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| UVP (Unity Vision Periscope) Used in Several Formats and Orientations on Observational and Fighting Vehicles |
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| Commanders Primary Sight for an Observation Patrol Vehicle |
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| A Vehicle Commander's Primary Sight |
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| Cosmetically Finished Moulding Ready for Assembly |
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Illustrated are typical examples of optical sights for a variety of fighting vehicles scheduled to take part in a major virtual military training scheme involving a large scale simulation programme.
Live exercises on Salisbury Plain are to be replaced with a computer-simulated battlefield based on sophisticated, interactive real-time video technology. Illustrated here are just some of the special optics designed to interface with the computer-graphics generators to be employed.
Designed and built by DAVIN OPTRONICS LIMITED of Watford, these sophisticated and fully operational devices represent just a part of the sets and sub-sets composed from a generic nucleus of components simulating in all salient and functional aspects the reality of battle conditions.
The manipulation of light and images in various forms using mirrors, prisms and lenses to create periscope sights with special combinations of magnification to accept either real or virtual images in totally realistic warfare conditions was the starting brief for the team of experts at DAVIN.
Among the many criteria to be taken into account at the commencement of the project were a series of factors relating to the main bodies and housings for these assemblies.
A. The final overall weight of each completed assembly was set at 20 kg max. which in the case of almost all of the major sights eliminated aluminium as an option even though it has always been the traditional choice for military products of this style.
B. The cost of tooling had not only to be within budgetary estimates for the development of the prototypes but in addition the same tooling would be required to proceed to volume manufacture without further or repeated tooling charges should the project proceed to full production status at a later date.
C. Time Compression Technology would have to be an integral part of any tooling and production procedures employed to manufacture the housings since the designs could only be finalised well into the programme and the schedule of factory acceptance tests was of the essence of the main contract with significant penalties for non-compliance. Only Rapid Tooling techniques could satisfy these deadlines.
D. The final housings would need to exhibit;
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Adequate strength and stability for their intended function. |
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Specific accuracies achieved by a combination of as-cast and machined tolerances. |
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Aesthetic standards including highlighted engraved text and 100% optically black internal surfaces. |
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Reproducibility to match the dimensionally critical optical components. |
The engineers at DAVIN OPTRONICS had been aware of Cellular Mouldings RIM as a process for some time and had been following with interest the brief documented case histories issued by Cellular Mouldings of Kettering Northants. Who pioneered this unique form of polyurethane casting into RAPID LOW-COST, production compatible tooling.
MIKE GOODEN of DAVIN OPTRONICS picks up the story at this point:
"We satisfied ourselves as a team that the Cellular Mouldings process and materials were to our requirements with the particular advantage that the S.G. of 1.4 gave us the design flexibility of aluminium with only half the weight.
Beyond the technical aspects however DAVIN'S board required a degree of co-operation beyond the normally accepted supplier relationship. The importance of communication dictated the establishment of a high level of mutual transparency and board level vetting of Cellular Mouldings's procedures and supply chain was performed before contracts were placed.
The resulting outcome was very satisfactory with Cellular Mouldings working within the framework of our overall programme enabling design feedback to be incorporated in the master patterns prior to tooling giving a much higher than expected degree of "RIGHT FIRST TIME " on our prototypes.
We found both the Cellular Mouldings process and team attitude user friendly even under the pressures of a tight programme and technically challenging design features."Cellular Mouldings's view is given by CHRIS BROOKER;
"My own background of prototyping special purpose instruments and devices at G.C.H.Q. Cheltenham was good preparation for this type of project but on my appointment I was amazed at the number and variety of projects with which Cellular Mouldings RIM division had already had success since it's formation in 1979.
Every new project brings with it aspects which push the Cellular Mouldings process to new technical heights but the DAVIN designs were truly exceptional. The degree of complexity involving undercut sections, coring, loose pieces in the tool was well above average but the Cellular Mouldings mould-making and production team took it all in their stride.
Also the emphasis placed by both companies on communication paid off time and again leading to a real feeling of mutual achievement each time a new moulding in the series emerged.
To be associated with such a technically advanced project has been a real highlight to the year."
On a technical note, the Cellular Mouldings process involves the low pressure casting of specially developed Polyurethane resins exhibiting high impact resistance and fire retardance to U.L.94 V0 from 3mm upwards into Cellular Mouldings's own unique form of Urethane-faced composite tooling known as Immediate Production Tooling (IPT)T.
Many hundreds of mouldings can be produced, effectively for the entire life of the product. There are no periodic retooling charges and no further costs after the initial set-up investment. Finished components are simply called off to an agreed J.I.T. schedule. Production rates from single tooling vary with product size and complexity but usually fall within the range of 2 to 5 castings per day.
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