THIS LETTER REPORT DESCRIBES THE ACTIVITY ON TASK ORDER NO. J DURING THE PERIOD FROM SEPTEMBER 10 TO OCTOBER 10, 1958.

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78-03642A000700100013-9
• Release Decision: RIPPUB
• Original Classification: S
• Document Page Count: 48
• Document Creation Date: December 22, 2016
• Document Release Date: August 10, 2011
• Sequence Number: 13
• Publication Date: October 24, 1958
• Content Type: LETTER

October 24, 1958
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This letter report describes the activity on Task Order
No. J during the period from September 10 to October 10, 1958.
During this period, the design of some of the parts in the
prototype timer was modified and the fabrication of a prototype unit
was started.
Before fabrication of the prototype-timer parts was
initiated, a production study was made of each part. As a result
of this study, it was found that the small 0.010-inch-diameter
orifice in the temperature-compensating housing could not be drilled
by standard production methods. In order to solve this problem, we
made the housing in three pieces and, instead of drilling the 0.010-
inch-diameter hole, we drilled a 0.050-inch-diameter hole and in-
serted a piece of metal capillary tubing in order to obtain the
proper orifice diameter. The capillary tubing used has a 0.010-
inch-ID and a 0.050-inch OD. In addition to the above, time was
spent in designing the springs for the pressurizing piston.
During the coming month, the prototype timer will be com-
pleted and evaluation testing of the unit will be started. In
CONHHDENT A
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CON Fl ENT AL
October 24, 1958
addition, we shall continue the long-term testing of the laboratory
model of the timing mechanism.
The total appropriation on this Task Order was $28,550.
As of October 1, 1958, the unexpended balance was approximately
$2,700.
Sincerely,
In Duplicate
CON FI DENI]AL
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rnNFIfFNT1AL
September 24, 1958
- u w t 0 c , S.
This letter report summarizes the activuty performed under
Task Order No. J during the period from August 10 to September 10,
1958.
During this period, the effort has been concentrated on
the long-term evaluation of the laboratory model of the timing
mechanism, and on the design of the prototype timer.
The laboratory model of the timing mechanism has been
modified for long-term testing, and the first test, of two weeks'
duration, has been concluded. The modification of the setup con-
sisted of inserting a low-pressure 0 to 5-psi gage and a low-rate
spring into the existing equipment. The two-week test was performed
under an ambient temperature of 120 F; a second test is being run
under the same conditions, to determine the repeatability of the
device.
The detailed design of the prototype timer is more than
50 per cent completed. This design is essentially the same as that
discussed with you during your recent visit. One primary change has
been made; a threaded ring around the case that will be used to set the
prototype timer has been added. This represents an improvement on the
previous design, since it simplifies the setting operation and is less
likely to overtravel.
CONE DENiI
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CDNF- ENTIA September 24, 1958
During the next month, we expect to complete the design
and fabrication of the prototype timer. In addition, we shall con-
tinue the long-term testing of the laboratory model of the timing
mechanism.
The total appropriation on this Task Order was $28,550.
As of September 1, 1958, the unexpended balance was approximately
$3,400.
Sincerely,
ABW:mjc
In Duplicate
CRONE IDENT IA
J n
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UIJ~
25X1
August 22, 1958
This letter report summarizes the activity performed
under Task Order No. J during the period from July 10 to August 10,
1956.
The project effort during this period was concentrated
primarily on the short-term evaluation of the laboratory model of
the timing mechanism. The short-term evaluation has now been con-
cluded, and the results are shown graphically in Figure 1. The
laboratory model was operated at three temperatures to obtain the
data shown. Each of the three experimental points represents two
or more tests at the same temperature. The total variation of flow
was ?14 per cent. Since our design objective is ?10 per cent
variation, we are not completely satisfied with the results and
hope to improve them substantially. However, we believe that the
evaluation program thus far has proven the basic components of the
design, and, consequently, have now begun the design of a complete
prototype timer.
In addition, we have prepared a preliminary cost estimate
for these timing mechanisms in quantities of 10,000 units and the
cost appears to be under $10 each. Since our prototype design has
not yet been completed, we have based this cost estimate on the
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LUNHDENTIAL
-2- August 22, 1958
laboratory model. This figure should give a good indication of the
final cost, since, as currently contemplated, most of the components
needed in the prototype are incorporated in the laboratory model.
During the next month, a modified unit with a firing
mechanism will be laid out and longer term evaluation experiments
with the laboratory model of the timing mechanism will be started.
The total appropriation on this Task Order was $28,55O.
As of August 1, 19525, the unexpended balance was approximately
$4,'700.
Sincerely,
ABW:mjc
In Duplicate
cp!EiDENTI4L
nn F~
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July 15, 1958
Dear Sir:
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25X1
This letter report describes the activity performed
under Task Order No. J during the period June 12 through
July 10, 1958.
During this period, the effort has been concentrated
on an evaluation of the laboratory timing-mechanism portion of
the delay device.
The evaluation program which has been set up consists
of a series of tests under three different ambient temperatures,
-20, 50, and 120 F. For a given temperature, the evaluation
procedure is as follows:
(1) The timing mechanism is placed in the temperature
chamber and rigidly fastened.
(2) The timing mechanism is allowed to "soak" in
the temperature chamber overnight.
(3) The timing-mechanism valve is opened, thus
initiating flow of the fluid from the timing
mechanism.
(4) The fluid flow is measured indirectly by measuring,
once every hour, the movement of the spring-
loaded piston used to maintain fluid pressure.
CONFIDENT IA
21
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CONMDENTIAL July 15, 1958
In addition to measuring the piston movement, we
also read the temperature and the fluid pressure. This information
is used to calculate fluid flow in terms of cubic inches per
second per psi of pressure. Flow data in this form are valuable
for use in determining the constant-flow characteristics of
the timing mechanism, and in addition, in the subsequent design
of a complete time-delay device.
The results of the tests to date have been'erratic,
primarily because of the human element in the test setup.
However, the test technique has been worked out and the results
now being obtained are consistent.
If the present rate of testing is continued, we
anticipate completing the short-period tests in about two weeks.
Then, if the results of this test program show the basic design
of the timing mechanism to be feasible, we expect to begin the
design of a complete model of the time-delay device, which will
incorporate a time-setting device, a firing-pin release, and a
mechanism for compensating for the volume change of the fluid
as a result of temperature changes.
The total appropriation on this Task Order was $28,550.
As of July 1, 1958, the unexpended balance was approximately $6,000.
Sincerely.
9BW:mlm
In Duplicate
CONFIDENTIAL
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Development of a Silicon Flind Time-Delay Mechanism
Design Objectives:
1. should have high degree of reliability
2. it should be accurate to within +10 per cent of time setting
3. it should retain its accuracy over a temperature range of -20 to +120 F
4. it should have an adjustable time range from 15 minutes to 2 months
5. it should weigh no more than 1/2 pound ~ub 5~-
6. it should not be larger than about 1 inch in diameter and about 4 inches
in length
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 CONFIDENTIAL
Development Program
determine optimum dimensions for t anperature-compensation device by
calculation
2. design experimental laboratory timer mechanism incorporating design
features that would be used in the final design.
fabricate experimental laboratory timer mechanism.
test experimental laboratory timer mechanism.
design complete prototype unit incorporating timer and firing pin release.
6. fabricate prototype.
7. test prototype
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CoIST, TEAAQ
MlCgoMETER SC.QEW
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r~~ F
CONFIDENTIAL
June 12, 1958
47~
25X1
Dear Sir:
is now ready for testing. The test equipment is being assembled and
will permit the accurate determination of the rate of piston motion
in the time-delay unit. Piston travel rather than actual flow was
chosen for measurement since piston travel is used to actuate the
time-delay device.
During the next month, we contemplate conducting the short-
term evaluation of the engineering prototype and making any necessary
modifications. The remaining time available will be used for long-
term testing, final design, and any other experimental work needed to
prove out the features of the final design.
The total appropriation under this Task Order was $28,550.
As of June 1, 1958, the unexpended balance was approximately $7,100.
This letter report describes the activity performed under
Task Order No. J during the period May 11 through June 11, 1958.
During this period, the effort has been concentrated pri-
marily on the fabrication of an engineering prototype time-delay
unit and suitable equipment for evaluating this prototype.
The engineering prototype has been completed and the unit
Sincerely,
7
ABW:mjc
In Duplicate
CONHDENTIA
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y ,
coNFIDENTIAL
25X1
May 19, 1958
This letter report describes the activity performed under
Task Order No. J during the period March 24 through May 10, 1958.
During this research period, development activities have
been concentrated in two distinct areas:
(1) Calculations of optimum orifice and annulus pro-
portions needed to obtain constant liquid flow
under varying ambient temperatures.
(2) Design of a working model both to prove out the
calculations and to check design features for
incorporation into a final time-delay design.
Considerable effort was devoted to making calculations
of fluid flow. These calculations were made in order to arrive at
the optimum dimensions for the fluid-flow-control device. On the
basis of these calculations, optimum dimensions were determined;
in addition, a procedure was developed that permits the extension
of these calculations to include increased or decreased sizes and
different materials.
Theoretically, there are no optimum dimensions for this
device. However, as the over-all size of the device is reduced,
the necessary tolerances required to maintain constant flow become
CONFIDENTIAL
q 1~ L.24~~
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CON FI NTIAL
May 19, 1958
very small. With this fact in mind, the metering device was
designed to be as large as possible, and yet compatible with the
over-all size requirements of the time-delay unit.
The design of a working model of the time-delay unit,
as presently developed, is simpler than we had anticipated since
it covers the complete range of time settings without there being
a need to change components. This design was discussed during
your visit of May 8, 1958. Particularly pertinent is the following
list of characteristics of interest:
Time-Delay-Unit Characteristics
Length 5 inches
Diameter 1-i/4 inches
Time Setting Range 15 minutes to 1,440 hours
Theoretical Accuracy ?3.5 per cent.
The theoretical accuracy, as mentioned above, includes
no allowance for machining and material variations. Since the
original accuracy requirement was ?10 per cent, we feel that our
chances of achieving this in the current design are very promising.
At the present time, we are completing the detail design
of this working model and preparing the evaluation equipment.
During the next month, we plan to complete the fabrication of the
working device and begin to evaluate it.
CONFIDENTIAL
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COPdFIftNTIAL
May 19, 1958
The total appropriation under this Task Order was
$28,550. As of May 1, 1958, the unexpended balance was approxi-
mately $8,900.
Sincerely,
In Duplicate
CONFIE_ __AL
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CONEIDENTIAI
September 20, 1957
This letter report describes the progress of Task Order No. J
from August 8 to September 8, 1957.
During this period, the leakage rate of the experimental model
was measured when the Viscasil was subjected to the maximum design pres-
sure. In addition, we calculated the clearance required between the main
body and the outer sleeve in order to achieve a reasonable leakage rate,
and we obtained data on the force required to rotate the outer sleeve.
The size of the thermostat spring needed to exert such a force would be
impractical for this application. Since the current design is not en-
tirely satisfactory, other types of compensators are being investigated.
During August, we measured the leakage rate of the experimental
model. When the Viscasil was subjected to the maximum design pressure,
the leakage rate was more than twice the flow rate through the port when
the clearance between the main body and the outer sleeve was 0.001 inch.
This clearance could be reduced to 0.0003 inch, in which case the calcu-
lated leakage rate would represent about 5 per cent of the flow rate
through the smallest orifice. However, small machining errors would have
a pronounced effect; an increase from 0.0003 to 0.0005 inch in the clear-
ance would increase the leakage rate to about 20 per cent of the total
flow rate.
At a temperature of 85 F and with a clearance of 0.001 inch,
CONFIDENTIAL
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ONFlDENTIAL
September 20, 1957
measurements indicated that a force of approximately 0.5 pound was required
to turn the outer sleeve at a rate of 0.0023 inch per second. These con-
ditions were more severe, but more realistic, than those used in the exper-
iments mentioned in the August 13, 1957, report. (The rate indicated in
the previous report should have been 1 inch per minute instead of 1 inch
per second.) As calculated, the force required to rotate the outer sleeve
at -20 F would be about 7 pounds if the clearance was reduced to 0.0003
inch. Calculations show that a thermostat spring 7 inches wide would be
needed to exert this force. It appears that this type of temperature com-
pensator has serious practical limitations.
Since we are not satisfied with the current design, a more prac-
tical solution to the problem is being sought. We believe that the design
criteria required to meet the specifications have been established., Ideally,
the temperature compensator should not move and the ports should not have
movable sides. The Bellofram piston seal, described in the May 10, 1957,
report, and the adjustable springs which provide the pressure would prob-
ably be useful in any pertinent design.
One idea, which has not been thoroughly investigated, may have
possibilities as indicated by preliminary calculations. This makes use of
the leakage as part of the total flow. Most of the material would be ex-
truded through a port while the leakage would be controlled by the tempera-
ture-compensating orifice formed by the annular space between two concen-
tric cylinders of different metals. As mentioned in the August 13, 1957,
report, this type of compensator would not be satisfactory by'itself.
However, if it were to control only a fraction of the flow, we estimate
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COl'ffIDENT IAL
3-
September 20, 1957
that the error in timing would be only ? 5 per cent over the entire tem-
perature range. In addition to this design, we are investigating other,
possibilities.
In September, we plan to search for other types of temperature
compensators and investigate their feasibility.
The original appropriation on this Task Order was $18,550. As
of September 1, 1957, the unexpended balance was approximately $!,.,7000
Sincerely,
ABW:dp
In Duplicate
CONFIDENTIAL
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UFIDEN
August 13, 1957
This letter report describes the progress of Task Order No. J
from July 8 to August 8, 1957.
During this period, the temperature compensator of the experi-
mental unit was evaluated with a thermostat spring installed. The com-
pensator did not perform satisfactorily. The forces in the Viscasil film
between the outer sleeve and the main body, and ice formation on the two
parts (while in a cold chamber) prevented relative movement. Although
experiments are continuing on this type of compensator, we have again in-
vestigated the use of the annular clearance space between two different
metals as a temperature-compensating orifice. This system still appears
to be theoretically possible, but with serious practical limitations.
The outer sleeve and the main body of the temperature compen-
sator were lapped together to obtain a clearance of approximately 0.0003
inch. With a thermostat spring (supplied by W. M. Chase Company) installed,
the load developed was not sufficient to rotate the outer sleeve when the
temperature was changed by as much as 50 F. The high resistance was cre-
ated by the forces in the Viscasil film and by ice formation on the two
parts during exposure to the lower temperature of the test range (25 F).
Coating the entire main body with Viscasil would probably minimize the
effect of the ice formation, but would increase the drag forces.
CONFIDENTIAL
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_ bNFIPENTIAL
August 13, 1957
The next step was to measure the force required to rotate the
outer sleeve with a 0.0003-inch clearance between it and the main body.
At an ambient temperature of 84 F, an 8.5-ounce load could rotate the
sleeve at a rate of approximately 1 in./sec. Our present thermostat
spring is too weak to exert such a load. Possibly, by coating the main
body with Viscasil and by increasing the clearance to 0.001 inch, we
could reduce the frictional forces, and consequently utilize to advan-
tage a thermostat spring of the same general type as, but slightly
stronger than, our present spring. Preliminary calculations show that
the leakage under such conditions would be less than 2 per cent of the
minimum flow. We are currently modifying the experimental unit to per-
mit measuring the actual leakage.
Since these two problems (ice formation and machining toler-
ances) have become increasingly significant, we again investigated the
use of the clearance space formed between two different metals as an ori-
fice. It is possible to design a unit from aluminum and steel that would
have an error of + 10 per cent (in delay time) when operating over a tem..
perature range of -10 to 109 F. However, in covering the range of time
periods for a given orifice length, the ratio of the average pressures
(exerted on the Viscasil by the spring) corresponding to the shortest and
longest time periods would be approximately 6,000 to 1. So far, we have
been unable to devise a satisfactory method for handling such a large
pressure variation.
In August, we plan to measure the leakage rate from the experi-
mental unit when the Viscasil is subjected to the maximum design pressure.
CONFIDEPAL
K
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CONFIDENTIAL
3-
August 13, 1957
The diametral clearance will be increased in increments, to permit deter-
mining the maximum clearance allowable within the design specifications.
In addition, the torque required to rotate the outer sleeve will be deter-
mined for the proper clearance, so that a suitable thermostat spring can
be selected and evaluated.
The original appropriation on this Task Order was $18,550. As
of August 1s 1957, the unexpended balance was approximately $5,000.
Sincerely,
d
ABW: dp
In Duplicate
CONF DENTIA
a
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WNFIDE~VTIAI
July 11, 1957
This letter report describes the work done under Task Order No. J
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