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Electronic Test Fuze

Wayne WorrellHamish MalinNSWCDD G33

Precision and Advanced Systems Branch

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ELECTRONIC TEST FUZE - ETF

What is ETF?

Designed to support realistic gun-shock testing of myriad subsystemsDigital processor can command and control subsystems under test in flight.ETF is a diagnostic suite of sensors including 3 axis magnetometer and single axis accelerometerETF is an analog and digital signal multiplexer that encodes data into a single stream used to modulate an RF transmitterETF is a gun hardened system with self contained power modules

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Program OverviewElectronic Test Fuze (ETF) designed to support Guidance Integrated Fuze (GIF) program

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Roll Brake Assembly

Explosive Train OR

TM Support Housing

Waffle Canard

GPS Antenna

Anti-Roll Strake

Lift-GIF

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Drag PanelsDon’t Rotate

Control Panels that RotateControlling the Spin Rate and “throttling” the Drag

COTS Battery ModuleHOB Sensor

GIF-Based GEU with Advanced Anti-Jam and

Backup “Command Mode”using PTS if GPS is Denied

4-Patch GPS Antenna System

GIF/VP Advantages:• Simpler than Navy “Lift-GIF” yet more robust

in terms of Jamming and Reliability.• ~$1K Less Expensive in Production• Capable of a 15m to 20m CEP.• Applicable to All Ammo Types.• Meets or Exceeds PGK Inc 1/2/3 Requirements.• Leverages All Previous Navy-GIF Developments

except the Roll Brake and Bearing Assemblies.

GIF COTS Actuator

VariPitch

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No Existing Product Could Meet GIF Requirements Awarded Contract to Mayflower Communications for Development of GPS Receiver

Low Cost (< $500)Low Power (< 1W)Small Size (< 2 in2)

Phased approach:C/A Version w/ FPGAAvailable Now!!P(Y) SAASM Receiver (TRL 6) Available Fall 2008

Not GIF-CentricOne Product, Many Applications

40mm diameter (VP Form Factor)

Miniaturized GPS SAASM Receiver Technology

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Overview - ETFFully designed in-house at NSWCDDInitially designed to support in-flight testing of ElectReleaseTM for Lift-GIF Designed to support realistic gun-shock testing of myriad subsystemsSix successful flight tests to date

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Board Stack - General

FPGA BoardFPGA I/O Support BoardSensor BoardPower BoardBatteries

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FPGA BoardInterfaces with ADCs and sensorsControls & monitors various subsystems under test

HOB sensor, ElectRelease actuator, IR transceivers,GPS Rx

Measures (time = 0) from forward-looking accelerometerEncodes test data into telemetry stream

FPGA architecture makes ETF adaptable for future tests

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Sensor BoardSilicon Designs 20k-g 1-axis accelerometerHoneywell HMC 1053 3-axis magnetometer2 Maxim MAX274 8th-Order Active Filters provide 2nd-Order Chebyshev LPF for each channel2 12-bit, 8-channel TI ADS7852 ADCs sample at up to 32 ksps

Vias available for additional external sensors

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Battery Puck &Power Board

Current configuration utilizes 4 CR2sPuck is designed to be removable such that fresh batteries can be used for flightSupplies 5V, 2A; 4V, 500mAOther voltages possibleCurrent puck can power full ETF stack for > 2hrs

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Projectile-EmbeddedTelemetry

IR Link

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IR Battery Puck

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TM Transmitter & Antenna

M/A-COM MA06836 ½-Watt S-Band HSTSS Telemetry TransmitterThree Antenna Versions

Round D-Fuze TM Antenna for ‘simple’ ETFIR link integrated between the fuze & the projectile to expand fuze test volumeGIF GPS Antennas also re-tuned to S-Band for future test applications

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IR TransceiversVishay TFBS6614 IrDA used for IR Battery Puck for TM linkVishay TFBS4711 IrDA to be used for cover release verification

Determine if canard covers have been successfully deployed2 transceivers/cover

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TM Data formatManchester encoded1 Mbps data rate1024 bits/frame (1.024 ms frame), including:

32 bit frame sync24 bit frame counter32 bit checksum

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Byte16-bit word32-bit word

Data F

Byte16-bit word32-bit word

Data

Byte16-bit word32-bit word

Data

Byte16-bit word32-bit word

Data

*

*

Total:

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103 107 112108 109 110 11153 58

119 121116 117 118 120

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TOF

6059

94

M1(i) M1(j)

A

2854 55

92

59

99 100 101 102

85 86 87

122

A

M1(k)

123

M1(j)

89 9190

2245

12

5857

A

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4384 88

42 44

13

M1(k)

157

125 126

4623

127

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3124 25 26 27 28 29 3020 21 22 2318 199

114 115

82

50 51

12

8381

Frame Counter

41

24

4080

15 16

48 49

817

GPS

6 12 13 14

45

63

9

36 4742 43

4 711

5

2010

21

2

108 9

19

52104

39

02

37 38

Power

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0 1 2 30 1

74 5

48 49

32 34 3533

3264 65

33

24

81716

96 97 98

16

66 67

20

113

70 7472 73 76 77 7938

4422

46

18 1937

75 78

2311

CRC Checksum

1110

636261

6

14

14

63

31

30626160

95

1531

93

124

5

13

5625

4

535226 27

A

A

M1(i)

54106

50 56 5755

A

2926

36 39

51

17

27

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ETF Telemetry Frame - 18 April 2007 Test Shotupdated on 16 April 2007

Frame Sync (0xFAF32019)

105

A

21

18

25

200.981

0.980.98

19.53

Samples / Frame

Bandwidth (kHz)

Sample Rate (kHz)

164.06

7.811.95

93.7570.31

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82

2432

0.9811168111

43.46%

1

1

0.981 0.98

0.9823.4431.25

31.25

GPS GPS GPS GPS

Label Signal

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# of Channels

1311

Resolution (bits)

GPS Data, see additional sheet for more info

A High-G AccelerometerM(i) M(j) M(k) 3-axis Mags (1 = South, 2 = North)

Time of Flight (ms)F Flags: In flight; Actuator Power; HOB Power; HOB CO

TOF

CRC Checksum 32-bit Cyclic Redundancy Check

GPSFrame Sync Frame Sync (0xFAF32019)

Frame Counter 24-bit counter (~4.8 hours of unique numbers)

A

GPS

71

40 41

34 35

GPS

68 69

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Flight Test 1August 2006

Core ETF stack shot at 7R out of 155mm Howitzer on Dahlgren AA Fuze RangePrimary objective of survival met99.96% of telemetry data recovered with receivers stationed at fuze rangePrimary sensors survived and functioned

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Flight Accel. Data

Muzzle Exit

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Flight Mag. Data

Muzzle Exit: 215 Hz

Splash: 175 Hz

Spin Rate matches expected flight profile

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Flight Test 2November 2006

ETF with IR Link shot at 7R out of 155mm Howitzer on Dahlgren AA Fuze RangePrimary objective of survival met, both for fuze and aft TM sectionPrimary sensors survived and functioned

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Flight Test 3April 2007

ETF with Mayflower GPS receiver shot at 7W out of 155mm Howitzer on Dahlgren AA Fuze RangePrimary objective of receiver survival met

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Flight Test 4August 2007

ETF with Mayflower GPS receiver shot at 7W on Dahlgren AA Fuze Range99% of telemetry data recovered with receivers stationed at fuze rangePrimary sensors survived and functionedValid GPS Receiver data collected the duration of the flight

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Mag. Data

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In-Bore Accel. Data

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Future ETF UsesMay 2008 – Follow-up C/A GPS Receiver Test ShotUsed on other gun programs to record gun fire dynamics - OngoingDecember 2008 – Mayflower P(Y) GPS Receiver Test ShotThis bullet reserved for YOUR subsystem!

2+ cubic inches available to test other subsystems

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Basic CostCore Electronics: $3500Mechanical Hardware: $3000EE Hardware Test: $2000Mechanical Assembly: $1500

Total: $10K / unit

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AcknowledgementsElectrical Team – Mike Irwin, Travis James, Hamish Malin, Wayne Worrell

Mechanical Team – Marc Bassett, Mark Engel, Nathan Joswiak

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QUESTIONS ?

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Backup Slides