Weapons and MaterialsResearch Directorate

Design & Flight Testing of a MortarDeployed Video Imager

4/10/01, NDIA PRES.

Author: John A. Condon Mechanical Engineer 410-306-0739 jac@arl.army.mil

US Army Research LabAPG, MD 21005

RECOGNITION OF CONTRIBUTORS:JOHN MCLAUGHLIN / JAMES SPANGLER - ELECTRONICS DESIGN / FAB. / ASSEMBLY & TESTING.DAVE HEPNER / WALLY CLAY - PCM/TM SUPPORT, XMTR/REC’R INTEGRATIONCHARLIE MITCHELL - H/W FABRICATIONERIC IRWIN / ED BUKOWSKI - BATTERY CONDITIONING SUPPORTTOM HARKINS - IMAGE ANALYSIS

SAM PEREZ / DIANE WAGNER / EUGENE SCHLENK - PM MORTAR SYSTEMS, ARDEC - MORTAR PARTS, DWGS, & INFO.

Report Documentation Page

Report Date 09Apr2001

Report Type N/A

Dates Covered (from... to) -

Title and Subtitle Design & Flight Testing of a Mortar Deployed Video Imager

Contract Number

Grant Number

Program Element Number

Author(s) Condon, John A.

Project Number

Task Number

Work Unit Number

Performing Organization Name(s) and Address(es) US Army Research Lab APG, MD 21005

Performing Organization Report Number

Sponsoring/Monitoring Agency Name(s) and Address(es) NDIA (National Defense Industrial Association) 211Wilson Blvd, STE. 400 Arlington, VA 22201-3061

Sponsor/Monitor’s Acronym(s)

Sponsor/Monitor’s Report Number(s)

Distribution/Availability Statement Approved for public release, distribution unlimited

Supplementary Notes Proceedings from the 36th Annual Gun & Ammunition Symposium & Exhibition 9-12 April 2001Sponsored by NDIA

Abstract

Subject Terms

Report Classification unclassified

Classification of this page unclassified

Classification of Abstract unclassified

Limitation of Abstract UU

Number of Pages 17

Weapons and MaterialsResearch Directorate

• OBJECTIVES: DESIGN & DEMONSTRATE AGUN-HARDENED, “WIRELESS”, DIGITALLY-ENCRYPTABLE, IMAGER SYSTEM (<$10k/imager)• SUPPORTS: ARDEC QUICKLOOK STO.• PLAN: APPLY COTS VIDEO AND XMTR TECHNOLOGIES & INTEGRATE INTO A MODIFIEDXM930 120mm MORTAR SUBMUNITION.• CONCLUSIONS: SUCCESSFULLY FLIGHT-TESTED IMAGER MORTAR TO ~2000 G’S, PCZ #1.• LESSONS LEARNED: IMAGERY MUST BEANALYZED TO DETERMINE USAGE, TLE, BDA, etc.& TO DETERMINE REQ’D. IMPROVEMENTS.

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

Weapons and MaterialsResearch Directorate

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

2. REPLACEDFIBERBOARDBAFFLEPLATE (.25”t)WITH STEELPUSHER PLATE

1. REPLACEDCANDLELOADING ASSY. W/IMAGER (3.68”dia.X5.24”L)

3. TRIMMED REARBODY JOINTEDGE (~ .160”)

EXPULSIONCHARGE

DROGUE & MAINPARACHUTES

FUZE

SHEARPIN

FLIGHT TEST PLATFORM – REQ.’D MODS.

ASSEM&y 1296/aea®

:LP. Exotstc» OS»

-C^TatXC.eOWViuiAWCTKG XW92C L.CA&NC ASSfVEir-12577651 ®

-iN,MOJTAnXAfiT30GE.M3l 12577513®

CARTRIDGE,IGNITION. MI020 I^977^64<

(-4- CHARGE ,=,ROPELUNG,I20MM.M234 f 12977375

Weapons and MaterialsResearch Directorate

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

IMAGERSUB-MUNITIONCONCEPT& DESIGN

PUSHER PLATT:,

MAT: STAINLESS STEEL, 17-4PH

1-RtNG, MAT: NEQPRENE

CCD CAMERA TRANSMITTER/ CAMERA PLATE

HOUSING, MAT: 7075-T6 ALUMINUM

BATTERY/ ENCODER HOLDER, MAT: ABS PLASTIC, RAPID PROTO- TYPE

SBAND TRANSMriTING ANTENNA

Weapons and MaterialsResearch Directorate

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

IMAGER BOM (NON-PROD. VERSION) $COTS CCD CAMERA 120COTS VIDEO COMPRESSION ENCODER 2880COTS XMTR, S-BAND, HI-G Q’D. 4000COTS ANTENNA, S-BAND 1525COTS BATTERIES, NICAD 50PER UNIT COST (W/O NRE & LABOR COSTS) 8575

Weapons and MaterialsResearch Directorate

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

KEY DESIGN FEATURES…. INTERFACETO EXISTINGPARACHUTEO-RING SEAL

FOR INTERNALEXPULSION GASRESISTANCE

INTEGRATEWRAP-AROUND

ANTENNA

IMAGERFOV

THRU-MORTAR-BODYMAN. TURN-ON

SWITCH

ENCAPSULATEINTERIOR VOL.& COMPS. TOSHOCK-HARDEN

Weapons and MaterialsResearch Directorate

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

GROUND SHOCK TABLE TESTING OFIMAGER COMPONENTS…

CAMERA TO40K-G PEAK

ENCODER TO10K-G PEAK

PWR DIST. PWB TO13K-G PEAK

Weapons and MaterialsResearch Directorate

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

ABS PLASTIC RPBATT+ENCD’R+PWR BOARDHOLDER(used CAE art-to-part technologies,FDM)

ENCD’R BRD(OEM as is)

PWR BRD4X NICAD BATTS,(20min. total discharge time)

ASSEMBLE….

ENCAPSULATE….

■

1 ^SlBn Hi«*;\ ■

^ 3 ^^^k.

Weapons and MaterialsResearch Directorate

IMAGER

GROUND-STATION

IMAGER SYSTEM

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

DATA

5VDC

ENCODER CONTROL EIA232

AUDIO

PCM

TELEMETRY TRANSMITTER

TELEMETRY RECOVER

AUDIO

PCM DEC210R5 DECODER

WITH BIT SYNCHRONIZER

ENERDYNE ENC210A4

VIDEO MONITOR

EIA232 DECODER CONTROL TERMINAL

-| Camera* /

Or Other NTSC or EIA170 Video Sources

Weapons and MaterialsResearch Directorate

IMAGER GROUND STATION

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

S-BAND TELEMETRY ANTENNA

S-BAND TELEMETRY RECEIVER W/PHASE MODULATION "PLUG-IN"

»■■

-f ir,»'** S-VHS PLAYER RECORDER

CUSTOM PC104 COMPUTER WITH LCDDISPLAY.ISA BIT SYNCH., ENCODER CONTROL INTERFACE,«: PCMCIA VIDEO DISPLAY« Hi AMI- GRABBER"

Weapons and MaterialsResearch Directorate

DESIGNED & BUILT A LOW-COST, IN-LABMORTAR BODY ASSEMBLY FIXTURE• FOR BATTERY TURN-ON SW. PORTINSTALL.• IMAGER INSTALLATION• MORTAR BODY SHEAR PIN INSERTION

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

MTB RF.MOVF MIT A A TURN CW \V WUfSTHm . r.-lli .: ;

liwistniK niiliii.uit. MJ. .1.1I I-

,n,Mi nuau nuimn .11 -l'.l II'

un »unman, mit» lOltawiiiiiuii aun

■s nni.-iiT.ii-iii

-VT 7. TH.IIl--- mmi in »i .:■

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\i:i<*-iKiinr.M'F roBonvpROM .MTfA-RSMOVINLTIl* TtiRNCC»

IV VVRfcSC'H IG UlSASit.MBU: »um irXBOU HEI» Wim WRENCH

XM930 ISRAELI BODY DRIWDISASSVASSYtlXrViai t«A*s-Arr«nxs*i<w

Weapons and MaterialsResearch Directorate

VERIFIED HSG. & PLATE STRUCTURAL INTEGRITYAND MORTAR EXPULSION DYNAMICS WITH FEA

DYNAMIC FEA:• AXI-SYM. HSG & PUSHERPLATE MODEL USING QUAD-RILATERAL ELEMENTS• LINEAR MAT.’L PROPS USED• TRANSIENT EXPULSIONOVERPRESSURE APPLIEDTO PUSHER PLATE PLUSLAUNCHING LOAD• MORTAR BODY HALVESMODELED USING HI-DENSITYELEMENTS & CONTACT ELEMENTS• BIRTH & DEATH OPTION DISPL.CONSTRAINTS USED TO MODELEXPULSION INITIATION

Pr

Displ. X 5

Max. dynamic defl. of pusher plate isis less than .030” &will not contactcamera lens or xmtr Steel pusher

plate & 7075-t6aluminum hsg.stresses are wellbelow yield

10 k-g’s Launchacceleration

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

Time: 0.0021 sees».

Von Mises

y 63370 54317 45264 36211 27158 18106 9052.8 0

SVIEW 12.04- hsg_axisym_pr_.. 24-AUG-2000 19:45 42/ 300 Vu=U5 Lo= 90 La= 0 R= 0

Weapons and MaterialsResearch Directorate

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

FEA ANIMATION…EXPULSION

Weapons and MaterialsResearch Directorate

• INSURED EXPULSION & CHUTEDEPLOYMENT• VERIFIED INTEGRITY OF HOUSING& FEA PREDICTIONS• VERIFIED INTEGRITY ANTENNA• VERIFIED O-RING SEAL• VERIFIED PUSHER PLATEDYNAMICS

RECOVERED MORTAR BODY HALVESAND MOCKUP IMAGER

RECOVERED MOCKUP IMAGER

120mm MORTARS…WARMERS& MOCKUP IMAGER ROUND

MINIMALRESIDUEDEPOSITEDBY EXPUL.CHARGE GASBLOW-BY...CAMERA LENSSHOULD BEO.K.

CONTACT PINSWERE NOTCONTACTEDBY PUSHERPLATE DURINGEXPULSION…CAMERA & XMTRSHOULD BE O.K.

FLIGHT TESTED MOCKUPIMAGER ROUNDS

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

Weapons and MaterialsResearch Directorate

FLIGHT TESTING OFIMAGER MORTARROUND

• PROVED IMAGER ROBUSTNESS TOTYPICAL MORTAR GUN-LAUNCHINGLOADS (1500-3000 g’s)…MINORANTENNA DAMAGE SUSTAINED INSHOT

• IMAGER RECOVERED AND WASREUSEABLE

• 5 FR/SEC (@1.25MBITS/SEC.)ACQUIRED FOR 90 SEC. DECENTFROM EXPULSION @ 1400’ ALTITUDE;INITIAL CAMERA FOV @ EXPULSION =1616’ x 1553’, i.e. ~ 1m x 1m = 1 pixel

20sec. of video from imager

20sec. of video of decendingimager from camcorder onground

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

Weapons and MaterialsResearch Directorate

BP’s Rangeis limited to Prop.Zone 3 @ Q.E. of85-deg. for XM930Mortar, 10k-ft ceiling

TEST RANGEDETAILS

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.

S all

Cartridge date: id/

Weapons and MaterialsResearch Directorate

Ø 120mm MORTAR IMAGER CONCEPT PROVEN

Ø IMAGER GUN-HARDENED TO ~2000 gs

Ø IMAGER LESSONS LEARNED & FUTURE…• IMAGE QUALITY & USE MUST BE ADDRESSED• ANTENNA RECEPTION ISSUES [VIDEO DROP-OUTS]MUST BE ADDRESSED• INTEGRATE NEW HSTSS XMTR, INERTIAL SENSORS, SIG.COND., ADDITIONAL PCM ENCODER, NEW BATTERY, &GPS REC’R…SENSORS TELL WHERE IMAGER IS LOOKING• ADDITION OF INTERNAL G-SWITCH TURN-ON FEATURE;REDUCES BATTERY VOL., ELIMINATES GUNNER TASK.

SUMMARY

Design & Flight Testing of a MortarDeployed Video Imager

poc: John Condon, 4/10/01, NDIA PRES.