DEVELOPMENT OF A MINIATURE HAND GENERATOR TASK 6

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78-03330A004100050001-6
• Release Decision: RIPPUB
• Original Classification: C
• Document Page Count: 19
• Document Creation Date: December 22, 2016
• Document Release Date: February 8, 2012
• Sequence Number: 1
• Content Type: REPORT

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DEVELOPMENT OF A MINIATURE HAND GENERATOR
Task 6,
FINAL REPORT
J
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CONFIDENTIAL
FINAL REPORT
Project 3027 Task 6
Development of a Miniature Hand Generator
I ScQJ&
The objective of Task 6 was fourfold as follows:
1. To fabricate a complete and tested prototype model of the
HG-1 hand generator.
2. To produce a complete set of production drawings includ-
ing bills of material for the 11G-1 hand generator.
3. To fabricate a complete and tested prototype model of the
IIG-3 hand generator.
4. To produce a complete set of production drawings includ-
ing bills of material for the HG-3 hand generator.
II IIan d Generator 11G-1
1. Prototype Model - The major portion of the time and effort under
Task 6 was spent in attempting to develop a practical version of the
hydraulic speed changer previously devised for this type of hand generator.
The allotment was made in this manner because of the greater saving in weight
and volume promised by such a unit. A description of the work performed has
been set forth in the bi-monthly Progress Reports on the task and more
particularly in Interim Report No. 3, covering the months of November and
December 1953.
As a result of tests of several modifications of the original
designs, the conclusion was reached that the hydraulic speed changer would
~D N11AL
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CONFIDENTIAL
require considerable further basic development before it could be made
practical for use in its intended application. It was demonstrated that
the required minimum efficiency of 85% could not be achieved without
basic re-design. The low efficiency of the system was due primarily to
certain fixed dynamic losses in the motor which were excessive when com-
pared to the small power output at the high rated speed.
Despite the failure to develop a practical hydraulic system
for this particular application, the studies during this period showed
that the motor, as presently designed, can be considered practical for
use under any one of the following conditions:
a. Where efficiency requirements may be relaxed to permit
use of a motor with about 50;o efficiency.
b. Where for the same speed (5450 RPM maximum) and high
efficiency requirement, the output power could be raised to about 1/4 horse-
power. Higher output could be obtained by increasing the axial length of
the motor while holding the diameter and pressure the same, or by retaining
the present dimensions and raising the operating pressure.
c. -Where for the same output, .15 horsepower, the speed require-
ment would be about 2500 RPM maximum, also employing higher pressure.
The conclusions discussed above were reached at the beginning
of December 1953. Accordingly, after conferring with liaison engineers of
the contracting agency, the emphasis of the task was removed from the
hydraulic device and placed on the HG-3, gear-driven model. As a result,
a complete, assembled model of the HG-1 unit is not available for delivery,
as originally planned. The important components, unassembled, are to be
delivered.
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2. Production Drawings - During the time when work was being
performed on the IIG-1 hand generator, production drawings for this unit
were drafted. The procedure followed was to make up the detail drawings
in accordance with the design of the piece at the time of drafting and then
to make corrections to conform to modifications found necessary during
fabrication or testing of the unit. As a result of this procedure, the
set of production drawings were substantially complete by the time it was
concluded that such a unit would be impractical. At that point, all
further effort toward completing the production drawings was abandoned
in favor of devoting the remaining time to completing the production draw-
ings of the HG-3 model.
III lia d Generator L -_G
1. Prototype Model -
a. Description - In accordance with the original intent of
Task 6, the hand generator Model I1G-3, employing a planetary gear speed-
changer and a hollow-shaft generator, was completed. The result of this
effort is a practical and efficient unit which, while not realizing as
much saving in weight and volume as was hoped for in the 11G-i Model, is
still a substantial improvement in this respect over the GN-53A. Included
in Appendix A to this report are photographs of this unit, taken in
the assembled and "knocked down" conditions.
Reference is made to Appendix B of this report for Tables I
and II which give the weight and volume of this model and the comparative
corresponding figures for the GN-53A. Included in Table I is an additional
set of weights for the production unit of the 1IG-3. These indicate, that it
will be almost three quarters of a pound light than the engineering prototype.
Page - 3
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The increased savings in weight was made possible through further modifi-
cations found to be practical during fabrication of the existing proto-
type. A list of these modifications and the resulting weight saving of
each is given in Appendix B, Table III.
b. Limitations - Although the hand fabricated engineering
prototype model is an adequately constructed unit for demonstrative and
laboratory test purposes, it has certain undesirable features which would
not be present in the production iteri. These limitations result from
the pressure of time and funds and compromises that had to be made in hand
fabricating the prototype. Appendix C contains a list of these features
and statements as to how they would be corrected in production. Also in-
cluded in this appendix is a detailed list of the differences in construc-
tion between the experimental and production units.
c. Performance Characteristics - Unfortunately, limitations
of time have prevented conducting detailed laboratory tests which would
give such firm figures on performance as mechanical and electrical efficiency,
voltage regulation, filtering, acoustical noise value, etc. However,
preliminary comparisons made between the I1G-3 and Git'-58A operating under
the same conditions indicate that the first should be equal in quality to
the second. It will be noted that the acoustical noise of the HG-3 is
greater than that of the present service unit but it is believed that the
installation of proper ball races in the speed-changer, dynamically balancing
the generator armature and correctly "wearing-in" the brushes will remedy
this deficiency.
d. Recommendations - Besides the improvements in construction
between the engineering model and a production unit listed in Appendix C.
experience gained in fabricating and testing the former indicated certain
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additional modifications that should be considered. Time would not permit
incorporating them in the actual production drawings. These recommendations
are submitted for consideration before the unit is put into production:
(1) The present system of shock mounting should be replaced
by a molded sponge rubber "boot" which fits over the entire inner assembly.
Resistance to turning would be secured by a boss cast as part of the end
plate to engage a mating depression in the boot.
(2) The present knurled leg-clamps should be replaced with a
stub wing form for easier tightening.
(3) The existing standard Signal Corps power receptacle
should be replaced with a lighter and smaller waterproof, five-pin type
such as the Cannon Electrical Development Company Type "U" or its equal.
(4) The present basic generator unit should be replaced
with one that employs aluminum windings. Such a unit, according to liaison
engineers of the contracting agency is already in an advanced stage of
development. This substitution would further reduce the weight of the
production HG-3 unit to 18 lbs.-7 oz. and realize a 32;a' saving over the
GN-58A.
2. Production Drawings - Along with the engineering prototype model
of the 11G-3 hand generator, a set of production drawings have been completed,
including all the changes outlined in Appendix C. The aim of these draw-
ings has been not only to make the details of each piece amenable to
standard production techniques but to suggest to the manufacturer the
logical steps for assembly of the various component units.
3. Assembly and Disassembly Instructions - Appendix D contains the steps
to be taken in disassembling the engineering prototype model.
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!~ r-)
APPENDIX A
FIG. I 25X1
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APPENDIX A
FIG. 2
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APPENDIX .B
T,1[]IL I
M-1
4-r
Engineering
Prototype
Production
Unit
Weight of Case
15 lbs.-15 oz.
15 lbs.- 5 oz.
23 lbs.- 0 oz.
Weight of Handles
14 oz.
14 oz.
14'C', oz.
ht of Stand
Wei
- '1 oz-
4 lbs
07.
.
3 11a.5~,-1
g
.
.
TOTAL
21 lbs. - 1 oz.
20 lbs.- 7 oz. ,
27 lbs.-12 oz.
;S Saving
25
27''*
This is the weight of the lightest GN-53A stand. A second type weighs
6 pounds.
00
Employment of aluminum generator windings would raise Savings to 32,").
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APPENDIX B
TAflLE I
L
G -5
aavino
Method I
672 cu. in.
904 cu. in
25!"
Method II
990 cu. in.
2302 cu. In.
53
Method III
784 cu. in.
1003 cu. in.
22
Due to the several definations that can be considered when speaking of
the volume of the unit, the comparative figures are based on the following
methods of computation:
METHOD I - The volume is considered to be the sum of the net volume of each
component.
METHOD II - The volume is considered to be the volume of a cube defined by
the over all dimensions of the unit considered as one package.
METHOD III - The volume is considered to be the approximate volume occupied
by the unit considered as one package, in which the contour of
the package has been considered.
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GLci t
Engineering Production
Descriotion of Differences in Construction ftototy Unit
Crank Socket Bearings - 2.0 oz. 1.0 oz.
Nylon is substituted in the production
unit for bronze in the engineering proto-
type.
Crank Socket - 5.0 oz. 1.5 oz.
Aluminum alloy is substituted in the
production unit for stainless steel in the
engineering prototype.
1st Stage Input Plate - Speed Changer - 1.0 oz.
Lightening holes in the web are pro-
vided for in the production unit.
Sun Gear 2nd Stage - Speed Changer -
Aluminum alloy is substituted in the
production unit for stainless steel in the
engineering prototype.
Sun Gear 3rd Stage - Speed Changer -
Aluminum alloy is substituted in the
production unit for stainless steel in
the engineering prototype.
Saving in IJeight
3.6 oz. 1.3 oz.
2.4 oz. .9 oz.
14.8 oz. 4.7 oz.
4-7 oz--
10.1 oz.
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Limitations present in the engineering prototype that would not be
characteristic of the production unit -
1. Excessive acoustic noise is present during operation. This is the
result of poor surface conditions of the ball races in the speed changer.
This condition is the result of dimensional errors in fabrication and in-
adequate hardness of the race material. The production unit will have
bearing race inserts with a 60 RC hardness as compared to the 45 RC hardness
of the engineering prototype.
2. There is present additional drag and resulting decrease in mechanical
efficiency due to the poor condition of the ball races in the speed changer
and dimensional errors in original assembly of the unit. This permits the
rotating elements to sag slightly, thus increasing the loss in the gears.
This is corrected in the production unit by adequate hardness of the ball
races which will permit slight pre-loading of the thrust bearing and more
positive positioning of the rotating parts.
3. There is present an undesirable vibration due to the sag rotating
parts in the speed changer, and to an unbalance in the generator armature.
The first will be corrected as described above and the second. by standard
production dynamic balancing procedures.
4. There is present a certain amount of acoustical and electrical
noise due to inadequate brush contact. This is automatically self-correct-
ing with use, and it will be prevented in production by standard run-in
techniques.
5. There is a tendency for the welded joints in the stand to crack
open due to movement of the stand during operation. This is because these
joints, of necessity, have been made with 9194 Eutecrod, a type of aluminum
brazing rod instead of by heliarc welding as will be the case with the
production unit.
6. The strength of the stand is below the design level because the
tubing is of 24S-T4 and 61S-T6. The production unit tubing will be of 75S-T6
aluminum alloy which was unavailable at the time of fabrication of the engineer-
ing prototype.
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Differences in contruction between the production unit and the engineer-
inc prototype -
PROpiKTION UNIT ENQUIEERING PROTOTYPE
1. Speed changer planetary gear shafts
(a) All shafts provided with axial (a) No provision for direct lub-
and radial lubricating. rication between gear and shaft.
2. Speed changer 1st stage Sun gear -
Bearing races to be inserted in gear. Bearing races are integral with gear.
3. Speed changer - input plate
(a) Bearing races to be inserted (a) Bearing races are integral
in plate. with plate.
(b) Coupling housing to be inte- (b) Coupling housing is keyed to
gral with plate plate.
(c) Lightening holes provided in (c) No lightening holes.
plate.
4. Speed changer gears - Back lash
tolerance to be double that of engineer-
ing model.
5. Speed changer planetary gears -
2nd and 3rd stages to be molded. Gears are machined.
6. Speed changer - fixed gears -
2nd and 3rd stages to be of 75S-T6
aluminum.
Now of 24S-T4 aluminum.
7. Speed changer thrust ball races -
to be of SAE 51440F hardened to 60 RC. Now of SAE 4130 hardened to 45 RC.
8. Speed changer 2nd stage Sun gear
(a) Bearing races to be inserted (a) Bearing races are integral
in gear. with gear.
(b) Material to be of 75S-T6 (b) Material is of SAE-4130.
aluminum.
9. Speed changer - 3rd stage Sun gear
(a) Bearing races to be inserted (a) Bearing races are integral
in gear. with gear.
(b) Material to be 75S-T6 aluminum. (b) Material is of SAE-4130.
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Differences in construction between
ing prototype - CONTINIED -
the production unit and the engineer-
PBOIauCT101; J;UT
10. Speed chanljer assembly
(a) To be held together with Allen
lid. screws.
(b) To be doweled with steel pins.
F? 1 ~ 1 I! ?:"l~T^II'; PRO -107f I''u
~l.~? ~
(a) Held together with round lid.
screws.
(b) Doweled with steel pin with
nuts on each end.
11. Crank sockets
(a) Both to be cast.
(1b) Both wade from 355S-T6
aluminum.
(a) Machined.
(b) 416 stainless steel.
12. Crank socket bearings - to be
made of molded nylon.
13. Crank socket thrust washer
to be Made of molded nylon.
Now machined from bearing bronze.
No such piece.
14. Power plug housing cover
(a) To be cast of 355S-T6
a luminum.
(b) To screw on plug threads
(c) To be secured by a bead chain.
(a) Machined of 24S-T4 aluminum.
(b) Screws in threads in housing.
(c) Not secured.
15. Case end plate - to be cast of
3555-T6 aluminum.
16. Case cover - to be cast of 355S-T6
aluminum.
17. Generator case - to be seamless
drawn aluminum tubing.
18. Stand legs - material to be
75S-T6.aluiuinum alloy.
19. Welding - joints to be heliarc
welded.
20. Seat stiffener - to be of 1/2"
wide x 1/16" thick 61S-T6 aluminum
strip welded to seat.
Machined from 24S-T4 aluminum.
Machined from 24S-T4 aluminum.
Rolled aluminum sheet welded
longitudinally.
Material now 24S-T4 aluminum alloy.
Joints now made with 194 Eutecrod.
Now of 1/2" x 1/2" x 3/32" aluminum
angle screwed to seat.
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Difference in construction between the production unit and the engineer-
incc prototype - CONTINUED -
PRODUCTION UNIT ENGINEERING PROTOTYPE
21. Leg hinge pins - to be attached Attached by welding brackets to mud-
directly to mudshoes by welding. shoes.
22. All hinge pins - to be Rollpins. Straight steel pins with 1/0" I.D.
23. Speed changer - cover 3rd stage end.
Ball bearing to be radial-thrust type. Ball bearing now radial type.
24. Speed changer - all Sun and fixed
gears. Provisions made to have .010" Face width of all gears are the
greater face width than planetary gears. same.
25. Speed changer - planetary gear
shaft 3rd stage - to be secured by nuts Secured to 2nd stage Sun gear by
to 2nd stage Sun gear. staking end of shaft.
26. Crank socket bearings -
(a) To be provided with screw (a) Provided with holes for
driver slot for removal, removal with pin wrench.
(b) To be locked in housing with (b) No provision for positive
set screw. locking in housing.
27. Voltage regulator - to be provided No provision for holding down strap.
with a holding down strap.
28. All aluminum pieces except tubular Now of various alloys.
sections of stand and speed changer
gears - to be of 61S-T6 aluminum alloy.
29. Stand-all lower leg section. Holes Pins are now ground off flush with out-
for retaining chain pins to be recessed side surface of leg section.
to prevent interference with sliding
into upper sections.
30. Stand - case support plate. Brace Brace now separate and welded to both
to be welded to back leg will be inte- leg and support plate.
gral with plate.
31. Stand - mudshoes - to be formed Mudshoes are now circular after
from circular blank. forming.
32. Stand - toggle pin lever - handle Handle section screwed to toggle section.
section to be riveted to toggle section.
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APPENDIX D
DISftSSE",SLY I'I;XEPI
1. Unscrew cover screws and remove cover. The resistance of this piece to
removal is due only to the presence of an O-ring seal.
2. Withdraw crank shaft from clearance hole at center of unit.
3. Unscrew power plug housing screws and pull housing out until back connec-
t4ons are exposed. Unsolder wire leads.
4. Remove all shock mount holding screws. Care should be taken not to lose
either the 0-ring or washer of the "Lock-U-Seals".
5. Remove crank socket bearing and crank socket from cover and case end
plate. Special pin wrench has been provided for this purpose.
6a Slide internal unit out of case with assistance of a 3/,1" diameter rod
pushing against speed changer through socket bearing housing hole at covered
end. Reasonable care should be taken that shock mounts are not injured
as they traverse the power plug opening or that output wires are not torn
or pinched as the electrical component section leaves the case.
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CO~~~~ENTIAL
ASSMLY PROCEDURE
1. Slide entire assembly into case with the speed changer end first. Inner
assembly should be oriented angularly so that the cut away section in inner
electrical component plate falls at the same point as the power plug housing
opening. The shock mounts on the inner end of the speed changer fall into
cut away sections in end plate. The shock mounts may be tilted enough to
free them if they interfere with the edge of the case mouth.
2. Engage end plate crank socket with matching square in speed changer and
screw end plate socket bearing into housing.
3. Screw in shock mount screws. Final tightening should be done in rotation
with all screws in place. Shock mounts may be moved about enough to match
up holes with case.
4. Slide in crank shaft. End with longest square engages square in end
plate crank socket.
5. Put on cover and screw in cover screws. Final tightening should be done in
rotation when all screws are in place. Some lubricant on O-ring will ease
pushing cover home.
6. Engage cover crank socket with crank shaft and screw cover socket
bearing in housing.
7. Solder output leads to proper pins in back of power plug.
0. Push power plug housing in place and screw in screws. Reasonable care
should be taken that the output leads lay in the case so as not to damage
the wire or the filter circuit components.
CO ,
DDET~
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CO~FMENTIAI,
PrdEC.lllllo 'JWW Y 1015
E' T AL
1. If the unit is operated outside of case, care should be exercised that the
input plate of the speed changer is not subject to radial loads. The use of
some type of intermediate bearing between input plate and power shaft is
recommended.
2. If the unit is operated outside the case in a horizontal position, the
main support and torque resisting clamps should be at the speed changer.
Supports should also be given to the generator to prevent destroying the
alignment between it and the speed changer.
3. The best method of storing the internal section outside of the case is
vertically and resting on the speed changer shock mounts.
4. Care should be taken to prevent foreign material from entering speed
changer through the hollow center of the unit.
5. Reasonable care should be taken not to damage regulator resistor panel
on outer electrical support plate.
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CONTRACT NO.XG--579. Task 6
VOUCHER NO.
PERIOD COVERED
Date of initiation to
July 31, 1953
July 31 to Aug. 31
Yx,fV. 1n~v. 3b ~~ s 3
uO~~ A 1 ENTIAL
CONFIDENTIAL
TOTAL ESTIMATED EXPENDITURES $46,1000
AMOUNT
$2,309.17
7,438.72
7,1~G.4to
io,3'tS.s3
TOTAL
$2,309.17
9742.89
649.37
72ggA0
s L12.9i
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