This paper is about the development, design, fabrication and use of the KH-9 Hexagon spy in the sky satellite camera system that was finally declassified by the National Reconnaissance Office on September 17, 2011 twenty five years after the program ended. It was the last film based reconnaissance camera and was known by experts in the field as “the most complicated system ever put up in orbit.” It provided important intelligence for the United States government and was the reason that President Nixon was able to sign the SALT treaty, and when President Reagan said “Trust but Verify” it provided the means of verification. Each satellite weighed 30,000 pounds and carried two cameras thereby permitting photographs of the entire landmass of the earth to be taken in stereo. Each camera carried up to 30 miles of film for a total of 60 miles of film. Ultra-complex mechanisms controlled the structurally “wimpy” film that traveled at speeds up to 204 inches per second at the focal plane and was perfectly synchronized to the optical image.
The purpose of this project was to design a “telescope” whose mirrors and support structures were all made of aluminum in order for it to remain in focus for all environmental temperatures. The telescope was mounted on a gimbal structure that was an elevation over azimuth assembly. The purpose of the telescope was to track in all directions in order to detect “enemy” activities such as visual or sound detection at the site of the telescope. The final assembly was eventually purchased by the Secession Activists of Quebec to scan all around for non-French speaking dissidents seeking to spy on them. It was also shipped to South Korea to detect activities by North Korea and shipped to Northern Ireland to spy on the British and finally it also was sent to a high altitude location in Israel. The peculiar thing about the one in Israel was that similar to reading and writing Hebrew from right to left, the telescope was only allowed to scan from right to left. Two unique mechanical designs involved in this telescope are discussed here. The first one is the design of a stop at each end of the azimuth travel that was greater than 360 degrees, and the second was the design of a gearing system that drove both elevation and azimuth assemblies with no backlash
This project was to design and build a protective weapon for a group of associations that believed in aliens and UFO’s. They collected enough contributions from societies and individuals to be able to sponsor and totally fund the design, fabrication and testing of this equipment. The location of this facility is classified. It also eventually was redesigned by the Quartus Engineering Company for use at a major amusement park as a “shoot at targets facility.” The challenge of this project was to design a “smart rock,” namely an infrared bullet (the size of a gallon can of paint) that could be shot from the ground to intercept a UFO or any incoming suspicious item heading towards the earth. Some of the challenges to design this weapon were to feed cryogenic helium at 5 degrees Kelvin from an inair environment through a unique rotary coupling and air-vacuum seal while spinning the bullet at 1500 rpm and maintain its dynamic stability (wobble) about its spin axis to less than 10 micro-radians (2 arc seconds) while it operated in a vacuum. Precision optics monitored the dynamic motion of the “smart rock.”
This paper describes the structural design, analysis, and load/deflection tests of a generic all- beryllium telescope truss (metering structure). The assembly serves to verify the viability of building lightweight precision mirrors and structures for high performance space-based optics and to measure the integrated performance of state-of-the-art CCD focal planes. It demonstrates the feasibility of manufacturing lightweight and stiff structures that can support high performance optical systems and meet their alignment requirements. The goal of building a telescope worthy of space flight was met.
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