BATTERY CHARGING HANDCRANK GENERATOR, HG-3

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78-03424A001400050013-9
• Release Decision: RIPPUB
• Original Classification: K
• Document Page Count: 30
• Document Creation Date: December 27, 2016
• Document Release Date: September 11, 2012
• Sequence Number: 13
• Publication Date: May 8, 1958
• Content Type: REPORT

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~~PY ~e ?FS.~~
F?I1VAL REPORT
SATTERT CFiAROI~G I3AI~DCRAI~I{ GEI~RATOR$~~C
r7pe~?e11i~v~~iJ.~~ 1~1~e 5$-A1071.~A.
Dated ~ ley 195$
W.O. 60t~)
GOC _.~----- R?d ~~T
~R~G CL SS ~M- RGES ~ ftEYgGLA~S --4~---
2
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.
6~EXT RE~f ---- l1UgtEa k~R
JUST ,-:---
Submitted b~
Pa?epared by:
Appz?ov~d by.:
1~2t3r 6, 1960
Distribution: ARD (Copies.#1-~9)
Conts?acting Offioer (Copy ~1Q )
STAT
STAT
STAT
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$s Pack~gn~ arii~ ountnge o~ o e o s o 0 o m m o 1.$~2O
B a ~r~ P~?og~?e ~~ 5 nee ReF~rt d o e $ e~ a m m a a o 0 20--23
~UGOES`PY(S FOR TN~ROVEN~T~ I FRS O~ELS e m o 0 0~ 24-26
E~P~T~~TRES o 0 0 o e o 0 o a~ o e a a s m o a o m o 26
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20 Pe?fo~?man~~ Ch~r~~t~i~3:~tc~ an~i T?~~t Dada
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VJ o 0 m f?
Nlay 6~ 19E~~ STAT
FINAL.~PpRT.
BAT?rERY .~HARGIItT,G ~~iANDCR~TK.__CEEtERATOR~ ~G,-
SpecY~f~cat~a ~T~s ;5$~A1:0?T1:=A
,Dated: $ lay 195
~~r~~os
The purpose of tk~~s p~?e~ect xs to de~rel+~p a po~?table
~iattex?y-charging, handcrarik generator ~ons~s.tn~ of a vol.t?
age gene~?at~~?9 po~ier ~?egulatar~ and and~catng mete~o hie
devise 3.s ~~ enatil:e nre Mari to ef':fcently aiid qui~kl.y re
charge secoada?y? batterYes .of the n~~el-ca~~ni,um ar~d lead
acid ty~e~ The electrical and mechanical de~~ga of the
ll .~
unity designated as the HG~;3; s~ia11 be especially di~?ecte
,. _ a
t~a~ard the development of a m~;n~:atu~~ec?i p~?oriu~~; ~iavr~:n~ a
high degree of relabil~:t~r Sheri exposed to roir~g~i handling
_ _ __ ~ ..
d~iring tYie f elc~ usage ~ Tri adriitoii to the a~~ive ?b jeo~~,ve~~
~_
the perforinaiace ~equa.reinent cif Spe~fic~toi l~o0 5$~~107~.~~
concern~.ng , caper~tng Zfe ~ no3:se ! etc a must tie me t m
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STAT
~~YR
~~e ~il~~~~'tm ~asl~ ca~1~~~ ~P~a~ '~~ de~~~~p~ierit ~~ a 1~,~~it
g~~ ~aiii~~~?a~k g~~~~?atr,~? ~?~~ ~at`~~~?~` ~Y~a~~~.ng ~.~.~ n~~ b~~
~~inp~;~t~d~ ~ ~~ri (~0~ ~~~~t~'fJ~~ ~od~~~ ~ia~~ '~~~n ~~~st~~zct~d
end ~~3pp~c~ tc~ ~~e ~~~~~?zi~n~i~t ~~c~~i~~a~ ~~p~~~~n~at~~~ nth the
~~~at~d a~~as~v~~~9 3:~i~t~u~t~~ b~~k~, and d~a~~ng~n ~h~~
.. LL.. .. _ . ~ -_ _.. ~ -. ~ _ >~_.. 4 - n a ._ -
~~~~~t ~~~~ti~u~e~ ~~~ ~,~'~ ~ta~a ~~ the ~~~~a~t and ~t~ ac~aptm
aii~e ~:]~: i~?~?~a~;l~ ~la~~ ~~.t ~h~ ~~~t~act,d
T~ ~ ~?~lt tla't t~~ ra~u~Lt~ v~' ~h3:~ p~~~~~~ have b~~n
~~~~~~~fti~1 and have ~ta.stif?~ed ~~i~ ~~p~~idtu~~ .~~ ~h~ t~.m~ and
,..
~on~p al~~t~~d~ A l~gYi'~~agY~~~ ~~~i~act ~aand~~ank g~ri~~a~~r ~a~
~e~r~ d~~+~~o~~d ~~~k~ ~;~ ~~~~~~~i~~~ ~~~,~~~~g~tla~ing amid of iio~i~
~~~~al i~antenanc~~f"~?~~ ~e~n~`t~?t~'tor~~ ~~~ c~p~~at~:or~ ~~ ;~iri~~~ ~
~e~q~x~?:~ig a m~~:~i~m ~f ~~~~c`t~~~i~ aid a~ a fu~t~e~ ~af~guard;
the ~x~~~ is p?~'t~~t~d against n~+~rre~~ m~i~ratc~n ?~ ~~nn~et~:e~~a
~~~ ~f f ci~r~~ ~ ~~~parata:vaz~ ~~g~ a ~~ns3c~srzag the i.~ihs~?ea~t
ds~i~at~:~n iri ~i~:gl ~`~^s~i't~~+~i~ ~~I.tage d~~~:.~~as l~irig a~ppr~at3:~-
mat~l~ 60~ t~ 6~~ over t2is cra~i~ng ra~ige?
._ _ ~ .. a
T~ aid tYi~ ~p~~?at~x? ~n i~st~s~^mr~~n~ tk~e stets o~ ~hargs
of tY~s ~a~tsr~ aid tie ~scessary c~a~leng rats e...r~d~at3~g
features are p~?~vd.~d s$~~~ng ~~arr?~iat ~l~~r .and.~ull-dhargs ~?im
d~:t~on for the ~a'ttei~e A ~ariet~ a~f fast~ni~g ~ie~~i?i~~ have
bash ~r~viisd t~Zr~~xg~i tie ~.~~ of ~rel~~aed straps and a pan-opener
ty'ps ~oizrat~:~g plate ~
Tie Mast. several: ~t~n:t~s9 si~~e the su~m3:ssiori ~.? P~?o,gr~s
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. ~ ~ ~ ~'
~. ~e~vt
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Depart ~~ o $ 9 have been spent ~ri repe.~:~? ~~i~ rno~f ~~e.tio~ ~~ the
~~~~;~~ prt~tc~t~rpe medal. anc aa~stat~a~ ~~? the eight a~ $) rem~~~~ng
~~e~d ~ade~~o The to?ctf~~~ata~ari dark ~i~ the secand triad~l ~~e.s cain
p~r~t~i~ly ffi~ri~r ~:~ ne,ture~ be~:ng ~ar~~ea~ied ma~~~y vrth r~v~soi~
of the a~~rik handle mnd hub ~ mid '~Ye ~va~l ino~iit~ng f'a.a~tura s
i~ na ~e~ aff`ectec~ the ge~ers:l s~ste~i ~~.~ ,1:s,yaut ~#? the g~n~ratara
The eight ~el.d, ura~ts halve been aoristru~t~t~ d~ritaal to the ~a~l
f ~ec~ seae~~acl ~ade1 ar~cl are ~e1t to be ~~ agreement with the ~av~rn~
went sp~~ifcatans~
~lt~iough the eight models mere aanstruat~d within the
rerBanaig fu~cls9 the tine rewired was safi~w~at 1ang~r than ~~s.
~x?g~ial:l~ eaepe~ted die ~ia~rily tee di~~iault~ in a~t~,inng fiber?
glass ~~~~~ of high qual~.ty ~oz~I~m~neh~p~ The aase~ ~at~aally us~c~
~,~?~ de:fntel.~ l~e]:a~ sta~nclarci b~.t are believed to b~ the best the
r~anu~'?~oturer aan or w],l supp5.y since the Faults iri the ~~~~ too
..
not partiaul:arly ~o~nproa~se the strength ~~ usefulri.ess ~f the
untsD e,g~eeme~tt was reached ?~~:~~ the Gove~imei~t teahi~ical. ~?~~~?~_
serat~.tive that they ~muli~ to acce,ptabl.e for ~%~~~ eight r~ioc~elsa
_This. I,abio~?ator~ ~~ Hour ~;ngage~ in ~ prac~~actiari e~iginee~^ig
STAT
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~?~~al ~e~~~?t ~
~~ ~ Oro 604
STAT
~t~dly o~ the Y~G? ~~~~~~~~~?~ Yt ~~ e~~se~ted; that this study ~y
the ~:~~e~:?pme~it ~~' ~~~n~lete aid e~~~~~:e~it t~~1~~~ ~ the ~~
~~~h c~ua~t~ I~oS:~ed ~~~~~ a~a~l the euhet~tut~i~ in the elect~?~i~e
~~? ~n~re e~~~~m~ca~ ~v~ip~~iente ~r11~ enat~:e ~ mai~u~a~tu~?e~? t~ c~n~
et~?u~t thae ~e~ie~?at~z~ ~~ a i~h y~~e~ ~~~`~ aid t~.th much g~eate~?
~~,~~; tha~i p~?e:~erit meth~d,~ al~:o~im
_~
~~~ HG~=3 gerie~?ato ~~ hae~~~~~:~ ~ ~~~y ~i~ap1~ eYect~?~=
mechanical t~aneciu~era '~~~ output ~hara~ter~st.~s ~f r~h~h ~~?~
_ ~- -
naucrtical ai~c~ ;~~~?~g~'~f ~~vva~?i~e T~i~ ina,~o~?ity ~~ the ~le~~~?~~
~i~cu~:t~y e~ip].oyed 3:s fo~? rite~.ttetiit rrluty .crily acad. d.u~?is~g
~ac~~a1 epex~at~~n :s not iri ueea Furtheric~~eg e~.rice the. ele~t~~i~ce
~~ baeca~:ly e~itch~i~ cii~cu~:t~?ys it also ~is~~r~~,s~na~~.y irteera-
~itf~e t~ vaz?yi~g c~mpenent pa~?a~iete~ea It t~ex?ef~~e f o11e~
that if thy. ~i~i;t pan ~~ triacl~ ~f i~~~pensl~~ m~t~~a1. and gain
- ~ e _ - -
p?r~e~tss ~:ts ecoa~omcal p~~d.icton is alrn~et, aei~ureel? WYa]~e
the teri (10 ~ units ae euppl.ed tii~ the Gave~?~ment are ~thri 'the
specif:catoras anal ~nr1~: vndouhted~:y meet tie ~p~rating lire
regarenents Frith coinparat~el:y la:tt~.e t~?~ubl:+e ~ they are hand
Made samples and v~ere ccrastrti~ted p~?i:tnarily. t~ .prc~e the # ease
tlty 8~ the i~e~rceo Tae p~?~ducti~~ eng~raee~?g studye the~?e-
_. ~ _
fox?e~ is a very necessaz~y anei ]:ogica~; ~~11~~~r~u~ ~~iae~ f'~~? this
c~ev~l~p~ierit cent~?act nc~ be~:~ig c~~npletec~ a~ci should ~:ead to the
o~ierall. goaY3 i~a~iely the ec?n~i~nical: p~?oc~iremerit df handcrarak
geriea~at~~?s ~:ra p~?~duct~:e~n $ua~tt~:~3~
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~? n 1 Repo~?t 5 a
Z^f ~ 0 ~~ 60~. STAT
DETAI~.ED DISCtTSSION
A o Review of Past t^d~~?k~
to General
In order to obtain a~clear understanding of the
progressive development of the HG-3 generato~?, a brief
chronological review of the work progress is in ordero
Details of these phases may be found in p~?evious eight
progress reports, together with pertinent drawings and
wiring diagramse
20 P?wer and Current Regulation
At the inception of the project, it was believed
that the. development of a subminiature power and current
regulator would require the greater shame of time and
money and, therefore, was undertaken as the initial phase
of the developmentm To attain the specified regulation
characteristics, two parallel approaches were studieda
The fi~?st involved a servo-type regulator in which two
silicon-controlled rectifiers, acting as ideal switches,
would be triggered by a feedback magnetic amplifier which,
in turn, would be controlled by a one ampere sensing
elemento It was felt that this type of regulator would
b~ non-dissipative in nature because of .the characteristics
of .the silicon-controlled rectifiers and thus be in keeping
with the high efficiency requirements of the specifications
The second approach involved a more simple network using a
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1 ~tepo~t
~oo? 64
~ ~STAT
~._
series power transistor v+i~iioh ~ouid be bused to a one
ampe~?e ~~:o~ ~?ate o Wril:e this ~iou~:d be a co~nparative~v
irief'fioient methods it also t~oiild be far less compl,e~
less expensive and more ooitipa~t~, H~i~ev~r~ because o
the Inherent inef?fioienc~ aiid, a~;so~ di~`~i~uity in stat~i
lining the cu~?rent to on.e m~ipere g this s,~:ternate approach
was soon dropped iiz favor of the first
The development of the riot?cl~.sepatve tyke ~egu~
tat?~? was pursued active]:y during the early phases and
was ~rough~ to a rather h~:gh degree of perforrraance s:nd
stabil:ityo its main disadvantage Sias a high degree of
circuit c~iip]:eaeity~ which Mould Piave made the packaging
protilein more severe s ~t sFiould be bone iri Mind, hover,
that the non~c~issipative pokier regu5.ator developed did
result iii acceptable regu.~:ati~n -over a fals~ly amide fre?
giiency and tetnperatiire range e.nd did definitely result
in inva]:uable e~cperience, particularly with ~?espect to
advanced .solid state s~itchirig technigi~esa
Concurrently Frith the complet3:oi of the develop=
rent phe,se f`or the non-dissipative po"~? regulatory the
fi~?st prototype gene~?atng unit i~as a~:so corripleteda Pre=
1iim~nar3r tests shored that the sel.~'=inpeddnce of the
generator was considerably higher than e~epectedo In ~apere,?
tion~ the actual; result eras .,a source impedance of si~.f
#'~:3:~nt inagzzit~icle .to ~is;1~e the unit a cur?~?et~t gene~?ata~?
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o
~in~l Report
~ ~a~a 6a~:
?e
STAT
rather than ~ ooraventional voltage generators Fu~?ther ~
pe~?it~entaton shoed that tYle generators s ia~g~clanc~ ~a~
almost purely inductive and couYd be ad,~u~ted to such a
ve:~;tie as to hold the oia:tput current into a 12mvolt batte~?
at a range of appro~emate y b 0 to 1~ 3 a~ipere s oven t~ e
specified ha~adcrankng ranges A ~o~starit . oizrrent~ non
elissipative gene~?ator^ lied been actually developed which
el~.inirtated the heed for any e~eternal regui.e,tir~g ~~anam It
vas found that the only e~terna]: components actually needed
mere a full rave bridge g a i'ilter condeii~er and f Ater choke ~
and the on~:~r other electronics z?e~uir?ed mere for au~ilar
( :nd:catng or protective) featiireso ~?urtlier~iare ~ in addi?
tors to regulating the current to appro~c~:mately constant
value, a:rideper~dent of speed; the hzgh sautes inductance of"
the geiierato~? also effectively prov3~eled.~.the f?.ret leg of
the T~filter, thus eliminating a ]large separate iron core
choke wh3:ch had been found iiecessar~y in the earlier inires~
ti:gat3:ois o
Tle above reeultsa of curse,. e]i~-inated the need
to develop a separate po~ier anti current regulat?~? and- this
~io~?~c phase Sias halted ?arnniedately~ die ` probl;ea~ of holding
the current to ]:~0 ampere then became a pant of the ge~e~?a~
for design phase9 basically 1~eng d.eperde~it upon p~?oper
clio~:ce of. imagne~tc ~?vtv~? conf~~gLirata~oii .and the number of
tu~?ns ,ri .tlie .i~:i~dings6 In optimizing these pa~?ariiete~?s~ a
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Final Report ~~
~~~ e 0,.: 60!~ STAT
c?nstant currents one_ampere generatox? was soon developed
and it way further found that in addition to holding a one?
ampere rate over th$ cx?anl~ing range ~ the current plateau
dropped for battery packs of mo~?e than 10 cells, clamping
the power output at approximately 15 watts, also a require?
meat of the specificationse Therefore all following work
was carried-out on the basis of employing tha inherent self-
regulation characteristics of the ba~~c gene~?ator unit?
3g The Basic Generator Unit
The initial development of the basic generator unit
was governed by three pz^mary factors, nar~elye a compact,
simple and rugged construction, a comparatively low rotor
speed because of the noise problem in a high speed ratio,
and avoidance of electromechanical commutators because of
the disadvantage of brush wear, sparking noise9 etce
These factors indicated the desirability~.of a simple magneto-
.. type alternator using a permanent magnet rotating field
thereby avoiding the complexity of a separately energized
field and distributed stator windingsa
Because of the acoustic noise specification of ~0 dba
maximums it was felt that the speed step-up mechanism should
have as low a ratio as compatible with..: the cranking speed,
and therefore a four-pole rotor was chosen as a suitable
compromises eliminating the high speed required for a t~ro-
pole .arrangement ox? the complicated coil configuration
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q ~ ... - ~~ep~~t
~~1f V ~J f' V~~
STAT
_ __
required in a s~m~~1:e con~?~uratlon? It has been ~~~oum
laced that ri order to avoid ~ severe faltering and ~?egu~-
laton problein~ a% output fregiienc~ froiri the alternator
of 66 cycles for a orank~ng speed of 66 rp~io rprould be a
inanimu~n fgu~eo . TYias called ~~~? a speed ratio of 36:1:9
tnrYich was f el;t to be ~ea~~~~:e th~?tiugh the iase ~f ~tYie~?
timing belts ~~? gearso
In: order to have the t~riri~~,ngs del;fvering current
.-
coritinu?usl~g it was f ?txa~cl advantageous t~ zee a series-
connected stator and fu].lt~ave br~:dge rather than a cente~?-
tapped winding and t~o~dode rectaf;er: For the stator
._ _ n
core ~ ~ ~iil 6rthornol laminations were tar~:grially chosen ~
althout'hs was liter changed to 1;2 mil Sl:ectrora rriate~
r~;al: for reasons of econo~ye
Most of the devel,op~ierit ~vo~k 3.n the generator unit
eventually entered about the des3:ga of a proper rotors
Initially; Alnico rotors we~?e procured because of their
co~iparatvely h~;gh flia~ denstym The original breadboard
model used a ~ou??~ole Alnico ro~toa? anci ~:ts p~rfo~?~anoe
gave the required; current outpito It tires found that as
much as 25I o~ the ~.nput po?~eir has lost ~n the ;rotor due
to severe eddy c%xrreitso Because of the high pr?eamu~i put
on opers;tng efficae~ncy~ 3t ~+ras dec~:ded to e]:~.znna.t~ the
A1'rico rotor and use instead a rotor constructed of a
cex?aari~c pe~?manent grtagne~ ai~.terRal kiioi as Indo~e 5~
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_a n..~, Z Resoidrt
Woo 60~.
lOm
STATI
_. ~ s ~ _ __
inanufactu~?ecl by lneiana Steel P^~idrxcts Co~ipanyo A nuffiber
of clesigrsg differ~:ng Mainly iii pole di~iensons9 mere con?
~t~?ucted and upan test the ef'~iciency of the r~itor was found
to be eaecell~nto t~lile the theoretical flue deiislty ?f tY
material is ~on~i~~~?a~iy~1-over ~~~n Airi~~ 5~ t~i~ e~f~?~~?~ra~~
in operating f~.u~ density is not as great because the ~riagaiets
_.~. - - - _ v ~ ~-
are alr stabil~:~eri before ~:nste.l:laton o Fiurtherzriore ~ Indo~c 5
,. .
was fouri~ to have at bast tv+"rce the etabilty? of Alii3;co
_ _ - --
ariiri therefore eras less sensitive to env~r?n~iental factors
such as heats vb?atoiis etco
Having found an acceptable rotor designs it re~iained
a imatter ~~ choosing the correct nu~i~er ~~ turns to obtain
tYie desired current ainpl~:tude a ~t was shortly found by
eanpircal experineritation that a large nuiriber of turns mould
provide a greater voltage at lo~er? speeds but v~ould also
result in a larger source ~:rid:v:ctance, therefore 1:ov~er:ng and
f latteing the ~urr^ent p-l-ateau ~, 4~i the other ha~c~ a e. sanaller
iiimbe~? of turns e i~hile riot barring the regulation nor as la~?ge
a current del.ve~?y at the lover cr?ankirig speedsg slid ~?esult
3:`r rather high ourreiit delivery at the lo~?er orankng speeclso
The final choices therefore, vas a matter of cor~ip~?~ai~ise
The present design uses tiro series-connected windings
of? Nom 19 Heavy Forrrivar wire and provides a regulation ?f
.~
appro~eimately 5 o into a battery terminal voltage of appro~eiP
maitely 13 voltse TY~ese figures are for the apecifaed cranking
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~_ _ 1 Reps
Udoo~ boo
llo
STAT
a?ange of 60 to 100 spins Yt y tie f~?the~? rioted tYiat con0
saderati]:e cu~~ent ielve is also available at 50 ~pino and
that the r^egtilat~:ori is ms,ntaned th~?ough a highe~? speed
~?ange than specifeelo the speed has been taken up to 1~0
spin; with Drily a Might ~.nc~ease ire output cu~?~ent o While
the Iiio~e ~oto~? must be fatia?3cat~d 3:nstead ~~ casts it is
st~:ll. felt that the gain Sri ope~atrig ef'f c~.ericy~ iri v~
of the fact that tha:s generato~? mixst be inanuall~ c~?an~edg
justifies this substtutono
.. ~ ~ ..
`Th~?aaughout the development the ina~ri p~?obletn with
tkie ~?ectf'yng aria;, Filtering coiiiponents has been one of
s~eo Because of the iistriet aclvai~tage of the generator
clesigri of us~;n~ a s~.rigle ~nndng output, a f4zll.vi+'ave bridge
teas ~?equred fo~? the rectifying e-l-emei~t e,nd th? oho~e of
_. _ _., _ ,
the General Electric I:N91 ge~?r~aiium diodes with t~? a.ri
parallel for each leg of the biodge was Made quite eaa?ly
in the devel:opznenta Although 4 slcori cl~:odes ~oulcl Have
_.. , - - -
suf?fced f?or this components the premium p-laced ?n ?pe~?at?
irig efficiency dictated the choice of ge~?me,n.~im diodes
because of their 1o~e~? fort;,rard voltage dropo Actuallye
the cliff ereiice in effc3.~ncy beten the tv~o is ~?ath~r
sin~ll acid because of the asseinti:7:y and size pr?obleii in using
~~odes as opposed to ~o it ~s b~l~.eved that futus?e riaoa.els
ce~tilc"i ;justify the iise of s~:lco~ dodeso
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For the ~~terg it had been planned fro~i the Mart of
tYe project to use ~ basis ~T4' ~ilte~ ~or~~~:n~ ~f two
iron core chokes and one large tantalum electrolyta;c capaci
tors ~Yieii the rion.edisspatve regia:la,tor was be~rig nvestm
_r ~ _ _ _
gateCl~ ~ ~reaclb?ard filter bias made up in order to feed the
D s C ~ oixtput current to the batteries and it vaa;~ dete~n~:ne ti
that the first choke in this f~:lte~ he,c to ~e v~r la~~e
...
due t~ the 1-a~?ge ~~n area anti tu~?ns r~qu~~cl f?r s~~?eot~v
filtering at b0 ~ycles~ When it vas f'oui~ci that the self?
~:iidretaice of 'the generi~tor~ ri addition to reg~:il:atiag the
current, also prova;ded an effect~:ve input l:eg for the filter
the large separate choice was quickly eli~~;nateda ~~ff~a;eiit
filtering vas obtained through the :ise of` a 1:200 inf?do elecd
trolytic tantislum capacto~? and a sma1:18 ti~om~lrading choke
using an AL~?71 Electron C=core, although se~rrera]: othe~?
core i~iateral=s and capacitors ~;ee~?e tried int~.allyo Ag~,:n~
the f'1:lter represents somewhat of a coiriproinise iii the of
ficiency parameter ,since the greater the nui~her of turns iii
the chokes tlae smaller-thQ capacitor can boo The ~ralues
rea~Yied a~iove ire felt ~o be ;justified sine :t all:od
the i?eplacement of a 2500 inf'do capacitor v~th the consid-
eral~ly is~ialler 1200 mf do size o The poi loss in the ~Y~o~Ce
is esta~rnatec~ to he appro~mat~ly Oo3 watts and further
optimization v~ould only result :n a very slight decrease iii
this Figure o
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1 Report
WaO~ b0~:
~.3 m
~a Ini3i.catin~~:F~ature_s
__ - - -
TYie original ~p~~~f ~atfori~ ca]:~ed ~'o~? ~~~~~..~e ~~d
current ndacat?n requiring ~ nultipurpoi~e ~iraiature metei?
with ~ selector sw~tcho Tt was soon real~e~ that such a
iievice ~oiilel die unpractical l~ecaise of space consderatioris9
arici therefore a subordinate investigation was requrei~o
-_._ _ _ e
die prot~leari of indicating current was solved fairly
. _
es.rl:__. with the .~
~' ~ procurement of a su~ianiniature ~iill,ia~rnote~?
inane by Marion Electrical lnstrutn~nts Companyo By ~?sading
the voltage across a Oo5 ohm resistor an the output lead9.
ancl, placing a gerinaiiuiii diode iii series with the metere
the cu~?rent range waa~ shifted. ff?c~m zero to l00 amperes t?.
005 to l00 amperese As such; the operator is given a
reasonably good incla:caton; since iii the extreme Left
position of the rieeclle; the current :s at half' value aid
in the s~ctreiiie righte is at the full, one ampere val:ueo
_- _ -- _ -
Tie prol~lein ?.? indicating output voltage eras found
to ~e far inure severe since tY~ie voltage charging character
stcs of` Nicad batteries generally have a very slow rise
anci9 furthermore a are clepenclent upmr anibi;ent ternpex?ature o
Only a high precision voltmeter coiil;d ~e used to give a
state==of-charge type of information s,nd even this v~oulci
Drily ~e accu~?ate at morn temperature if no compen~ati~g
irneans mere ~:ricluded,e Obvous.ly9 anew approach was
required. and tie result was the iievelopineiit of tYe ~rc~t
.now e~nployed~ ~nc~h iii basically a transistor~drven
STAT
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l 14:eport 140
W'ti0a 604
incandescent lamp triggered on by a ~ener dioe~e~resistor
..
network? The charging characteristics of T~icaci b~,tt~r~~~
were f ouni3 to exger~ric~e a coripar?at~rely ~hax?p rise a't ~:
point where the batteries ?eached 90J to loaf fully chargede
.t. _
By designing the Zener diode-resistor netw?rk to have a
f ~?~:ng ~ioltage appx^o~c3:iziately at this po~:nt~ the tix~?nng on
of the lamp indicates to the operator that his batteries
are at a state?~f mcharge of app~?o~cfrr~tel.~r ~0~ to 100 00
Because of ambient tempex?ature conditions and differences
betwe?n various types and capacities of nickel.-cadmium
batteries, this indicating point represents a compromise
and the final setting v~ll probably be dictated by f"~.eld
experience snore than anjr other f?actoro The circuit can
be ad;jizsted for different ttfully charged~a valueso The.re~
fore; for a given battery configuration and approximately
known teiriperature conditions, it can probably be modified
for a setting very close to 100f Even without modifca?
t;ion~ it shou].cl serve as a valuable indicator after a
brief period of fa~nxlarzat3:on in field usageo
6o Protective_Features
The HG-3 electrical system, as originally conceived,
consisted of an alternator, fullwave bridge, filter-and
indicating nieanso Vdth cot?reet connection and usage, no
electrical t?ouble was envsionede Fioweverg because of
its possible use by untrained per?soniel in the field
STAT
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1 deport
W. 0~ 60~i
l5?
STAT
several protecti~~e ~eat~z.res we:~xz ~?equest~d during the
development to guard against the po~~~bi-~_~-~tie~ o=:? ~perat~.ng
-into an open load circuit (such as the cl~.p ~,ead; fa~,iing
off the battery terminal during operation), or incorrect.
battery connection to the generator (due, possibly, to
indistinct polarity markings on the battery)o ~lithout
protective features, the first condition due to the sudden
loss of armature reacti?n in the generator can result ~.n
very high output voltage which, of course, can cause failure
in the filter capacitor, transistor and Zener diodesm The
-second condition, by inspection of the wiring diagram,. can
result in a severe short circuit current through the recti-
fier diodes, burning them-out.
To provide protection against an open circuit condi-
tion, it-was first decided to employ a heavy duty Zener
diode which would simply clamp the output voltage at a
rate sufficiently above the battery terminal voltage so
as not to bother normal operation, but sufficiently low.
t? protect the critical components? Except for co~t~
this solution seemed quite simple and was incorporated
in one of the early modelse The later request, however,
for a circuit to protect against incorrect polarity, lead
to the development of a transistor-driven relay ci~?cuit
employing a red indicating light and. further investigation
showed that by proper circuit arrangement, both features
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-1 Repo~?t
W o 0 0 60~~:
~.~ o
STAT
could ~~ .sup~?alied uisiig the same components and th~r~~y
el,~riins,ting the nigh po~~e~~ ~ne~~. made o the ~??~~nt circuit
was the rasult of this e~pearimentation and operates in
~eileral; in the following mannero
In the event of ari open load cirCUi:te a Zenez? diode
resistor network in tYie base of a 1:ow power transistor
recognizes the increase iii output vol:tage~ turning on the
transistor and energ~.z3.ng the ~?elayo 7~he ~?e1.sy~ in tu~?n~
closes in a 5 ohm load across. the generator which then
de1:3:vers approxanately ls2 amperes into this loado This
low vo7:tage :s sufficient to h~l;d the relay in and there?
fo~?e the ciz?cui:t is ,protected anti]. the crank stopso In
the case of reverse battery connection, the relay is
energised throizg~ a diode and sinp].y opens up the path to
the remainde~? of the genes^ator electronicse protecting the
bridge elements and fi]:ter condenser from high current
- ~ - -
surgesa Iri this condition, the red indicatoz? light is
immediately energized, indicating the incorrect connection
to the operatoro Lamp indication is not necessa~?y in the
case of an. open load condition since the sudden decrease
- _.
in triaiiual; input power (because the output powe~? will have
- . - - - -
dropped from 12 to .15 v~atts do'r+v~i to 5 ?r 6 watts) is
definitely noticeable aid therefore .the condition_is brought
to tYie opex?ator$ s attent3ono
Operation of these circuits is con~side~?ed quite
~. _ _ . ~ - -
.po.s3:.t~va :.at~.d.:re..'Latvely tro~ibl~~-free o `~1ieg~ have the
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F?ira ~ l Rep?rt
X10 0 0 601
STAT
ad~aiitage ?f being free from component failure for ~ very
long period of time due to the very minor operating duty
unposed upon therria Assum~.ng the generator is always ?perated
correctl:y~~ thzs circuitry will actually never be energized
and, theref?re~ should contribute t?a co~nparati~rely trouble-.
free operating life for the generatoro
Me_chana:cal D~?ive_ Svstiem
After.establish~ent of the generator rotor speed
investigation was started to deter~iirie a suitable speed
etep~=up mechanism for the 30:1 rat3.o req,uir?ed? In ~ri~w ?f
the.Zow ac?ustical noise requirement, it was felt that a
dining belt arrangement w?uld be ctes~?able ~xn.cl pr?~ide
c?nsiderably quieter operation than a gear traino Such
a drive was included in the first model submitted to the
Government arid, although it provided a very low noise
fguz~e~ the mechanical stresses were such that a se~rere
coggig action was noted after a sTiort operating period
due to e~ce~sve wear of the tiding be],tp As a compromise
correction to maintain quiet operations the first stage of
the transmii~sion was cYanged to gears and this hybrid system
was substituted in the -first inodel8 At the same tune an
investigation was made ~iito the use of a coiriplete gear .
transmission using nylon drive 'gears aiad stainless steel
pinonso It was found that the cm~npletely gea~?ecl trans
mission did i~ait result in as severe a noise problem as
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final Re~~t 1$0
1+s1 ~ 0 0 60~; STAT
e~epeeted acid a change to this type of drive was made because
of ~~~ increased effe~.eney and tYi~ co~.si.de~ab5~y ~edueed
_ ___ .
mechanical ~oinpl.e~.tyb This gear train has ri?~ been stand
ardi~ed in the present modals and. with the use of a ~~ope~?
lubricant, found to operate quite well and ~.l~l, undoubtedly
f?ur?nish the 1000 haws operating life ~?equired in the spec
ifeaton without troubleb ~'Y~.e noise output is approximately
56 db~; because t2ies~ specifications represent design goals
rather than absolute requi?ements~ this figure. has been
accepted b~ the Government authoritaeso The 64t cr?anlc
- - -
provcl.ed with the generator was the result of considerable
study into the a;ssoc~.ated human engineering factors in
which it was determined that this dimension resulted in
.comfortable cranking action.,
Packa~in~___and__Mountna
- -
The original development phases of this generator
were based on the use of a die east aluminum easeH ohos~ri
primarily because of the weight limitation and its resist
ante to shoe~ce vibration and weave iTnfortua~atelye the
first prototype models showed that the use of aluminum
way e~tr?emely detrimental to the eff3.ci.eney because of
the eddy cu~^rerits rssul.tng fro~i the ~.nherentl.y loose
magnetic circuit of the magneto-type generator unito
S~:nee stainless steel having high resistivity was pro=
.h~.bt.vs..fro~i..t~oth ..ari e~penss and v~ea~gYit st~lp.o.i~t~ .a:t
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Report loo
00 604 STAT
was decided to design a case of non~~rietallic rnateriale
For reasons of ~~eped3:ency,a molded f'berg;lass case tnras
procuredo This design has resulted in an e~etremely strong
stricture, although 3:t is sotne~nihat e~pens~.ve to ~anuf act~a~?e o
A def3.nte econo~iy cap undoubtedly be made in future pro
ducton by go3~iig to a molded case ia.sing some compound such
as nylozia Delrr~~ etco It was not economicay feasible
du~?ng the devel:opa~ent to engage ai this particular type
of fabrication because of the rather eaepensve mold costs
and the requirement f'or? only ten untsa
_~, r _ _ .
The; specifications .o~?gnally called for mounting
facilities such that the gene-rator could be fastened
secuY^ely to a fatale, a table leggy ~ p?st~ tr?ee~ etco a or
a person8s kneed E~pea?mentaton over the course of the
project .has p~?o~veel fairly ,conclusively that fastening to
the human knee mould.result in e~ecess.ve operator fatigue
and therefore is unrea-lstc o All ~iociels have been made
with facilities for fasten3:ng to posts or trees by the
incorporation of ~?ings for i~ebbed straps on the sides
of tihe generato~? case o During the coia.~?se of the p~?o,ject
a fiarthea? request was ~iacle by the Govern~ient to have the
genea?ator contain a wa]:1: mounting future 3.n the earns
m ~. - -
fashion as the ordinary can openero ~?his has been clone
by providing a separate back plate which can be wood
screwed to a ~a]:l and putt3.ng slides on the back of the
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~_r_~al Report
20.
Wa d,? Ei01~ STAT I!,I
a sariple anti rapid m~tin~ting deans; zt has also been found
that tYie generator sari be fastened by securing the bacx~
-- - _
plate to a table top by means of doub3.e?sded s.dhesive
--
tape, main cranking hor~ontallya The tape I11u~t be
- - - -
changed each time but the use of straps ~,s avodedo
and the generator 3s crarikeci in tie hor3:~orital plane o
generator stick that it sari be sl:a into the back plate
securely arid; crariketl iri a vertical p~sit.ona ~~ providing
slots for v~iebbed straps ri this back plate ~ the facility
f o~ ~iourit~t~ to a flat t-able a also offe~edo ~'o~? this
- - _ - -
type of mouratng~ the. back plate is strapped, t?a table
Be jif~_~~?~-,~~'_OkY`~_~~-__~~:YlG.G'__~.~pOY?'~- ~..C~a~
~:ndcatoio_ .ca.^.~ttry ..in that the c~mpei~sat._ .thesto~? vas
Since submission of Progress Report 1Voa $ the sec?nd
prototype model of the generator vas modified in line with
the Governments s evaluation reports dated No~rernber 278 1959s
and resiibini.tted to the Teciriica]: Representative in early
Decembers 1.9598 fo]:lo~^rg a conference v~3:th Government engi-
nears on December? ~:s 1959? Th?se modifications cons~:steds
maalys of revisions of the ii~;n hizii anal crank assembly ri
order to - -- -- - - - - - -
prevent.- the cra,rik froiri scraping against the genex?atsar
case during operations anal a revision of the mall ~?txnting back
plate assembly to provide a More compact arrangeinento
_ - - --
A. minor c~iaii~ge .s also made in the "Bill -chargedEe
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1 Report 21.
W~O~ 60~
e i~inate an a scrag t,res3;stive networle substitutedm This
.s done after? agreement i~th the Government engineers that
te~riperature compensation-.for this circuit was of questionable
value due to the varying characteristics of,different 1Vicad
batteres~.and was further complicated by the inherent build
up of heat inside the generator case due to normal dissipations
this b~ildmup being entirely variable depending on the amount
Of craiikizag times Ira other worcls~ since there is no way. to
pre=-program the compensating circuit for the large number of
combinations of conditions that could e~ei.st in practice, it is
rather pointless to include the tihertnstor ~rhich is an addi-
tion~l item of e~cperise arid, also, so~iewhat fragile m There-
-fore, the fully charged circuit indications are valid only
__ P
at room temperature ?30o F~ Above and below these tem statures
the operator should keep a log of the amount of the charge
-~.
delivered to the battez?yo This, actua].ly~ is a very simple
ina.tter sracee the HG-3 being eons--ampere generator8 he need
only multiply bg~ the tide he has craa~ked to determine the
amount of ampere-hours delivered to the batterym
At-the time the changes on the sec?nd prototype model
were frined up, this Z,abmratory also received approval to
construct the eight ($) additional models in line with revised
- -
Model Noo 2m The majority of the work from that time to the
present date has ~b~e~en ~g3~re~ to this Lasko Al?though there
have been. soave .minor difficulties in bu-lcing these e,~ht
STAT
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~v -1 Repot 22
~b~a 604 STAT
- - in actuaYit
~odels~ the 'bugs" encounte~?ed have be~n8 y~ nothing
--
triore than ~ioi~ld nori2iall--q` be e:iected in the construction ~~ hand
_ ~.
rr~ade medals fol.lo~ng the development of a prototype o fibs only
ii-ajor trouble encountered. has been in the procure~ient.of fiber
- -._
glass eases of go"od quality iwo~?kmansYipo -This 'has not been
accomplished and the cases suppl~.ed for the e~:ght models have,...:..
been accepted only because. they apparently are the best that '::
the supplier can provide and are the z?esult of a second complete
- - - - - - --
ritri; the first ha~v:ng been rejected by this t,aborato~?y? There--~
.fore; these cases are actually not considered acceptable work
- _ - -
manshp by ttie Laboratory and are on1:y being sent for ~reasoris
of e~epediency aid; also; because future models. gill undoubtedly
use a different molding ffiater3:al -and processa It should be;
noted; however, that the cases are believed sufficiently sans--
factoi?y foi^ field use and e~cpermentaton and since this is
their primary pu,rpose~ should not present any particular prob==
lam to the Governmento
After f~br3.catian; the eight i~oeiels given a complete
._
electrical and. ~eo~ancal checko,ito The performance results
are sho~in iii Fgiire 2 t~lach indicates a fa3:rly close grouping,
particularly v~hen it is borne iin ffi:nd that the electra:cal: ,
parts Mere taken front stock utthov.t any para~etric selection
Figure 1 shoves the final electrical scheinatcn
-..~ _
TYie e~eperence gained :n the construction of these eight
units has been ve~?y valuable to the laboratory since it has
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1 Report
fiT~ o O o 604
2? -
STAT
pointed out var~.ous areas in which improvement f rim a qu~r~tty
p~?odiiction standpoint can be inane to facilitate easier asse~r~bly
and party fabricationo. This .nfortion has been oi? treinenclous
help iri carryang out the production engineering study and it
- -
is considered. actually fortiiriate .that the construction of the
eight. generators vas delayed such- that tkie tv~o projects ran
~__
concurrently in that it alloviied the personnel concerned t~ith
the production engineering study to observe the generator being
- - -
fabricated and note the deficiencies in the asse~ibly proceduresm
Durfng this past report period the 30 instruction books
waste ina~ie up in line with the corrections requested on the
original draft sttbinitted to ~'ashngiyon East inoi~tho The necesw
sary sets of drayrings have also been sent to the Governatient
- -
giving the manufacturing details of .the various parts and
- -
assembles comprising. the HG-3: This final engneer~.ng report,
thene constitutes the last deliverable item iri the contract
and its .submission twill officially close the projector
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ail Report
WoOo 60t~
t =.~ _ _ _ __~ _ ~ _ _n~ r ._,_ _ ~ ._
SUG_GESTSONS_F`Q~r_I1-~PR;O~ENIENT~~II~ F~J~tTR;~__.~IOI9ELS
This Le;taoratory f~e1s that the p~?eserit design of the ~IG~3
fulf]:1s the desg~i ,goals of ,the specifications aria mill meet
- - - - - --
ttie operating requireirieiits outlined ttie~?eiio TYie imaiii a~?eas for
improve~rient are those coiicer?ned ~tti ease aiid eco~iomy of pro=
ducto~io zt has been estimated that ail eacpenditure of approxi--
._
__~ _ __
iiately 308000 for tools ~roul.d result iii e.ffcieiit procluctiori
ariethods for this geiae~?ator?o 0loviously9 such an expenditure could
riot be justified iri file Bevel?pirient contract dust cornpleteda It
~:~ iiot meant to imply that the unit ce:nnot be inaziufaotured uride~
present methocise allies sut>missioii of the eight unite sho~rs that
this can be doneo This ise liot+veve~?e a coiuparatvely e~peiisive
procedure -ands as sucti9 is iiot ~?ecoiiuriended f?oi? quantity p~?o=
ductiorio The issiiirig of the production engineering contract
eaipected to result - iii a much less escperisve unit through the
-_
fabi?catiori of tools Tnrtich mill allour economical parts proi~..tzctiori
_ ~ ~ ~ _ F
in large. q,uarititya and should tie completely ;justified by making
available a low costs compact Yandet?aik geiaerator foz~ l~atte~?y
chargingo
-~ - _ -
The only area ~rtiich this Labo~?atory f'ee].s is ~;rortti future
rivestigatoii is the feature b? indicating the fu];1.yacha~?ged con
dtioii of title ~atte~y? Because this indicator is oiil.y? accurate
over a 1:iinited temperature ~?arige and inay he misYeada.ng for certain
.-
types of Nicads rio~ under development (since develop~ient in tTiis
field is in a coiistaiit state of ad~-arice~ient) s it is questionable
as to dust .hog. va~:uat?;le tills feature ~?ill `be iii field usages
STAT
Declassified in Part -Sanitized Copy Approved for Release 2012/09/11 :CIA-RDP78-03424A001400050013-9
 Declassified in Part -Sanitized Copy Approved for Release 2012/09/11 :CIA-RDP78-03424A001400050013-9
1 Report
Wo0? b0~
~ ~ $ STAT
_.. - - - - -
Ths rivestgaton~ however can o~.ly be Made by the Government
since they alone tow, just -what type of batteries w~.~.l be used
and under what corda:tons they wit-1 be chargedo It 3.s r?ecominen~;ed~
th~~?ef ire e ~t~at t2i~ Go~~~?r~me~t engineers keep a cl~~~ check ~~.
- - - -
the f e];cl a~pl~ato~ of the ~g~t mod~~.s to ~e~ dust h~~r p~a~t~~al
-- - - - -
ths pa~?tcu1ar ~:ndcating feature is in practiced 1Veeclless to
says if it turns out , to be unnecessary or impractical, its elfin
nation wi save a def~:nite arrioiiit of space and cost in futu~?e
producton?
- - -
T'Yiere are several- changes which coia.1d be effected in the
geiieratt~r el.ectroii~;cs t~hch wott]:d reduce the cost and s,ll.evate
- _ - - --
tle packaging problem cons~:derably; These are a htawever~ in the
province of the production ?ngneerng study an:d; as suche will
e - _ - -
be the subject of future conferences ~w:tl the Government engieerse
To the best of our knowledge there are no recognitied defcenc~:es
in the present generator, the fully-charged circuit being mentioned
only in the interest of pr^a.ct~cal;i.ty rather tha~ai f~?oan the po3.nt
of an unstable or troubl:esoine ci~?cut desa.g~o
The only other area possibly woi?thy of investigation by
- - - - - -
the Goveri~ient in the use of their field models :s the general
- --
area of mounting featureso The generator at low cranking speed
- - -
takes a corisiiie~?able amount of input torque anti it i:s agaf.n
questionable whether ariy strapping is su.ff~:c.ent to ht5ld the
unit securely, partf:cula~?ly .n ?the ...case of a table i~ountinga
Our e~perence...has shown that the really only secure mounting
Declassified in Part -Sanitized Copy Approved for Release 2012/09/11 :CIA-RDP78-03424A001400050013-9
 Declassified in Part -Sanitized Copy Approved for Release 2012/09/11 :CIA-RDP78-03424A001400050013-9
~' ~, ~~~~ 2ho
~d ?0 0 6t~4 STAT
methods are that of strapp~:ng to a rattier sizable poet ~~? tree,
~vs.]~:irioin~Z~ aid Yiorizorital. rrioiantrig ~y ~ooi~-screi~r~g tY~e beck
plate to a t~bleo This ~hol:a ~uestoiie hoirve~e~?; is beet solved
by fie lcl. e~epereieea
EXPEIVeDZ.TtJRES
r
As of l~p~?l 1.~ 1960 a total.. of $72s.194069 has been spent
on the ~bntra~tm
Declassified in Part -Sanitized Copy Approved for Release 2012/09/11 :CIA-RDP78-03424A001400050013-9
 Declassified in Part -Sanitized Copy Approved for Release 2012/09/11 :CIA-RDP78-03424A001400050013-9
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Declassified in Part -Sanitized Copy Approved for Release 2012/09/11 :CIA-RDP78-03424A001400050013-9
 Declassified in Part -Sanitized Copy Approved for Release 2012/09/11 :CIA-RDP78-03424A001400050013-9
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Declassified in Part -Sanitized Copy Approved for Release 2012/09/11 :CIA-RDP78-03424A001400050013-9