point to the inside
of the unit. This is to reduce the velocity of the nitrogen which would
enter the unit.
36. It was found quite diMcult to make these small threads accurately enough ?
to provide a tight capillary, so the nitrogen did enter the unit more rapidly
than desired.
37. An alternative solution is to use a ball and seat to seal off this pressure.
The ball would be held into the seat bp a screw without a spring. There would
be a small hole leading from a point along this screw into the TEA unit.
36. After the nitrogen bottle had been pierced and the pressure exerted upon this
ball assembly the screw described would be 'pecked off very slightly until the
1500 lb. pressure had been relieved slowly into the TEN unit and then opened
fully, giving a final charge to the unit.
39. During this charging period a screw is removed from the front end of the TEM-A
unit to permit egress of the moist atmosphere as dry nitrogen is being intro-
duced.
40. If the indicator show the presence of considerable moisture it would be de-
sirable to charge the unit by using more than one of the bottles of nitrogen.
Each bottle of nitrogen provides several volumes of gas compare' : to the space
inside the TEN-A unit.
41. It has been found that there is very little cooling from the e'xpansion of this
gas since there is no change of state. Therefore, a simpler arrangement is
being tried which will involve the use of a very fine tube ( a. hypodermic
needle is contemplated) extending into the unit from the piercing pin. It
is anticipated that this will provide sufficient restriction to the iidtial
' inrush of nitrogen to avoid blastine effects and building up too high pressure
inside the unit with possible rupture of a gasket.
42. It was agreed that altho the fine threads originally used would not now be
required for the capillary- effect no change would be made on the present
unit, thereby saving consideraele time and effort. (The fine thread also
works out better for the SAD unit with the restrictions placed on it 11-11-59)
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43. It would be undesirable for the case of the unit to be entirely loose
from the unit itself when replacing the desiccant unit with the adapter.
We will, therefore, provide two screws for holding the assembly together
in addition to this larger hex assembly.
44. Desiccant unit - SAD. To avoid changing cases and other parts on SAD,
and still use the present planned desiccant package for the TEM-A it was
agreed a bushing assembly will be fastened to the case to space out the
hex unit far enough that it will not interfere with the electronic package
on the inside. Our customer engineer is going to give us more definite
information on the electronic package so that we ma.,1) determine the length
required in this bushing.
45. Information 11-11-59 directs that (1) we use an indicator only
place of a desiccant package, to save space, (2) we do not use
the case of SAD, (3) use a bushing maximum extension from case
maintain present desiccant package assembly for TEM-A (5) make
adapter to fit TEM-A and SAD interchangeably.
46. We have found this desiccant package with its indication in the far end
from the absorbent material te be rather slow at indicating a change in
moisture. We will, therefore, investigate the availability of a simple
paper unit to be put outside the desiccant package and next to the window
for quick indication of humidity. The desiccant package would then really
be depended upon to keep down the moisture until the desiccant unit could
be replaced, and purged with dry nitrogen.
for SAD in
space inside
of *" (4)
the purging
47. A number of things have been done in connection with Project #163 for the
TEM-A as indicated below:
48. New, smaller wires have been placed in the unit for the connections from
the top printed circuits to the connecting plug and to the bottom of printed
circuit. This will improve flexibility and reduce the likelihood of breaking
wires when the unit is taken apart for study or correction of adjustments.
49. Some problems have been experienced due to moisture and dirt. The TEM-A
unit has been disassembled and our latest findings in connection with proper
plating of plungers and plunger stops applied to all parts. Mating surfaces
were reground and protective plating applied such that no trouble should
be experienced in service.
50. Everything was cleaned while it was disassembled. All printed circuits
were polished by powder polishing---then cleaned with trichlorethylene,
alcohol, and dry wiping.
Si. Experimental work was done on encapsulation but as mentioned in a previous
paragraph this is to be abandoned.
52. A carrying case for this unit has been ordered and will be delivered with it.
It consists of a wooden box with hinge and clasp assembly. It is large enough
to provide foam mounting for shock protection to the unit and will, in addition,
carry the mating plug, two desiccant charge units, two nitrogen bottles, and
either a tube or a small salve can of meterial for sealing the threads of the
nitrogen bottle when it is screwed into the adapter, and theadapter iself.
53. It has been agreed that we will test all 160 units at normal temperature and
progressively to lower temperatures so that there is a separate record for
each unit of its lower tempeeature limit if this limit is above -30?.
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54.
TM-A, Project #1631 is to be delivered by Friday the first week in
December. We are to advise our customer engineer approximately two
weeks before this of the state of our tests and the time we expect to
deliver so that evaluation tests can be arranged.
55. Our customer engineer reported that in some tests on the TEM, Project
1/160 delivered to them, the sweep would alternately read out one time
and three times when given a sweep command. This was explained as
likely being due to a change in adjustment of the sweep bridge position
at its stop location. 'The ratchet driven by the solenoid has a Lear
on its Shaft which drives the sweep bridge around four times for one
complete revolution of the sweep ratchet which has 96 teeth. Even very
nominal eccentricity of this first gear might, therefore, cause a slight
difference in the position at which the sweep bridge would nominally
stop. All units are adjusted here to stop in what is considered a safe
position compared with other adjustments which must be met.
56. We have not experienced the type of change in adjustmeet which rias apparently
occurred here but have in previous cases noted that when a unit was first
set up for test without its final adjustments we would find errors in
readout which would occur in multiples of four readouts. All units are
adjusted here to. take out these irregularities.
57. Some units have set for as long as three weeks in storage here without any
vvisible deeraduation in adjustment when later tested. This one was apparently
left with too close an adjustment or has been damaged in some way. It
has been found that some units tested at normal temperature reproduced radical
errors in readout at low temperature unless tiey have been sealed with dry
nitrogen at the normal temperature. This,phenomenon is explained by the
development of frost on the contacts and printed circuits from the moisture
which was in the air before the temperatere was reduced.
58. SAD electronics. We have been considering further the action of the electronic
package supplied by our customer with the SAD unit returned. We find the
electronic package is insensitive to two or three pulses.
Eventually a pulse is reached which energizes the last transistor but does
not saturate it. Succeeding pulses give a step input to the solenoid and
condenser combination as you saw.
59. As explained this is bad if the pulses are reasonably far apart.
The phenomenon of the plateau provides the efleCt of partially
charging the condenser so that when later the transistor is saturated the
new energy transferred thru the partially charged condenser is a great deal
less than would be provided thru the uncharged condenser. In our study,
we found as high as 5 plateaus of this sort before the output transistor
was sufeiciently saturated to provide full output.
60. From this we might assume that if we were to provide a number of pulses which
were so close together that there was not any appreciable charging of the con-
denser in the first pulses required to get up to a saturation point, we should
get operation. We find that this is in feet true, and that the unit we have
works quite satisfactorily at 1000 cycles. (This is not a limit, merely one
positive value)
61. It appears, therefore, that this type of electronic unit will operate the
solenoid under certain conditions of pulses but not others, the differences
resulting from the fact that the eesistor-condenser combination was not
sufficiently considered in designing she unit.
PAM cinclun A I
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,
CONFIDENTIAL
November 5-6, 1959
62 u'e replaced the hack and hack back-up spring in the unit -- left with
us and have taken considerable care in obtaining the minimum possible
adjustments. This results in a stroke for the solenoid of only .010"
W.th a contact closure of approximately .005". The resilt of this is
an operative value so low that this unit now works 'on the electronic
unit supplied at a value somewhat below 6 volts at normal temperature
:,Ind -30?C.
63. We will attempt tc5 adjust new units to work as low as this one.
CONFIpENTIAL,
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