MOONSHINE STATUS REPORT

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP70B00198R000700040001-5
• Release Decision: RIPPUB
• Original Classification: K
• Document Page Count: 22
• Document Creation Date: December 23, 2016
• Document Release Date: August 15, 2013
• Sequence Number: 1
• Publication Date: March 25, 1963
• Content Type: MISC

Declassified in Part - Sanitized Copy Approved for Release 2013/08/15: CIA-RDP70600198R000700040001-5
II
? Performance
System resolution has continued to show improvement (Table I)
despite the fact that weather has continued to impair operations. At low
altitude, as in ATF-16, the camera is not focussed and boundary layer
seeing is relatively poor. At the present operating altitude of about
40000 feet (35000 feet over terrain) severe buffeting is now being
experienced, causing excessively frequent caging and allowing the stabil--;
ization system insufficient time to settle. It appears that as long as
operations continue at the present altitude, maximum resolution will
continue to remain in 'the 140 to 160 1/mm range limited by the system, and
by atmospheric and boundary, layer turbulence. In ATP-17 with all subsystems
except the heading reference functioning, median resolution exceeded 100
lines per mm as predicted.
Retrofits
During this period several retrofit packages have been installed.
These include a new control package, a new knuckle with friction reducing
tension rod, circuit changes in stabilization, V/h sensor and INC.
Additional retrofit packages presently in work include the following:
a scanner with better quality flats for the forward bench, new c-coil
with more reliable connectors, new V/h interface package, improved V/h sensor
head, new operational control panel with exposure programmer, magnetic
recorder signal outputs. Our intention is to install these just prior to
the first "hot" flights if these should be scheduled in the near future.
However, if these should be scheduled two months or more in the future,
we will install them when all are available, scheduling a general cleaning
and overhaul for the same period. The camera must also be refocussed
for higher altitude's.
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Ckt?
SYSTEM LA
Field OPerations
' During this period we have continued flight testing4in the
Area, but these have been limited in altitude-speed for reasons
'beyond our control. While the primary purpose has been to effect
improvement in performance, a secondary objective at the beginning of this
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?
period was to provide more practice for the field crew in more operational
aspects of their jobs. Accordingly, a series of quick turn-around experi-
ments were designed in which we were able to
successive days. Besides
I'
mount three flights on three
accomplishing our technical objectives, we
.were thua'also able to demonstrate turn around capability comparable to that
of the vehicle.
'retrofit,
to design
Later flights
were deliberately spaced to provide time for .
fine adjustment,
all improvements
be checked out
in the
. It
and maintenance. So far, we,h:aire been able
in such a way that substitute package! could
fli,a ? .
retrofitting-in the field. This
in servicetwith minimum down-time
..? 4i
laboratorysprioteo
? Ai ?. ty.
practice has served to keep the equipment
? 'tt ":?)%jie
vitae performance has been-ateadiliiimproved.
have also been incorporated inl4tro.;1:2: and
?
?
Systems.
?
Reliability
continues
Improvements thus demonstrated)
40.Tflatitl
? 4.74,5%..;?;
where applicable, inCo the IC ).
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The performance history is indicated in Figure 1. Reliability
? .3 ..e.
`II
high. Photographs have been obtained each time the systemehas
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1,
been turned on. Only once has it been advisable to postpone a flight due
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to a metiA
llction enCountered during preflight operations. A failure
'report suessary is-I-Included in the Appendix.
. ? -4
te,
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? Performance
System resolution has continued to show improvement (Table I)
despite the fact that weather has continued to impair operations. At low
altitude, as in ATF-16, the camera is not focussed and boundary layer
seeing is relatively poor. At the present operating altitude of about
40000 feet (35000 feet over terrain) severe buffeting is now being
experienced, causing excessively frequent caging and allowing the stabil-!
ization sync= insufficient time to settle. It appears that as long as
operations continue at the present altitude, maximum resolution will
continue to remain in the 140 to 160 1/mm range limited by the system, and
by atmospheric and boundary layer turbulence. In ATF-17 with all subsystems
except the heading reference functioning, median resolution exceeded 100
lines per mm as predicted.
Retrofits
During this period several retrofit packages have been installed.
These include a new control package, a new knuckle with friction reducing
tension rod, circuit changes in stabilization, V/h sensor and INC.
Additional retrofit packages presently in work include the following:
a scanner with better quality flats for the forward bench, new c-coil
with more reliable connectors, new V/h interface package, improved V/h sensor
head, new operational control panel with exposure programmer, magnetic
recorder signal outputs. Our intention is to install these just prior to
the first "hot" flights if these should be scheduled in the near future.
However, if these should be scheduled two months or more in the future,
we will install them when all are available, scheduling a general cleaning
and overhaul for the same period. The camera must also be refocussed '
for *higher altitudes.
. ?
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Although the direction we have received calls merely for
making a lA camera system operate, and that this extensive program of
improvement could justifiably be considered over the present scope, we
?
have continued thid'activity wherever possible in the belief that the prime
interest Still lies in ultimate performance, even in this prototype system.
We have tried to do as much of this as possible without interfering excessiVely
either in the progress of 1B or le, or. the operation of 1A.
? Heading Reference
More attention Must be given to the Heading Reference sub-system.
We have yet to run a teat in which this system was running properly and it.
, ". .
has generally been locked out. With short exposure times, this is not
as serious as with long exposure times.
Acceptance
yThe present contract does not clearly specify an acceptance test.
Accordingly we would, at 'this point, like to define what remaining services
and operating subsystems should be provided under this present contract.
First, we must deliver and test an operational control panel
with data flash extinction and automatic under-tension (of film) cut-out.
Second, we must get the steppers in the data chamber to operate, and must
repair the data fladhso two images occur as required. Third, we must
achieve "125 1/mm photography" on a long, hot flight. These three tasks
should satisfy the commitments on 1A.
However, the date of the long, hot flight is uncertain, and (1)
we will therefore use the intervening time to further improve the V/h
sensor. (2) We may shorten the time constant of that part of the V/h
signal which gives INC. Also, (3) we should try to improve the heading
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reference sub-system and (4) reboresight the platform sub-systems. These
last four items, are probably necessary to meet IC objectives, but they do
not seem necessary for IA and can be considered new scope. Similarily,
we will complete the magnetic data recorder outputs and the photo-
interpreters manual as new scope.
If lA is to be operationally committed, it may be desirable
to remove some test instrumentation leads but the field crew can do this
part of their duties.
Future Plans
Since we believe we are rapidly reaching the performance
1Likits imposed by the present vehicle's operating conditions, and since
we have demonstrated rapid turn around capability, we now have less of a
fe4ing'of urgency to run frequent flight tects. Since other systems will
. ? '
, alio require test time, we will schedule flights with decreasing frequency
)1 .the immediate future, preferring to utilize the time for more detailed
data analysis and for systematic fine tuning. /n approximately two weeks ?
we expect to remove the equipment from service to install retrofit kits,
and conduct a thorough cleaning and overhaul in preparation for "hot"
'V/1.1 Testing
We have been cooperating with the Type II people in their Vill
' sensor test program, supplying them with a replacement fibre optics
collector when theirs was broken and providing a new sensor head and pre-
amplifier of current design for inclusion in the test program. This head
. has a solid rather than fibre optic collector designed to improve the
.signal to noise ratio.
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APPENDIX I
A
This appendix-summarizes failure reports received from the field only:
Number of Failures Reported on Test Equipment 34
Number of Failures Due to Human Error
Number of Failures Due to Other Component
? Failures '
' Number of Prime Failure Reports .
TOTAL
.Sulmiry of Prime Failure Reports:
? -444. ,`_ ?
-1
Edge.Sepsor 3 reports
Air Pax Model 40 Chopper 2
Edge Sensor Modulator 1
10
3
The Air Fax Model 40 Chopper has m contact problem
inherent in its design and has been replaced with a
:solid state chopper. The Edge Sensor Modulator was
received from the field and studied, but the
failure symptoms could not be found in the unit.
. .
Stabilization 2 reports
Pitch Weight Shifter - Cause Unknown
Time Delay Relay - Design Problem
Data Chamber 1 report
Data Chamber Clock - Cleaning was required
Shuttles 2 reports
Voice Coil - Design Problem
Slip Clutch - Weak-Readjustment required
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SYSTEM 13
Status
Assembly status of the more critical items is tabulated
In the following section.
-.Platform & Bridge - Figures 2 and 3
The 13 platform and electronics bridge have been assembled
1
:1
and operated. All subsystems operate and turn in the proper direction.
Film has been passed through the system. Only minor realignment cit
film path was necessary. Corrective work of this nature is
scheduled for completion by the end of the month so that final
testing and adjustment can commence on schedule April 1.
The modification of the knuckle assembly to incorporate a torsion
bar has been completed and installed in the system.
Stabilization
Changes in circuitry proved out on the breadboard and the lA
system are being incorporated in this system also. The gyros in the
gyro package have been replaced from stock since the units have had
considerable prior use and were getting noisy.
Attitude reference unit is assembled except for porro mirror).and
is being wired.
Frame Assembly
Assembly is nearly complete. Since this assembly is not
required until near the end of the process, it has not been rushed
and La not behind schedule.
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1
4
. Helium Tank
The helium tanks loaned to the vehicle manufacturer had to be
. recalled because the additional tanks that were on order failed to
meet specification and the lot was rejected.
Schedule
The schedule'Oreviously supplied showed a three week extension of
4alivery to May 20 reflecting a slippage of the Budd platform, a critical
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path item. We are attempting to reCover a portion of this time by operating
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on'a double 'shift basis.
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3.1
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General.
SYSTEM 1C
Almost all releases have been made for System IC components.
In fact many of the smaller assemblies (aver 125) have already been completed.
Particular attention is being given to critical path items. Most
vendor delivery slippages to date have not affected schedule. However,
' those. that lie on or near the critical path are discussed in detail
later. A revised GPM chart is included in,tha envelope attached to this
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report.
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Platform
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Plafform delivery continues to slip according to the vendor.
Our schedule was designed, based on prior experience with this vendor,
to allow a three week slippage on this item. A short time ago
we were advised of a 5 working day slippage and, more recently, a 9
working day slippage which would essentially lose this buffer. We
are currently negotiating means to try to recover 4 or 5 of these lost
days. Progress otherwise is reasonably satisfactory according to the
engineer and. quality control representative who make periodic
inspection tr.ips.
Budd is doing the honeycomb laminating in house this time.
.They are experiencing some difficulties although not appreciably
different than those encountered previously on 1B when they had sub-
contracted this work.
? Electronic Bridge
The electronic bridge is recognized to be the next most
critical item. To reduce drafting effort, and to save time we are using
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? 15.1;111''''l
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tzft:
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simplified techniques in the design of the modules. Each module, during
the initial design stages, is represented only by a single schematic
. diagram and a parts list. Finally, when the design is essentially
complete, photographs of each side at unit magnification will be made
and appropriate call-outs will be added by the drafteman. Several
boards have already been constructed in this manner with considerable
saving in time and effort., -
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Shuttles_
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14
, . The -complex shuttle assembIy.cOuld,alio fallon"the critical?:
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t?path?if too much $
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41, .44' tun ,-
.1i.p.Page,is.permitteditoloCcur. %These-ashiMblies'j
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. -;lirtiArttUL
released),are:alreadyebeing aerie:1;1Kit in the clean
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(nearly last to 'be
room. We Elie experiencing only minor trouble in piOdurring some
ecif the subcomponents on a satisfactory time schedule. Some delay has
been experienced in manufacturing the special drag cup motors for the
capstans. (Reference Figure 15, Document 482). The manufacturer had
experienced some difficulty at one stage of manufacture but by applying
considerable overtime effort he has succeeded in solving that problem.
Optics
Flats sufficient for one scanner have been received and are
being assembled.
Aspherizing of the second corrector is continuing; however,
the image quality is not yet within specification. In work of this
nature it is extremely difficult to predict precisely when satisfactory
performance will be obtained. Since all the mechanical parts for the
benches are on band and are assembled, the Optical Group is concentrating
on this problem.
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Synchronization
A magnetic track of sufficient accuracy for scanner synchronization
has been generated. It can be improved so that only one pickup head re-
quired, but this can be done later.
Completed Assemblies
Approximately 125 subassemblies for type 1C have been completed.
. Photographs of some of the major subassemblies are.includeckin the envelope
? at the end of the report.
. .
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SYSTEM 11)
The only items being worked on for 1D are the set of three
refracting optical elements authorized previously. Work on these
elements has stopped until the elements for System IC are complete.
? .......i
We have prepared a schedule fram which we can determine the
- + :;-- k'"" . *. ? ? . .-
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l'.' 7!.. 1.4. C. order.? in which' releases must' beimride _to , assure shortest ? possible
i:it'si?!,2 :;i.- J.- ii,........? ? ;.i.i t.,i .:-.7w,v?:?.?.,,t`ek .;t.t..i,Z.LA...r.1/1rpc., 1 ill'ci? ...i t,w? r0.' fr ? ...,4 . ??? ??? ?
tg . ?. : 4.? ; f L' . ? ?7, ?? ? ? ., ? .
? ' ?? ?? ? t al .1. 4;0.4 ?? M4k 4 C,.?447?ta . 44?04.? I i .1 ?;" kr( 741e tit. t :14.2 i ' ? ? t4 ? ??? t
? 4 delivery of ?a fourth camera: sy- stem:4:A.Since critical glass 1 b Janke 'are ?
C1.1
7.-'?3--A.:-. -.,::W-,,.........? --1,-4'..VirltrIV,ttr'PtIttlr,9#11?.;47- - grlt-=:!7-,7-72.74
. 4r1 on hand -and ? the,correctors:are well....alongyinimanufaeturitigfin..-eight ..i.
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Lind a .half Month Cycle is indicated. This means that the, tittle has
- ? just passed passed for an early December delivery. An order must be given
by mid-April for delivery in this calendar year.
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1
a quartz were made and one was annealed at 6500F after every third cycle while
WINDOW STATUS REPORT
Three 14 x 20 vacuum window assemblies constructed during this period.
Of these, the fiist two were plate glass units built for the purpose of check-
ing Mount fit, assembly procedures, etc. The first of these units, complete
with mount is shown in Figure 4. The third unit built is a non-optical window I
using coated quartz and plate glass. It appears to be leak tight, although
resealing of the tube to block and bellows to foil joints was required. This
window will be used for outgassing tests at resent and possible thermal tests
? ? .
in the future.
.*TwO tight 7 x 10 windows were recently built as indicated in the last
progress report. After cycling the first of these successfully 12 times, thermal
cycling was initiated on the second. After cycling the second unit 14 times,
cracks began to develop in the aluminum which was jointed to the quartz. It
was felt that this might be a fatigue phenomena associated with strain hardening
of the aluminum upon extended thermal cycling. and that periodic annealing might
A
eliminate this effect. Small test samples of aluminum ultrasonically welded to
the other was not. After 35 cycles the sample which had been periodically an-
nealed showed no cracking of the aluminum, while the other exhibited both actual
and incipient cracking.
Consultation with
'was initiated on this .subject.
cycle, low stress fatigue, the' life of the metal part varies inversely as the
.square of the strain amplitude arid calculated that for the strain to which Our
pointed out that in the case of high
?
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STAT
STAT
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WINDOW STATUS REPORT (Cont'd)
aluminum is subjected the life should be of the order of several thousand cycles
before this type of fatigue could be expected. Further investigations were
undertaken and indicated that the cracking, rather than being of a fatigue nature,
or due to progressive plastic deformation (high strain, low cycle fatigue) and
.characterized by necking, is due to high temperature creep. This is demonstrated-,
in the photomicrographs showing metallurgical cross-sections of the aluminum. (Fig. 5).
Consultation with
creep of. high purity aluminum alloys has been initiated.
?
who has done extensive work in
?-? ? - ? .4
STAT
. r*
An improved design for a non-vacuum window, based on eliminating helium
from the gap, has been reported previously. Further analytical investigations
and redeSign indicate that it is feasible to convert a vacuum window configura-
tion. into such a non-vacuum unit by substitution of a pressure regulation system
An place of the vac-ion pump and valve, and some spacer changes. This gives the
possibility of converting a leaky vacuum window into such a configuration. A
model of this concept has been made and is now being prepared for environmental
tests.
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GENERAL
1. Manpower
The number of personnel employed on the project has remained essen-
tially constant. The notable changes are that the drafting effort has reduced
sufficiently to release two people. One field engineer was terminated. \
t
-
There has been an improvement in recruiting personnel for the field.
.47,-.-41:4\ ';4.? . .
Three persons are in training for field activities byworxing on the assembly
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4.
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- of System 1.8. Two of these are,Perkin-Elmer employees, one of whom has been
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. working ?.(
on project for some time. - ? :'41
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t1V,
A report covering the composition offield staging and recovery crews
is in preparation and will be submitted shortly. Also included in this report
ar:e.-"lists of materials required for "Fly Away Kits".
2. Project Control
In an effort to control costs better, the entire project is being
reestimated on the modified PERT cost basis. This rather considerable activity
will be completed in approximately three weeks.
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