J. Inst. Eng. India Ser.

C
DOI 10.1007/s40032-017-0394-6

ORIGINAL CONTRIBUTION

Integration of Flex Nozzle System and Electro Hydraulic

Actuators to Solid Rocket Motors
Kishore Nath Nayani1 • Dinesh Kumar Bajaj1

Received: 21 December 2016 / Accepted: 12 September 2017

Ó The Institution of Engineers (India) 2017

Abstract A rocket motor assembly comprised of solid between motor and nozzle to be ensured with no gap and
rocket motor and flex nozzle system. Integration of flex the uniform torquing of all bolts.
nozzle system and hydraulic actuators to the solid rocket
motors are done after transportation to the required place
where integration occurred. The flex nozzle system is Rocket Motor Casing Initial Conditions
integrated to the rocket motor in horizontal condition and
the electro hydraulic actuators are assembled to the flex Rocket motor assembly with flex nozzle system (FNS) is
nozzle systems. The electro hydraulic actuators are con- positioned on a pair of rotating-cum-resting fixture (RCRF)
nected to the hydraulic power pack to operate the actuators. as shown in Fig. 1. Rocket motor case is filled with
The nozzle-motor critical interface are insulation diamet- hydroxy terminated poly butadiene (HTPB) based propel-
rical compression, inhibition resin-28, insulation facial lant [1] as shown in Fig. 2. After placing the rocket motor
compression, shaft seal ‘O’ ring compression and face seal casing on RCRF the establishment of motor axis is com-
‘O’ ring compression. pleted. The availability of all the subsystems such as ‘O’
rings, fasteners should be ensured. Boro-scope inspection
Keywords Flex nozzle system  of propellant surface and segment joint, coin tapping
Electro hydraulic actuators  Inhibition resin-28  examination of full motor, comprehensive visual inspection
Shaft seal  Face seal  Mirror image sensors of propellant surface have been adopted after transportation
of rocket motor from casting location to integration loca-
tion. Inspection of the motor casing for any abnormalities
Introduction on nozzle end be carried out. If the insulation depth/ID is
found more, inhibition resin on the interface to be applied.
The rocket motor and nozzle assembly should be obtained
with utmost care because these joints have to withstand Preparation of Nozzle
very high operating pressures up to 80 bar. The joints also
have to withstand high temperature and velocity of gases. Further, visual inspection of all the nozzle interfaces be
Hence the joints have to be ensured with required insula- carried out. Again, three number M24 long eye bolts with
tion facial and radial compressions and also ‘O’ ring the nozzle be assembled at 120° apart. The sling legs with
compression between metal joints. The flange joints eye bolts using D-shackles be attached and the bolts/nuts
containing the split plates with column of container be
removed. The nozzle along with split plates be lifted in
creep speed till the divergent portion of nozzle clears the
& Kishore Nath Nayani containers column. The nozzle further be lifted in normal
[email protected]
speed and bring down for easy approach of the interfaces.
1
Advanced Systems Laboratory, Kanchanbagh, Hyderabad Now visual inspection of the interfaces be obtained. Next
500058, Telangana, India the turnbuckle/arresting fixture connecting the nozzle

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intermediate dome and compliance ring be removed. The

nozzle should be kept open for further inspection/cleaning/
dimensional inspection. Visual inspection of all the inter-
faces is required.

Inspection of the Nozzle

Cleaning of the nozzle-motor mating interfaces on nozzle

intermediate dome with TCE/acetone and banian cloth be
obtained. Inspection of the interface mating dimensions
and depth of the insulation (Rocasin) rubber should be
done with proper care.

Fig. 1 Rocket motor along with flex nozzle system positioned on a

pair of RCRF
Inspection of the ‘O’ Rings

The shaft and face seal ‘O’ rings meant for nozzle-motor
casing interface be identified. Inspection of both the iden-
tified ‘O’ rings be carried out visually [2]. All the ‘O’ rings
cross section diameter be inspected. The hardness of ‘O’
rings from clearance certificates should be verified, because
it is difficult to measure the hardness of ‘O’ rings, unless
special devices are available [3]. The specified value is
2–5% on insulation diametrical compression. The compu-
tations of compressions are shown in Table 1.
Readings of groove depth of nozzle end side are 5.22,
5.22, 5.23, 5.22, 5.23, 5.22, 5.23, 5.22.
Groove depthmin = 5.22 mm.
Groove depthmax = 5.23 mm.
‘O’ ring compression values are -7.03, 7.10, 7.01, 7.08,
Fig. 2 Rocket motor case filled with HTPB based propellant 7.04, 7.10, 7.07.
‘O’ ring compressionmin = 7.01 mm.

Table 1 Computation of compressions

0 0 Depth min  ðGrovedepth max þ Radial clerances maxÞ

Computation of shaft seal O ring compressionmin ¼  100
Depth min
4:90  ð3:76 þ 0:05Þ
¼  100 ¼ 22:24%
4:90
0 0 Depth max  ðGrovedepth min þ Radial clerances minÞ
Computation of shaft seal O ring compressionmax ¼  100
Depth max
4:99  ð3:70 þ 0:05Þ
¼  100 ¼ 24:84%
4:99

0 0 Depth min  Grovedepth max

Computation of face seal O ring compressionmin ¼  100
Depth min
7:10  5:22
¼  100 ¼ 25:39%
7:10

0 0 Depth max  Grovedepth min

Computation of face seal O ring compressionmax ¼  100
Depth max
7:10  5:22
¼  100 ¼ 26:47%
7:10

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Fig. 3 Electro hydraulic actuators mounted on flex nozzle

Fig. 5 Flex nozzle before assembly to rocket motor

Fig. 4 Motor nozzle interface

Fig. 6 Flex nozzle assembled to rocket motor

‘O’ ring compressionmax = 7.10 mm.

Integration Test Objective
Motor diameter min  Nozzle diameter max
Radial clearancemin ¼
2
918:05  917:95 The flex nozzle system is integrated to the rocket motor
¼ ¼ 0:05 casing in horizontal condition and the hydraulic actuators
2
are assembled to the flex nozzle systems [5]. The nozzle-
Motor diameter max  Nozzle diameter min motor critical interface are insulation diametrical com-
Radial clearancemax ¼
2
918:06  917:96
pression, IR-28 resign, insulation facial compression, shaft
¼ ¼ 0:05 seal ‘O’ ring compression and face seal ‘O’ ring com-
2
pression which are measured and compared with the
Electro Hydraulic Actuators specified values.

Two numbers of electro hydraulic actuators of 5.5 t

capacity are used in pitch and yaw planes for vectoring Integration of Flex Nozzle Systems and Hydraulic
based on the input command from control electronics [4]. Actuators to Solid Rocket Motor
Flex seal consists of seven numbers of 15CDV6 spherical
shims and 8 numbers of low modulus natural rubber elas- Flex nozzle control system is assembled to the rocket
tomer pads with cylindrical body configuration are applied. motor and hydraulic actuators are mounted on the motor
Electro hydraulic actuators of 5.5 t capacity which are and nozzle [6]. The hydraulic actuators will be mounted on
mounted on nozzle are shown in the Fig. 3. the nozzle using mounting brackets with pins and fasteners.

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Fig. 7 Nozzle with hydraulic actuators

handling eye bolts, at 120° apart be ensured. The rocket

motor casing position be seen, such that the location R1R is
at the top when viewing from nozzle end side. The nozzle
be lifted and position it over the nozzle tilting fixture. The
verticality of the intermediate dome flange face using the
spirit level be checked [8]. Also the verticality by means of
CG correction mechanism provided in the horizontal han-
dling tackle be adjusted [9]. The identified face seal ‘O’
ring in the rocket motor casing face seal ‘O’ ring groove be
positioned, after smearing with thin layer of silicone grease
[10]. A thin layer of silicone grease on the mating ID of the
motor case be applied, for easy entry of shaft seal ‘O’ ring
without any cut during assembly. The nozzle gently be
inserted into the nozzle end boss by engaging the guide
pins. Six numbers of M20 9 1.5 mm long studs equi-
Fig. 8 Integration of hydraulic actuators and MI sensors to solid
rocket motor
spaced with the nuts be assembled. The M20 nuts in the
studs slowly be tightened by maintaining uniform gap all
The identified shaft seal ‘O’ ring in the ‘O’ ring groove be around, until the mating flanges are butt. Eight numbers of
positioned, after smearing with thin layer of silicone M20 9 1.5 mm long screws along with plain washers at
grease. Locations of nozzle intermediate dome for fixing 45° apart and tightened. The locations be identified where
horizontal handling to be tackled between actuators posi- actuator mounting brackets are to be assembled. All the
tion, that is, at R1R (top). Then the location for fixing two M20 9 1.5 screws along with M20 plain washers be
nozzle tilting brackets, that is, at R2T and R2B be ensured assembled, leaving the location where actuator mounting
[7]. Further location for fixing 3 numbers nozzle vertical brackets are to be installed. Actuators and MI sensor

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Table 2 Integration test important interface compression values

Nozzle-motor interface Specifications Measured values

Insulation diametrical compression 4.0–4.6 mm 4.13–4.59

Inhibition resin-28 IR-28 to be applied IR-28 applied
Insulation facial compression 1.0–1.5 mm 1.15–1.30
Shaft seal ‘O’ ring compression 15–30% 22.24–24.84%
Face seal ‘O’ ring compression 20–30% 25.39–26.47%

Table 3 Details of weight added after nozzle Integration to solid rocket motor
Sub-system Weight, kg Sub-system Weight, kg

Nozzle 666.6 M20 fasteners (72 set) 15.720

Face and shaft seal ‘O’ rings 0.312 Loctite-242 0.018
IR 28 resin used in interface 0.228 0.228 Silicone grease 0.005
IR 01 resin used for rework 0.194
Weight added during nozzle assembly 678.07
Weight of actuator and MI sensor brackets with fasteners 9.26
Total weight added during nozzle assembly 687.1

mounting brackets at their identified locations be assem- mode. The actuators be kept using hydraulic power packs
bled one by one using M20 9 1.5 screws along with the in null position and the alignment be checked again using
M20 plain washers. Following diagonal opposite 90° theodlite. The turn buckles be removed before alignment.
sequence, 425 Nm torque on all the M20 9 1.5 fasteners Both the turn buckles be assembled with the nozzle-rocket-
be applied. The motor-nozzle interface is shown in Fig. 4. motor interface after completion of electrical alignment.
The flex nozzle before assembly to rocket motor is shown
in Fig. 5 and after assembly to the rocket motor shown in
Fig. 6. The hydraulic actuators are mounted on the nozzle Integration Test Important Interface Compression
as shown in Fig. 7. integration of hydraulic actuators and Values
MI sensors is shown in Fig. 8.
The nozzle-motor critical interface are insulation diamet-
rical compression, IR-28 resign, insulation facial com-
Assembly of Actuators, MI Sensors and LVDTS pression, shaft seal ‘O’ ring compression and face seal ‘O’
ring compression which have been achieved for two tests
Four numbers LVDT brackets on the motor side with skirt and compared with the specified test values and have been
of motor case at P?/Y-/P-/Y? locations (90° apart) tabulated in Table 2.
using M10 screws and plain washers be assembled. Fur-
ther, another four numbers of actuator/MI sensor brackets
(nozzle side) along with four numbers LVDT brackets at Details of Weight Added After Nozzle Integration
P?/Y-/P-/Y? locations (90° apart) over the compliance to Solid Rocket Motor
ring of nozzle using M8 screws and plain washers be
assembled. The assembly with nozzle-motor casing be Weight addition during the flex nozzle system and sub-
carried out as per the procedure consist of two numbers systems to the rocket motor is shown in Table 3.
actuators, two numbers MI sensors and four sets of LVDTs.

Conclusion
Mechanical and Electrical Alignment of the Nozzle
In the present study, comprehensive visual inspection of
Mechanical alignment of the nozzle be checked using turn propellant surface has been adopted and no abnormalities
buckles and theodalite/RMS. Electrical alignment is mea- observed. The nozzle-motor critical interface like insula-
sured by mounting actuators and MI sensors in power tion diametrical compression, inhibition resin-28,

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