Thursday, August 13, 2015

Dalmo Victor Corporation

Dalmo Victor, a division of Textron, was one of the companies of which I accepted contract engineering. This time was a low light level, LASER illuminated, gated television camera. The basic camera in non-gated mode was capable of generating a high resolution, full TV picture at starlight levels and with the LASER, in full overcast night conditions. The main purpose of the LASER was to provide the ability to “see” through fog and smoke by minimizing backscatter. This was done by firing the LASER at the horizontal line rate, 15,750 lines per second, during the retrace time, and using a very narrow pulse equal to the equivalent of 20 feet in length. The 1st intensifier of the camera would be turned on during the line delayed by 2 nanoseconds per foot of the desired target distance thereby ignoring backscatter, and 1 nanosecond per foot width of the desired target depth. Also, the frequency of the LASER was able to penetrate fog. Neat, huh?!

Wellllll, there's a couple or three engineering problems that have to get a little love before the gadget would work. The video signal coming from the sensor is typically 200 nanoamps full white and 1% of that is visible enough to be seen. There is approximately 1 inch separating the target (sensor) lead from the intensifier gating lead. Here's part of the fun: volts/second equals amps/farad. Now lets put some real-world numbers in that: 1,500 volts (the amount that has to be switched) in 3 nanoseconds equals X amps in 300 picofarads (switching electrode). Hmmmm, that comes to 225 kilowatts. With the duty factor, it's barely over 5 watts average but quite a stroke of lightning! Right next to the target. Not too amazing that in addition to D-V failing, both RCA and Amperex (sensor mfr. & gated intensifier mfr.) failed. Amperex HAD designed a slick, totem-pole avalanche switch for the gadget, not bullet-proof but nice and small. I had designed one for a different project that only died when near ground-zero of a atomic bomb, however it needed a wheelbarrow to move. Also, the Amperex device had the coupler allowing the switch to safely ride on the 2,000 volt to 25,000 volt intensifier acceleration voltage.

As an aside (as usual ;o), you might have noticed I used “contract engineer” instead of “consulting engineer.” A contract engineer comes into a company to design what needs designing, fix what needs fixin', and, if he's unfortunate, pour oil on some wounds. A consultant comes into a company to take the blame when nothing works. You'll find a LOT of consultants “working” for the gummit. This I learned from a very wise man, my uncle. Look up A. Ernest Fitzgerald in Wikipedia.

Since this device was intended to convert the UH-I helicopter into a gunship (1972, Vietnam “war”), and the range was 4 miles with the required long lens, a serious image stabilizing system was mandatory. The UH-1 isn't a nice, smooth craft, rather it's a collection of 10,000 loose parts kinda flying in formation. Most of the time. Hopefully. I don't much like helicopters.

It has to climb to a minimum of 500 feet before it can auto-rotate and crash. Not fun. Lower than 500 feet, you just crash and I hear that isn't fun either. It's a helicopter. If something isn't broken, it soon will be. I don't much like them. My helicopter pilot was a screwball.

...back to the image stabilizer, I got to work with an old Chinese physicist/mathematician who was a delight. He knew exactly zero English and my Chinese was a bit lacking! You've heard math is the universal language? Yeah, if you use the same symbology. He could use western terminology and we did rather delightfully work together. The image intensifier deflection sensitivity was calculated out as something like 4/3rds times the square root of delta V where V is the accelerator voltage.

Most of the “motion” we needed to stabilize against was the terrific vibration the turbine and the rotor set up. The vibration became much worse if one blade of the rotor flew off. That would make me sad.

Without the stabilizer, the image was nothing but a blur. With it, crystal clear! It could go from 2 KV to 25KV in the old rattle-trap of a chopper as smooth as silk! (I was kinda proud of it)

This missive is a little slap-dash, maybe I'll straiten it out later.

Once we had the camera and LASER working to our satisfaction, it was time for real world trials plus data taking to fit the army's requirements. That meant several trips in the 10 wheel instrumented lab truck with the gear over to Crystal Springs Reservoir, probably the darkest place in the entire area. San Francisco was cooperative enough to send some of their fog into the valley allowing us to do some with/without gating recording. With gating on, it was almost like having X-ray vision. The silly thing worked. Charlie Moore, the young tech working with me, and myself also got a little freebie for the night work. Dinner was on Dalmo Victor, the Bay area had 4,500 real restaurants, and we weren't limited. “More wine, wench!” Ah! ...to be young and foolish!

My part of the job was complete except for the usual 47 pounds of gummit & military paperwork plus MTBF (mean time before failure) calculations which, under mil-spec, makes one cry. Boeing and the Italian Navy had already ordered units for their hydrofoils. Seems submerged, but still floating logs are a real problem for them at night. The LASER (910 nanometer wavelength) illuminated camera made them stand out as if they were lit up. They were, and no water reflection at the LASER's 910 nm.

A couple of months later, I got a phone call from my engineering manager at D-V, Justin Rouge, inviting me to come and see some video footage back from Vietnam. I mention Justin because all of the engineering staff really liked him. He sat out to become an engineer but had to settle for administration since he wasn't too bright. Everybody who can't make the grade in assembly, cafeteria, facility maintenance, etc. sends their dregs to administration! (I can't help it..)

One morning, the young grandson, about 30, of the company's founder, decided he needed his Jaguar XKE washed and filled with gas. He called into engineering and asked specifically for me. Now poor Justin knew I was paid regardless if da boss wants me and my rather substantial pay came out of his budget. This being one of President Peanut's gas crisis times, I'd probably be in line for hours. Justin had a nervous reaction when things weren't going right; he blew repeatedly through his mustache, earning him the nickname “Puff, the Magic Dragon.” BTW, the Jag is a tractor. Zero to 60 in a week give or take, understears like a sow with rickets, and has a British gearbox (sez it all). It also leaks oil. Looks cool though.

Back to the Vietnam video, there were 6 or 7 D-V employees plus a pair of army brass in attendence. I knew the video would be messy, I was too familiar with what combat did and the 100 round per second minigun is just plain nasty.

The range display was indicating 1,700 yards and the video window about a hundred feet deep (no display, just approx.). The image was as clear as if we were just a couple of hundred feet away on a sunny day, no VC showing, just some women. The gunner cut loose.

Dresden, Hiroshima, and Nagasaki doesn't justify cold-blooded murder even if North Vietnamese women were considered deadly. Made me sick. What really got me was the army brass cheering and high-fiving each other.

That's the reason I told Grumman and Sandia National Labs I wouldn't work on offensive weaponry.
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