docDevelopment of the XM982 Excalibur Fuzing System
download 
Report Transcription
Development of the XM982 Excalibur Fuzing System
Development of the XM982 Excalibur Fuzing System David Gudjohnsen -ARDEC Marc Worthington -L3 KDI NDIA 49th Annual Fuze Conference 5-7 April, 2005 Distribution A. Approved for public release; distribution is Unlimited 1 AGENDA • • • • • Program Background System Overview Key milestones Concept of Operations Fuzing (FSA) System Overview • Mechanical FSA features • Electronic FSA features • • • • • • Events timeline System block diagram Testing Key Design Changes Analyses Summary Distribution A. Approved for public release; distribution is Unlimited 2 Background • • • • System Development and Demonstration(SDD) commenced in Jan 98 Dec 02 – U.S Army & Kingdom of Sweden issued contract to merge XM982 with Trajectory Correctable Munitions(TCM) program Program managed by PM Excalibur, PM Combat Ammunition Systems (PMCAS), Program Executive Officer for Ammunition (PEO AMMO) , Product manager: LTC William Cole, Picatinny Arsenal Contract Team (Payload and Fuze IPT related) – – – – Raytheon Missile Systems (RMS) – Prime contractor Bofors Defence – Projectile and system engineering General Dynamics OTS –Unitary payload and projectile body L3 KDI Precision Products – Fuze, safe and arm/ Height of Burst sensor Distribution A. Approved for public release; distribution is Unlimited 3 System Overview Characteristics/Description: •155MM Extended Range guided projectile •Fin Stabilized Glide Air Frame • Inductive Set with Enhanced Setter • GPS - Inertial Navigation System (INS) Guidance • All Weather, Day and Night • Compatible with JLW155 & FCS Digitized 155mm Platforms • One Meter Length / 106 lb •Current program: SDD unitary •Accuracy: 10MCEP objective •Range: 40Km objective •Targets : Personnel, light materiel, structures •Fuze modes: PD, PD delay, Prox •Environments: •15.5 KG set back • 50+ KG penetration Distribution A. Approved for public release; distribution is Unlimited 4 Excalibur System Blk I Unitary Baseline HOB Ind. coil Radome Antenna Damping Material (Gunlaunch & Penetration env) •Production fuze Prox sensor chipset • Burst Height of 3.7 +/- 1 meters • Point Detonate Backup • Unpowered until 3.5 seconds from target Distribution A. Approved for public release; distribution is Unlimited 5 Key Milestones • System Development and demonstration (SDD) unitary projectile Dec 02 - present – – – – – • • System CDR - 3Q FY05 Firing train end to end – 4Q FY 05 Safety Test Series – 4Q FY05 Guided gunfire (GGB) – 4Q FY05 End to End Demo – 1QFY06 MSC (Initial capability) completed by FY06 Full Initial Operational Capability FY08 Distribution A. Approved for public release; distribution is Unlimited 6 Concept of Operations •• •• •• •• Deploy Canards prior to Apogee (Ballistic prior to Apogee) Precision Precision Delivery Delivery Regardless Regardless of of Range Range Limits Limits Collateral Collateral Damage Damage Decreases Decreases Volume Volume of of Fire Fire Per Per Engagement Engagement Enhances Enhances Soldier Soldier Survivability Survivability GPS Acquisition and Track Fragmenting Warhead System Initialization •• Gun Gun Target Target Location Location •• Trajectory Trajectory Information Information •• GPS GPS Crypto Crypto Keys Keys •• Precise Precise Time Time •• Fuze Fuze Setting Setting •• Power Power Mission Mission Planning Planning Structure Top Attack (Detonation after Penetration) Latitude / Longitude / Altitude Impact Near Vertical for Max Lethality Top Attack, 3 Fuzing Modes: -Height of Burst -Point Detonating -Delay/Penetration Sensors: Sensors: •• M707 M707 Knight Knight w/FS3 w/FS3 •• Stryker Stryker FSV FSV w/FS3 w/FS3 •• M7 M7 & & M2A3 M2A3 BFIST BFIST •• OH-58D OH-58D Distribution A. Approved for public release; distribution is Unlimited 7 Fuze Safe & Arm (FSA) Key Features • • • 1.730 DIA • • • 4.165 • • FSA consists of electronics module and mechanical module First Arming Environment is setback acceleration implemented mechanically Second Arming Environment is detection of despin event using a “g” switch Safe separation via independent timers Point Detonate fuze is implemented by a gswitch opening at impact. Delay after Point Detonate implemented by electronic timer HOB function implemented by RF proximity sensor using production fuze components L3 KDI Subcontract Main explosive Unitary warhead/FSA Booster FSA SES Distribution A. Approved for public release; distribution is Unlimited 8 FSA FEATURES Flex circuit Electronics Section FPGA Potting Rotor Detonator: M84 Mechanical Section Lead charge: PA 509 Firing direction Safe Armed Distribution A. Approved for public release; distribution is Unlimited 9 Mechanical S&A Setback Mechanism Contact Board Rotor contact side Contact Board Side Setback Mechanism Side Distribution A. Approved for public release; distribution is Unlimited 10 Mechanical S&A, Safe, Wound and Armed SAFE ARMED 1st Lock Leaf Spring Detent Engaged Rotor Arming Spring Wound 2nd Lock Piston Actuator Extended and 2nd Lock Removed First Lock Removed No go – 300g All go –1250g WOUND Distribution A. Approved for public release; distribution is Unlimited 11 Mechanical S&A, Contact Board SAFE ARMED Status Contacts Closed Status Contacts Open Connector for Interface with Electronics M84 Ground Contacts Ground Contact M84 Hot Contacts Contacts Shunted Hot Contact M84 Distribution A. Approved for public release; distribution is Unlimited 12 FSA Electronic Sub-Assembly Housing Alignment pin Connector (Interface with Mechanical S&A) Cap (Pressed Into Housing) Potting Fill Hole RTV Potting around Spin Switch Distribution A. Approved for public release; distribution is Unlimited 13 Electronic Flex Assembly Spacers Spin Switch Independent Timer Fire Capacitor Impact Switch FPGA Distribution A. Approved for public release; distribution is Unlimited 14 Electronics Functional Block Diagram 9 ACT BATT 36 Volt Nom ELEC BATT 12 Volt Nom ARM RTN SAFE SEPAR SWITCHES +Vcc 6 VOLTAGE REGULATOR OSCILLATOR 11 LOGIC RTN +Vcc 12 1 SER DATA BUFFER DATA CLK BUFFER +Vcc 5 SES RESET Vcc BUFFER 7 FPGA LOGIC HOB OUT ARM ENV2 STAT 10 BUFFER 3 Rotor Contacts Vss DET PISTON ACTUATOR BUFFER SAFE STATUS SS RTN FIRING SWITCH CHG 8 STATUS FIRING SWITCH BLEED DOWN CIRCUIT CLK 2 SER CLK IND SAFE SEP TIMER ENERGY STORAGE DET. Pd SWITCH STATUS CKT. 4 XM982 S&A ELECTRONICS P1 P2 ROTOR SWITCH XM982 S&A MECHANICAL Arming Power Distribution A. Approved for public release; distribution is Unlimited 15 FSA /Flight Timeline 4. “Measure Spin” 3. Arm Power Available Cmd to FSA Canards Deployed 5. Valid 2nd Arming Environment •Unique Excalibur spin profile T1 = 11 Sec •switch closed initially (spin rate >7hz) FSA Measures Despin Profile •switch opens after despin (<2hz) 6. Pass Det Mode to FSA 8. Arm Command To FSA 7. Power Up HOB (Optional) 2. Initialize FSA 9. Detonate <1.0 Sec T1 Electronics Battery Powerup 3 SEC Safe Separation Timer Projectile Flight (Unarmed) Projectile Flight (Armed) Total flight time 55 to 185 seconds Distribution A. Approved for public release; distribution is Unlimited 16 Testing • FSA Component – Engineering tests – Design verification tests (DVT) • • • • Mil Std-331 Seq environmental Airgun, Railgun,Shock table, Centrifuge Pre post Mechanical/electrical function checks DVT 90 %complete – Qualification • Test matrix similar to DVT, Higher QTY • Subsystem – Concrete penetration – Gunfirings Yuma, Bofors • System – Safety test – Guided Gunfire – End to End Demo prior to early fielding Distribution A. Approved for public release; distribution is Unlimited 17 Significant tests and results • • Gunfire - Setback force up to ~15KG’s, – 14 firings in 2004-05, 4 complete successes i.e.; FSA survived gunfire and impact, problems noted: • Setback mechanism not locked • 1st lock interference issue • Spin switch Penetration – Steel reinforced concrete 4”, 8” thick ~50KG+ axial force recorded – Sled tests conducted at Bofors Defense and GD OTS – Sled with rocket motors propelled on track up to 1000 ft /sec (max terminal velocity of round) into concrete wall – 12 firings in 2004-05, FSA fully survived 2 firings, problems noted: • Housing deformation • Damaged electronics Sled test configuration • Det contact open circuit • PA contact open circuit Distribution A. Approved for public release; distribution is Unlimited 18 Penetration Test Distribution A. Approved for public release; distribution is Unlimited 19 Housing & Electronics Section Housing Corrective Action Electronics Fill Improvements Mat’l - Steel (17-4 PH) Orig- 2024 Al Joint Configuration Revised Joint Mechanical Section Urethane Potting Foam for Thermal Expansion •Latest rev- Polystyrene bead foam Weld Urethane (Uralite) Potting Electronics Section Cap Original Joint Closed Cell Foam (thermal expansion) Forward Volume previously filled with glass beads Distribution A. Approved for public release; distribution is Unlimited 20 Contact improvements Previous Design Rotor contacts properly positioned in armed condition Contact pass by after penetration test New Design Slot for Continuity Check Material “tab” and body backup added to prevent contact pass by Material Stake not adequate For 8” concrete environment Damaged Contact Assy Section of retaining spacer rotates under “shelf” in rotor for positive engagement. Rotor material is then staked over to prevent spacer from rotating out of position Distribution A. Approved for public release; distribution is Unlimited 21 Analyses • • • Entire FSA analyzed prior to setback testing – Axial Setback: 15,500 g’s +25% – Balloting g’s: 5,000 g’s +25% – Set Forward g’s: 5,000 g’s +25% Entire FSA analyzed prior to Penetration testing – Axial: 12,500 g’s +25% (Actual ~50KG+) – Lateral g’s: 6,800 g’s +25% Setback mechanism issue – – Set Forward and balloting loads caused previous version of mechanism to unwind due to ineffective detent (spring mass) design Structural Analysis Engineering Corporation(SAEC) Cincinnati, Ohio contracted by KDI • Dynamic simulation of setback mechanism • Design and analysis of new leaf spring detent design. • Ansys/LS Dyna software was used • Performed 34 dynamic analyses including min/max cases with margin • Model predicted correct function of mechanism in each case • New leaf spring design functioned properly in subsequent gunfirings Distribution A. Approved for public release; distribution is Unlimited 22 Setback mechanism New Design Original Design 15000 39 CAL-PMP+5%-AXIAL 13000 39 CAL-PMP+5%-BALLOTING-CH2 11000 39 CAL-PMP+5%-BALLOTING-CH3 ACC (G) 9000 7000 5000 3000 1000 -1000 -3000 -5000 0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 TIME (SEC) Distribution A. Approved for public release; distribution is Unlimited 23 Summary • Significant progress made through Iterative design process • Fuze safety and function modes verified by component and subsystem testing • Setback and Penetration Environments – Design improvements identified/incorporated for survivability • Fuze hardware maturing – Field test database increasing Distribution A. Approved for public release; distribution is Unlimited 24
