Final Proposal:
Enhanced Counter Air Projectile
(ECAP)
IPT 3
Submitted By:
Progressive Ammunition
April 22, 2004
Submitted To:
Dr. Robert A. Frederick, Jr.
Associate Professor
Technology Hall N231
Department of Mechanical and Aerospace Engineering
University of Alabama in Huntsville
Huntsville, AL 35899
Class Web Page:
Contributors
Project Office: / Wesley GladdenSystems Engineering / Michael Ray, Wayna Esquibel, Byron Phillips
Seekers and Guidance / Michael Youngblood
Control / Stuart Johnson, Tracey Smith
Navigation and Power / Eulice Chapman
Modeling and Simulation / Amanda Brewer, Cheryl Steely
Advanced Analysis / ESTACA (Clement Ducasse, Romain Monery)
Launch Platform/ Prototyping / Ruben Hall, Terry Lingenfelter
Industrial Mentors
Participating Agencies
U.S. Army Aviation and Missile research, Development and Engineering Center / The University of Alabama in HuntsvilleGeneral Dynamics Armament and Technical Products / Ecole Superieure des Techniques Aeronautiques et de Construction
Sigma Services of America / ONERA
The University of Alabama in Huntsville
April 22, 2004
Executive Summary [T. Smith]
English
The following report provides detailed information about the design and development of the Super Moth ECAP system by Progressive Ammunition. The report not only identifies the process and technical aspects of the ECAP system, the need for the product, manufacturing considerations, and future development issues. The first section of the report deals with the need for the ECAP system and the requirements that must be met as laid out by the customer. The main purpose of the system is to protect U.S. military troops from incoming projectile attacks, by destroying the threat before it can cause damage. The technical aspects of this system are laid out in the second part of the report. This section includes information on guidance, control, sensors, power, structural analysis, and launch platforms. The guidance system employs a dynamic control algorithm to provide output to the control system. The control system consists of a set of thrusters powered by solid rocket propellant, which apply up to 38 N of force. A CAP-12087 thermal battery powers the bullet and the launch platform is the MK3. This section also includes analysis performed using simulations in both six and three degrees of freedom. The main points of each of these systems and how they interact are given, but more specific information can be found in the appendices of the report. The final section of the report addresses manufacturing processes, summary of the technical information, and also lays out Progressive Ammunition’s recommendations and plans for future development of the Super Moth ECAP system.
French [ESTACA]
Le rapport suivant fournit l'information détaillée de la conception et le développement du système de ECAP de Papillon Super par les Munitions Progressives. Le rapport identifie non seulement le procédé et les aspects techniques du système de ECAP, le besoin pour le produit, fabriquant des considérations, et les problèmes de développement futurs. La première section du rapport traite le besoin pour le système de ECAP et les conditions qui doit être rencontré comme a fait la mise en page de par le client. Le but principal du système sera obligé à protéger des troupes militaires américaines des assauts de projectile reçus, en détruisant la menace avant qu'il peut ait causé des dommages. Les aspects techniques de ce système sont faits la mise en page de dans la deuxième partie du rapport. Cette section inclut l'information sur la direction, le contrôle, les détecteurs, le pouvoir, l'analyse structurale et lance des plate-formes. Le système de direction emploie un algorithme de contrôle dynamique pour fournir la production au système de contrôle. Le système de contrôle consiste en une série de thrusters a alimenté par le propulseur de fusée solide, qui applique jusqu'à 38 N de force. Une CASQUETTE-12087 pouvoirs de pile thermiques la balle et le lance la plate-forme est le MK3. Cette section inclut aussi l'analyse exécutée utilisant simulations dans les deux six et trois degrés de liberté. Les points principaux de chacun de ces systèmes et comment ils réagissent réciproquement sont donnés, mais l'information plus spécifique peut être trouvée dans les annexes du rapport. La section finale des adresses de rapport fabriquant des procédés, le résumé de l'information technique, et fait la mise en page d'aussi des Munitions Progressives’les recommandations de s et les projets pour le développement futur du système de ECAP de Papillon Super.
1
ECAP Compliance List
Specification:CDD location: Report location:
Maximum range of 4 km 2.1.4 1.2.2
Mimim Range of .5 km2.1.41.2.2
System must hit 12 Targets @ 42.1.41.3.3
Second intervals
Accuracy2.3.1.21.2.2
Maximum burst of 15 shells per target2.3.1.21.2.3
Maximum crosswind of 65 kph sustained and2.3.1.31.2.4
85 kph gusts.
Weather conditions2.3.1.31.2.3
Maximum Outer Diameter of 40 mm2.4.21.2.2
Maintenance2.4.4.11.2.4
Compatible with current 40mm gun systems2.4.4.11.2.4
Reliability2.4.5.11.4
20 year minimum shelf life2.4.5.21.2.4
System safety2.4.71.2.4
Launch platform: MK44 or better3.1.42.8
Kill mechanism: Hit-to-kill3.1.52.2
1
Table of Contents
List of Figures
List of Tables
IPT 3: Feasibility of Enhanced Counter Air Projectile (ECAP)
3.01.0 ECAP-Enhanced Counter Air Projectile
1.1 The Need [W. Gladden]
1.2 The Requirements [E. Chapman]
1.2.1 Requirements List
1.2.2 Functional Requirements
1.2.3 Environmental Requirements
1.2.4 Interface and Safety Requirements
1.3The Solution [S. Johnson]
1.3.1Concept Overview
1.3.2Dimensional Properties
1.3.3 Operations Scenario
1.4 The Performance [W. Esquibel]
1.5The Implementation [B. Phillips]
1.5.1 Design and Research Phase
1.5.2 Testing Phase
1.5.3 Implementation
4.02.0 Technical Description of Methods Used
2.1 Project Office [W. Gladden]
2.2 Systems Engineering [B. Phillips]
2.3 Seekers and Guidance [M. Youngblood]
2.3.1 Methods and Assumptions
2.3.2 Results and Discussion
2.3.2 Possible Drawbacks
2.4 Control [T. Smith]
2.4.1 Methods and Assumptions
2.4.2 Results and Discussion
2.4.3 Spin Considerations
2.5 Navigation and Power [E. Chapman]
2.5.1 Methods and Assumptions
2.5.2 Results and Discussion
2.6 Modeling and Simulation [A. Brewer]
2.6.1 Methods and Assumptions
2.6.2 Results and Discussion
2.7 Advanced Analysis [C. Ducasse and R. Monery]
2.7.1 Methods and Assumptions
2.7.2 Results and Discussion
2.7.3 User Defined
2.8 Launch Platform/ Prototyping [R. Hall]
2.8.1 Methods and Assumptions
2.8.2 Results and Discussion
2.9 Trade Studies and Interactions of Subsystems [M. Ray]
2.9.1 Examples of Trade Study Affects on Overall System
2.9.2 System Integration
5.0Implementation Issues
3.1 Production Cost [T. Lingenfelter]
3.2 Manufacturability [C. Steely]
3.3 Test Schedule [M. Youngblood]
3.4 Discussion of Application and Feasibility [R. Hall]
4.0 Company Capabilities
4.1 Company Overview [T. Smith]
4.2 Personnel Description [W. Gladden]
5.0 Summary and Conclusions[M. Ray]
5.1 Summary of Design Process
5.2 Conclusions as to Functionality, Manufacturability, and Cost Efficiency
5.3 Feasibility and Choice Rational
6.0 Recommendations [T. Lingenfelter]
6.1 Recommendations for the search of new types of technologies
6.2 Recommendations for the launch platform
6.3 Recommendations for the guidance systems
6.4 Recommendations for Controls
References [W. Gladden]
Appendix A -Concept Description Document
Appendix B -Electronic File Index [W. Gladden]
Appendix C -Project Office (W. Gladden)
Appendix D – Systems Engineering (W. Esquibel, M. Ray, B. Phillips)
Appendix E – Seekers and Guidance (M. Youngblood)
Appendix F- Control (S. Johnson, T. Smith)
Appendix G- Navigation and Power (E. Chapman)
Appendix H - Modeling and Simulation (A. Brewer, C. Steely)
Appendix I - Advanced Analysis (C. Ducasse, R. Monery)
Appendix J - Launch Platform/ Prototyping (T. Lingenfelter, R. Hall)
Appendix K – PRODAS Documentation on Benchmark Trajectories (A. Brewer, C. Steely)
Appendix L – Other Ideas/Concepts (M. Ray)
1
List of Figures
Figure 1: Concept Drawing
Figure 2: Three-View Drawing
Figure 3: Internal Geometry
Figure 4: PRODAS Stability Model
Figure 5: Operations Scenario
Figure 6: Cross Sectional Drawing of the ECAP
Figure 7: Bullet Control Features
Figure 8: Diagram of Nozzle
Figure 9: Fin Design
Figure 10: Z vs Time graph
Figure 11: Y vs Time graph
Figure 12: CFD Model of Thrusters firing
Figure 13: Stress model of bullet
Figure 14: CFD model of flow with Thrusters firing
Figure 15: Bofors MK3
Figure 16: Overall Systems Interaction flowchart
Figure 17: Interior Bullet Systems Interaction Flowchart
1
List of Tables
Table 1: Overall Configuration of the ECAP Weapon System
Table 2: ECAP geometries (measurements in mm)
Table 3: Values for PRODAS stability Model
Table 4: Final Concept Evaluation
Table 5: Summary of Technical Parameters Calculations
Table 6: ECAP Engineering Summary
Table 7: Propellant Evaluation Table
Table 8: Propellant Properties
Table 9: PRODAS Results
Table 10: cRocket Results
Table 11: Dimensions and performance data
Table 12: Component Price List for the Super Moth
Table 13: ECAP Test and Development Schedule
1
Common Terms and Acronyms List
Word or symbol / CommentsAMRDEC / Army Aviation and Missile Research, Development, and Engineering Center
MAP / Mortar or Artillery Projectile
ECAP / Enhanced Counter Air Projectile
CDD / Concept Description Document
MMW / Millimeter Wave
Ogive / The nose of the bullet
CP / Center of Pressure (Aerodynamic Center)
CG / Center of Gravity
Cd / Coefficient of Drag
ASL / Above Sea Level
MEMS / Micro-Electro-Mechanical Systems
CL / Center Line
IR / Infared
Section 2.3 Variables, ordered by occurance
S / Target Signal Power
P / Transmitted Pulse Power
AD / Aperture Area of Designating Laser
Adel / Aperture Area of Laser Seeker Onboard Missile
/ Target Cross-section Area
/ Target Back Scattering Coefficient
/ Laser Wavelength
RD / Range from Designator to Target
Rdel / Range from Target to missile
Xi / x-coordinate of the center of one element
Xbar / x-coordinate of the centroid
Ai / Surface area of one element
Yi / y-coordinate of the center of one element
Ybar / y-coordinate of the centroid
ft / Focal Length
x1 / Distance from Lens to the Array
x2 / Distance from Lens to the Target
n / Index of Refraction for Lens
FOV / Field of View
S / Linear Dimension of Array
R / Range to Target
J / Target Radiant Intensity
A / Atmospheric Transmittance
Do / Entrance Diameter of Optics
NA / Numerical Aperture
D* / Detector Sensitivity
o / Optics Transmittance
W / Instantaneous FOV of the Seeker
F / Noise Bandwidth
S/N / Minimum Signal to Noise Ratio for Target Detection
n1 / Index of Refraction of Air
n2 / Index of Refraction of the Nose material
1 / Angle of Incidence
2 / Angle of Refraction
End Section 2.3 Variables
3-DOF / Three Degrees of Freedom
MathCAD / A Mathematical Analysis/Simulation Software Package
PRODAS / A Powerful Projectile Simulation Software Package
GAS 2.0 / A Propulsion Analysis Excel Spreadsheet by Dr. Robert A. Frederick
Section 2.4 Variables
T / Thrust
CT / Thrust Coefficient
A* / Area Ratio
Po / Chamber Pressure
r / Burn Rate
a / Burn Rate Coefficient
n / Burn Rate Exponent
End Section 2.4 Variables
AMCOM / Aviation and Missile Command
DC / Direct Current
LLC / Limited Liability Corporation
cRocket / A Trajectory Analysis Program
FINNER / PRODAS Fin Analysis Module
CONTRAJ / PRODAS Thruster Analysis Module
Cma / Pitching Moment
Z / Vertical Displacement
Y / Horizontal Displacement
CFD / Computational Fluid Dynamics
CMOS / Complementary Metal Oxide Semiconductor
CAD / Computer Aided Design
ESTACA / Êcole d'Ingénieur du Transport
BOOST / Barbie Outfit Organizer Slider Thing
AIAA / American Institute of Astronautics and Aeronautics
PSC / Project Standard Conditions
UAH / University of Alabama in Huntsville
1
IPT 3: Feasibility of Enhanced Counter Air Projectile (ECAP)
3.01.0 ECAP-Enhanced Counter Air Projectile
1.1 The Need [W. Gladden]
In the age of smart bombs that can destroy a building with heretofore-unknown accuracy and safety for the bomber, it is one of the great ironies that the single greatest killer of American soldiers is the simple mortar.[1] In “face-to-face” fighting, the soldier on the battlefield is totally unprotected from this sort of relatively unsophisticated threat. To date, there is no system capable of protecting a squad-sized and up unit from this form of attack.[2][RF1]
New reports from Iraq and Afghanistan give witness to the toll that this lack of protection takes on America’s fighting men. Therefore, Progressive Ammunition is developing a solution to this problem for the US Army Aviation and Missile Research, Development and Engineering Center (AMRDEC). AMRDEC has identified the need for an anti-MAP (Mortar or Artillery Projectile) system, and has been determined to be the best possible organization to further develop and test such a system, due to their present assignment as a US Army missile development center.[RF2]
As was stated before, an America soldier, under mortar or artillery attack, is basically helpless. He or she can only hunker down and wait with the rest of the unit and hope the incoming shell does not hit their position. The Enhanced Counter Air Projectile (ECAP) can change all of that. As will be seen in this report, the ECAP system has the capacity to kill an incoming target (as defined by the CDD, see Appendix A) at distances ranging from 500 meters to four kilometers distant from the gun position. In other words, this system has the capacity to eliminate the threat of a mortar/artillery/rocket attack on an American position, and to do so far enough away that the troops are not exposed to threats of shrapnel.
America, in the current environment of the War on Terror and in the possible realities of other, future conflicts heretofore unimagined, will require a reliable anti-MAP system. Our men will continue to fall under attack from mortar shells, and larger, in the two current theatres of operation (Iraq and Afghanistan). We owe it to them, our soldiers who are placed in harms way for our sake and the sake of the country as a whole, to do whatever is humanly possible to preserve their lives in the face of the enemy. Our current enemy is ruthless, determined, and dependent on attacks and technologies that smart bombs are simply unable to counter. The ECAP can counter and remove at least one of those attacks, the mortar round, from the enemy’s options. It will protect our troops; that alone is worth development.
1.2 The Requirements [E. Chapman]
1.2.1 Requirements List[3]
AMRDEC, our customer, has presented UAH with requirements that would meet the need described above and ultimately provide a solution to the problem. Table 1 lists the CDD system configuration, with some company-defined specifications.
DESIGN ELEMENT / Concept Name[RF3]Gun Platform / NA
Acquisition Sensor / IR
Projectile / 40mm
Shell / NA
Projectile Rotational Velocity / 40 Hz
Guidance Concepts
Homing Configurations / Semi-Active
Homing Sensors / Radar
Actuators & Controls / Bent Nose
Computer & Electronics / Both
Power / Thermal Batteries
Structures & Packaging / NA
Warhead / Fragment
Table 1: Overall Configuration of the ECAP Weapon System
1.2.2 Functional Requirements
The ECAP projectile must be 40mm in diameter, with a length that is compatible with the gun system that is chosen. The ECAP projectile must guide to intercept the primary threat and destroy it by a method of hit to kill. The primary threat includes rockets, artillery, and mortars, which can range in sizes from 80mm to 300mm. The ECAP projectile must meet have and effective range of 500 meters to a maximum threshold range of 2000 meters and maximum objective range of 4000 meters in all weather conditions. The ECAP must achieve a greater than 90 % probability of hit against a moving threat target. The ECAP must be able to handle a threat target moving at a velocity of up to 1800 kilometer/hour. The ECAP system must maintain a maximum threshold burst of fifteen rounds and maximum objective burst of ten rounds of ECAP projectiles.
1.2.3 Environmental Requirements
The ECAP must be capable of performance in the same environment as the host platform and accuracy requirements must be over the effective range during daylight as well as darkness. The ECAP must withstand temperatures from +71o C to -45 o C at altitudes from 0 to 12, 190 meters above sea level. ECAP must operate before and after exposure to temperature from +63o C to -43 o C at altitudes from 0 to 4570 meters above sea level. The ECAP must be able to operate in wind conditions up to 65 kilometer/hour sustained wind speed with gusts of up to 83 kilometers/hour.
1.2.4 Interface and Safety Requirements
The ECAP must provide operational interface and integration with other elements comprising the ECAP weapon system and with the acquisition sensor chosen. The ECAP system must be safely transportable and must not develop new or unique packaging, handling or transportation requirements. The ECAP projectile must be designed such that an onboard guidance failure must not affect the ability of the ECAP projectile to launch, fly, and detonate as an unguided 40 mm projectile. The ECAP must require no maintenance and must produce no harmful or unusual chemicals, gasses or vapors and must have a shelf life of 20 years. The materials chosen must do so on the basis of suitability and availability in this country. The ECAP must remain safe after being subjected to a 12.2meter drop onto a 76.2 mm thick steel plate, which is backed by reinforcement concrete 0.61 meters thick. Finally the ECAP must not require maintenance and operational checks of the components during their stated lives.
1.3The Solution [S. Johnson]
1.3.1Concept Overview
The Super Moth is a highly innovative interceptor that combines high maneuverability, superior aerodynamic attributes, and small packaging to provide a real world solution for force protection from incoming artillery/missile threats. Every component and technology that is required for the Super Moth to become an operational entity is available or achievable right now. This solution could provide the military with a force protection system in the very near future. The design of the Super Moth relies on simplicity and few moving parts to meet or exceed the operational capabilities set forth by the CDD.
The most critical features of the Super Moth are the solid fuel control system, the thermal battery, and the guidance/navigation system. The solid fuel control system incorporates a solid rocket propellant that acts as a gas generator, a complex flow control system comprised of a four valve manifold, and nozzles that accelerate the flow of exhaust gases to provide maneuverability in the form of pitch and yaw control. A thermal battery provides power for the ignition of the solid rocket motor, operation of the guidance computer/sensors, and actuation of the valves in the manifold. Guidance and navigation of the ECAP is accomplished by a system that incorporates a clear lens placed on the nose of the ECAP for focusing laser energy, a photo sensor array for sensing the laser as focused by the lens, and a guidance/navigation computer that processes the information relayed by the photo array to generate commands for controlling valves in the manifold for aerodynamic control. Ground based systems that are critical to the operation of include a laser emitter and MMW radar, which provide painting of the target and target acquisition, respectively.
The Phase II concept that was selected by the team to pursue in Phase III was thrown out. After more careful inspection, the vectored thrust concept proved to be a serious packaging problem. However, the team decided to pursue the concept of using a solid rocket motor for control. The only other way to use the solid rocket motor for control was to place a number of nozzles around the perimeter of the ECAP at some axial location and direct exhaust gas to these nozzles to provide attitude control. This did not solve all packaging issues because of the size of the projectile that the team had to begin with and the considerable amount of space required by the control system. As a result of this, the guidance/navigation system had to be a design that was simple and elegant. It does not require any space outside of the nose of the projectile, which leaves the rest of the internal volume for the battery and control system. An additional factor that allowed more room for the control system was the decision to use of thermal battery to meet power requirements. The thermal battery has a high energy density, which provides for excellent packaging characteristics.