Source: Company Data
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Beck Engineering, Inc.'s core competencies include leading-edge R&D, development of proprietary manufacturing processes, and the ability to produce product/equipment using state-of-the-art machine tools and proprietary manufacturing processes. The firm's R&D work focuses on thermo-fluidic equipment and advanced-technology machine tools. The thermo-fluidic product/equipment includes thermal power systems (for example, Stirling generators), refrigeration systems (coolers), cryogenic refrigeration systems (cryocoolers), and compact heat exchangers. The advanced-technology machine tools include machining centers, turning centers, high-speed compact milling heads, compact drilling heads, and proprietary manufacturing processes. Beck Engineering, Inc. constantly develops and refines proprietary manufacturing processes enabling improved R&D. One of the firm's proprietary manufacturing processes is Finishing Touch Honing (FTH)(R) process: processing of hardened (to greater than 45 Rockwell C) parts for various industry segments: automotive, bearing, marine, punch and die, mold, hydraulics and pneumatics, machine tool, and aerospace.
Beck Engineering, Inc. produces parts and tools for its internal products/equipment using state-of-the-art Computer Numerically Controlled (CNC) machine tools from our internal machine shop. In addition, we also use our proprietary manufacturing processes on R&D projects.
Compact High-Speed High-Power Right-Angle Milling Head (HSHP/RAMH).
Under a Phase II SBIR contract with the Air Force Research Laboratory (AFRL), we developed a Compact High- Speed (30,000 RPM) High-Power (2 hp) Right-Angle Milling Head (HSHP/RAMH) for machining complex geometries in aircraft structures (see Figure 1). Our HSHP/RAMH uses hydrostatic bearings, direct fluid-turbine drive, and our proprietary tool-holder system.
We use our proprietary advanced manufacturing techniques to fabricate the parts of our HSHP/RAMH. As a Phase II subcontractor, the Boeing Phantom Works demonstrated a reduced-power prototype HSHP/RAMH by conducting milling tests. Boeing also conducted tap tests of our HSHP/RAMH, and the tap tests (tap tests experimentally identify the dynamic compliance of the spindle/toolholder/tool system) indicate the full spindle power (2 hp) can be used for chatter-free milling of aluminum with important tools. Current machine tools cannot efficiently mill aircraft structures with integral return flanges and other complex internal features. Our spindle will enable efficient milling of the complex features.
Rotary Union for Navy High-Speed Liquid-Cooled Generators and Motors
The Navy needs robust high-speed rotary unions for advanced high-speed liquid-cooled generators and motors. Under a Phase II SBIR contract for the Naval Sea Systems Command (NAVSEA), we developed a Rotary Union to meet Navy needs. Our Rotary Union uses hydrostatic radial and thrust bearings to support a rotor and maintain tight clearances in clearance seals. Figure 2 shows our Rotary Union in a setup for testing. Our setup includes a servomotor, which is driven by a computer-controlled servomotor drive to achieve desired rotational speeds for our Rotary Union. We demonstrated the capability of our Rotary Union to pass 5 GPM of coolant with only a 43 psi pressure drop at a rotational speed of 12,000 RPM. Hydrostatic bearings can operate at large radii with fast rotational speeds, so our Rotary Union has room for large flow capabilities. The hydrostatic bearings offer the same advantages to our Rotary Union that hydrostatic bearings offer to spindles of high-precision high-speed machine tools (including nano-precision diamond-turning lathes for optics): high-speed capability, long life, durable, reliable, large damping of shocks and vibrations, and dynamically stable. Proprietary designs give our Rotary Union for liquid-cooled generators minimal seal leakage. Our Rotary Union uses materials that give our Rotary Union graceful degradation to avoid catastrophic failures.
Vacuum-Compatible Multi-Axis Manipulator/Machining Center for Long-Duration Space Missions
NASA has many needs for maintenance and repair technologies for long-duration human space missions.
Under a Phase II SBIR contract for NASA, we are developing a compact, portable, vacuum compatible, multi-axis Manipulator/Machining Center (M/MC) to satisfy many of NASA's needs. Our M/MC moves a milling head through three axes of linear motion (x-axis, y-axis, and z-axis). Servomotor driven ballscrew linear actuators drive the milling head along linear guideways. The eventual M/MC system that NASA uses for space missions might include a high-speed (for example, 100 kRPM) spindle that uses hydrostatic bearings. In Phase I, we generated a preliminary design of our M/MC; projected the machining performance, mass, volume, and power consumption of our M/MC; and showed how our M/MC can be integrated with layer-additive quipment. In Phase II, we are designing-in-detail, building, testing, and zero-g flight-testing a prototype M/MC.
Vacuum Nose-Lock/Drill End-Effector for Robotic Drilling
The Air Force needs a flexible robotic drilling system for drilling and countersinking holes in JSF inlet ducts. Under a Phase I SBIR contract with the Air Force, we designed, built, and demonstrated a compact Vacuum Nose-Lock/Drill End-Effector (VNL/ DEE), which is a critical component of a flexible robotic drilling system. Figure 5 shows the VNL/DEE we designed, built, and demonstrated. A fluid turbine drives the shaft of our VNL/DEE, and hydrostatic (water) bearings support the shaft. We drilled a ¼ inch hole through a graphite-epoxy composite material sample, to demonstrate our VNL/DEE. Robots
can accurately position drills, but robots lack rigidity required during drilling, so hole quality is poor. On
the other hand, the Vacuum Nose-Lock (VNL) of our drill provides maximum rigidity, so our VNL/DEE can
produce high-quality holes.
Compact Powerfeed Drill for Limited-Access Drilling of Aircraft Structures
Under a Phase I SBIR contract with the Navy, we designed, built, and demonstrated critical components (the drill heads) of two types of compact powerfeed drill: (1) Nose-Lock Drill; and (2) Tool-Less Drill. The two types of drill each have shafts that are driven by fluid turbines and supported by hydrostatic (water) bearings. Our two drill types are suitable for two different types of applications for limited-access drilling of aircraft structures.
In Phase I, we tested the head of the Nose-Lock Compat Powerfeed Drill by drilling smooth burr-free holes
through: titanium 6Al-4V, graphite composite, and aluminum plate. rable, reliable, large damping of shocks and vibrations, and dynamically stable. Proprietary designs give our Rotary Union for liquid-cooled generators minimal seal leakage. Our Rotary Union uses materials that give our Rotary Union graceful degradation to avoid catastrophic failures.
Vacuum-Compatible Multi-Axis Manipulator/Machining Center for Long-Duration Space Missions
NASA has many needs for maintenance and repair
technologies for long-duration human space missions.
Under a Phase II SBIR contract for NASA,
we are developing a compact, portable, vacuumcompatible,
multi-axis Manipulator/Machining Center (M/MC) to satisfy many of NASA's needs. Our M/MC
moves a milling head through three axes of linear motion (x-axis, y-axis, and z-axis). Servomotor driven ballscrew
linear actuators drive the milling head along linear guideways. The eventual M/MC system that NASA
uses for space missions might include a high-speed (for example, 100 kRPM) spindle that uses hydrostatic
bearings. In Phase I, we generated a preliminary design of our M/MC; projected the machining performance,
mass, volume, and power consumption of our M/MC; and showed how our M/MC can be integrated with
layer-additive equipment. In Phase II, we are designing-in-detail, building, testing, and zero-g flight-testing a
prototype M/MC.
Vacuum Nose-Lock/Drill End-Effector for Robotic Drilling
The Air Force needs a flexible robotic drilling system for drilling and countersinking holes in JSF inlet ducts. Under a Phase I SBIR contract with the Air Force, we designed, built, and demonstrated a compact Vacuum Nose-Lock/Drill End-Effector (VNL/ DEE), which is a critical component of a flexible robotic drilling system. Figure 5 shows the VNL/DEE we designed, built, and demonstrated. A fluid turbine drives the shaft of our VNL/DEE, and hydrostatic (water) bearings support the shaft. We drilled a ¼ inch hole through a graphite-epoxy composite material sample, to demonstrate our VNL/DEE. Robots can accurately position drills, but robots lack rigidity required during drilling, so hole quality is poor. On the other hand, the Vacuum Nose-Lock (VNL) of our drill provides maximum rigidity, so our VNL/DEE can produce high-quality holes.
Compact Powerfeed Drill for Limited-Access Drilling of Aircraft Structures
Under a Phase I SBIR contract with the Navy, we designed, built, and demonstrated critical components (the drill heads) of two types of compact powerfeed drill: (1) Nose-Lock Drill; and (2) Tool-Less Drill. The two types of drill each have shafts that are driven by fluid turbines and supported by hydrostatic (water) bearings. Our two drill types are suitable for two different types of applications for limited-access drilling of aircraft structures. In Phase I, we tested the head of the Nose-Lock Compat Powerfeed Drill by drilling smooth burr-free holes through: titanium 6Al-4V, graphite composite, and aluminum plate.
rable, reliable, large damping of shocks and vibrations, and dynamically stable. Proprietary designs give our Rotary Union for liquid-cooled generators minimal seal leakage. Our Rotary Union uses materials
that give our Rotary Union graceful degradation to avoid catastrophic failures.
Vacuum-Compatible Multi-Axis Manipulator/Machining Center for Long-Duration Space Missions
NASA has many needs for maintenance and repair technologies for long-duration human space missions. Under a Phase II SBIR contract for NASA, we are developing a compact, portable, vacuum compatible, multi-axis Manipulator/Machining Center (M/MC) to satisfy many of NASA's needs. Our M/MC moves a milling head through three axes of linear motion (x-axis, y-axis, and z-axis). Servomotor driven ballscrew linear actuators drive the milling head along linear guideways. The eventual M/MC system that NASA uses for space missions might include a high-speed (for example, 100 kRPM) spindle that uses hydrostatic bearings. In Phase I, we generated a preliminary design of our M/MC; projected the machining performance, mass, volume, and power consumption of our M/MC; and showed how our M/MC can be integrated with layer-additive equipment. In Phase II, we are designing-in-detail, building, testing, and zero-g flight-testing aprototype M/MC.
Vacuum Nose-Lock/Drill End-Effector for Robotic Drilling
The Air Force needs a flexible robotic drilling system for drilling and countersinking holes in JSF
inlet ducts. Under a Phase I SBIR contract with the Air Force, we designed, built, and demonstrated a
compact Vacuum Nose-Lock/Drill End-Effector (VNL/ DEE), which is a critical component of a flexible robotic drilling system. Figure 5 shows the VNL/DEE we designed, built, and demonstrated. A fluid turbine
drives the shaft of our VNL/DEE, and hydrostatic (water) bearings support the shaft. We drilled a ¼ inch hole through a graphite-epoxy composite material sample, to demonstrate our VNL/DEE. Robots can accurately position drills, but robots lack rigidity required during drilling, so hole quality is poor. On the other hand, the Vacuum Nose-Lock (VNL) of our drill provides maximum rigidity, so our VNL/DEE can produce high-quality holes.
Compact Powerfeed Drill for Limited-Access Drilling of Aircraft Structures
Under a Phase I SBIR contract with the Navy, we designed, built, and demonstrated critical components (the drill heads) of two types of compact powerfeed drill: (1) Nose-Lock Drill; and (2) Tool-Less Drill. The two types of drill each have shafts that are driven by fluid turbines and supported by hydrostatic (water) bearings. Our two drill types are suitable for two different types of applications for limited-access drilling of aircraft structures. In Phase I, we tested the head of the Nose-Lock Compat Powerfeed Drill by drilling smooth burr-free holes through: titanium 6Al-4V, graphite composite, and aluminum plate.
