accelerate special edition

S p e c i a l 2 0 1 0 E d i t i o n

L e a d · I n n o v a t e · I n t e g r a t e · D e l i v e r

SystemsEngineering

SPECIAL DOUBLE ISSUE

• People, Collaboration and NASA-Style Innovation — RDECOM Commander Shares Vision• Fueling Development for Future Force Vehicles• Innovative Materials Bridge Partnership Between TARDEC and Lawrence Tech• Total Immersion in Virtual Environments Leads to Engineering Innovation• TARDEC Chief Scientist Helps Develop Army Ground Systems Technology Focus

IN THIS ISSUE

Intellectual Rigor a Hallmark of TARDEC Capabilities

Within TARDEC’s labs, the heavy lifting needed to provide innovative, integrated solutions for our warfi ghters takes place. Our sophisticated labora-tories are only one of the means through which we complete our work. It is the intellectual rigor of our people, the thoroughness

of our processes and our innovative technologies that give these labs life. The combination of state-of-the-art equipment and the expertise of our engineers, scien-tists and technicians allows us to tackle the challenges faced by the Army’s ground vehicle fl eet.

A particularly powerful capability is our advanced modeling methods, through which we can simulate conditions faced by Soldiers in the fi eld. Physics-based modeling allows us to realistically assess system per-formance and Soldier responses under realistic condi-tions, which in turn gives us a deeper understanding of what warfi ghters go through and the training they need to successfully complete their missions. With these capabilities we are able to infuse intellectual rigor early in the development phase, which shortens lead times and makes the integration process more effi cient in both time and cost. We work out the details, large and small, in the labs so the integration into the vehicle is part of a seamless, repeatable process.

Part of what makes TARDEC unique is our focus on systems integration. TARDEC’s more than 50 labs have the capabilities to evaluate entire vehicle systems, individual components and all levels in between. Our Systems Integration Laboratories offer a platform for engineers to fi nd the best fi t for new technology within an existing vehicle and see how all systems work to-gether before fi nal integration. The equipment we use allows us to push vehicles to their limits, checking the durability and reliability of the system and thereby al-lowing us to fi nd potential problems before they occur. That is the case in the High-Performance Computing Center, which allows us to do classifi ed and unclassi-fi ed analysis. One thousand processors spread over two systems and accounting for a combined 12.4 tera-fl ops of memory are used in conducting tests that help verify vehicles meet the Army’s rigorous requirements. Vehicle armor also must meet very high standards,

and our Ground System Survivability Armor Ballis-tics Lab performs ballistic testing on transparent and opaque armor materials to determine whether they meet necessary threat levels. Additionally, we must be able to react quickly as problems arise, and the Cave Automatic Virtual Environment uses virtual reality to create 3-dimensional models that signifi cantly cut down on the time needed for the design process.

Part of our role is to bring systems integration excellence to the community, which is why we pride ourselves on the openness of our labs. Private organizations can use our labs through Test Service Agreements (TSAs) where all inventions and data belong to the partner organization, but the work is performed using TARDEC associates, equipment, material and facilities.

We continue to bring capabilities to the Ground Systems Enterprise with the addition of two labs that focus on areas of growing importance to the military — power and energy (P&E) and robotics. The new Ground Systems Power and Energy Laboratory will be completed in September 2011 and has the capability to further research into alternative fuels and propulsion systems and focus efforts to address critical combat vehicle fuel effi ciencies. Once complete, the 8-labs-in-1 complex will have one-of-a-kind research and testing capabilities and will serve as the cornerstone for the Army’s next generation of P&E initiatives. Just as P&E will continue to be a focus, so too will robotics. Au-tonomous ground systems have incredible potential to positively impact Soldiers. The U.S. Army TACOM Life Cycle Management Command’s Joint Center for Robotics has built a state-of-the-art robotics lab at the United States Military Academy at West Point. This facility provides a venue for educational and research opportunities and familiarizes future military leaders with the benefi ts robotic systems can provide.

We provide capabilities that match the broadness and importance of our mission. Our systems integration responsibilities mean we must be ready to address whatever problems — current or future — we are presented with. The resources available in our labs provide us what we need to lead, innovate, integrate and deliver solutions to meet those challenges. Dr. Grace M. BochenekTARDEC Director

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On the Cover: The 3-dimensional cubes depict TARDEC laboratory facilities and the integrated approach our scientists and engineers take to ground vehicle systems engineering and design. Each cube represents a carefully integrated system-of-systems capability designed to produce unprecedented battlefi eld lethality, survivability, mobility and sustainability across the full spectrum of confl ict.

TARDEC’s laboratory facilities provide a home for the U.S. Army’s and Department of Defense’s advanced science and technology research, development, life cycle engineering and ground vehicle systems integration. TARDEC technicians, scientists and engineers partner with other major defense laboratory associates, industry representatives and engineers, and academic researchers, engineers and scientists to integrate technology into the Army’s and other services’ manned and unmanned ground vehicle systems.

This special edition is designed to give the reader an up-close-and-personal look into the science behind the technology and the systems engineering integration that makes the technology possible.

Many of our labs are one-of-a-kind and provide our associates with a leading-edge environment to build the most capable combat and tactical vehicle fl eet in the world. And because the pieces are engineered to fi t together using a system-of-systems approach, the Ground Systems Enterprise has constructed a solid foundation of laboratories that interlock to provide the American Soldier signifi -cant overmatch capability in any environment, night or day, against any potential threat.

Take the time to learn more about Team TARDEC and the awesome capabilities our people bring to the design table. We deliver the most technologically advanced integrated solutions and sustain-ment expertise possible so that our Soldiers are protected by the best vehicle systems imaginable.

Michael I. RoddinEditor-in-Chief

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5 Collaboration Yields Game-Changing Innovation for Our Warfi ghters

Michael I. Roddin

6 People, Collaboration and NASA-Style Innovation — RDECOM Commander Shares Vision Katherine H. Crawford

14 Intelligent Ground Systems (IGS) Robotics Laboratories — Finding Robotics Technology Solutions Through Innovation Michael D. Kaplun

16 VSIL Technology Test and Validation Center Provides Systems Engineering Integration Capability Carrie Deming

18 TARDEC Robotics Systems Integration Lab (SIL) Carrie Deming

20 Technology Integration for Unmanned Ground Vehicles Michael D. Kaplun

22 Integrating Systems Engineering for Robotic Battlefi eld Deployment — Intelligent Ground Systems (IGS) Laboratory and Vehicle Bay Michael D. Kaplun

24 TARDEC’s Battlefi eld Observation Room (BOR) Provides Leading-Edge Teleoperation and Data-Sharing Capabilities Matthew Sablan

28 TARDEC-Funded West Point Robotics Lab Builds Future Engineers Patrick Pinter

34 TARDEC Associates Display Capabilities to ARDEC Visitors Chris Williams

38 Designing a Unique Lab for Advanced Military Vehicles Michael A. Kluger and Felt A. Mounce

I N T E L L I G E N T G R O U N DSYS T E M S

P O W E R A N D M O B I L I T Y

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Dr. Grace M. BochenekTARDEC Director

Magid AthnasiosExecutive Director of Engineering

Thomas MathesExecutive Director of Product Development

Dr. Paul RogersExecutive Director of Research

Dr. David GorsichChief Scientist

Paul Skalny Director of National Automotive Center

Terry GondaDirector of Strategic Transformation

Jennifer HitchcockChief of Staff

Michael I. RoddinDirector of StrategicCommunications


Meg A. CarpenterPublications Manager

Katherine H. CrawfordManaging Editor

Pete WardropeSenior Editor

Carrie DemingWriter

Michael D. KaplunWriter/Editor

Patrick PinterWriter/Editor

Matt SablanWriter/Editor

Chris WilliamsWriter/Editor

Nojae KimHenry MarnghitrRhonda WiltGraphic Design

To contact the Editorial Offi ce, call (586) 582-0288 or (586) 838-2302FAX: (586) 838-2360e-mail: [email protected]

EDITORIAL ADVISORY BOARD EDITORIAL STAFF

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DISCLAIMER: accelerate is published by TARDEC. Articles express the written views of the authors and not necessarily offi cial opinion of the Department of the Army (DOA). If articles are reprinted, please cite accelerate, the author and photographer.

Reference herein to any specifi c commercial company, product, process or service by trade name, trademark, manufacturer or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or DOA. The opinions of the authors expressed herein do not necessarily state or refl ect those of the United States government or DOA and shall not be used for advertising or product endorsement purposes.

POSTMASTER: Please send address changes to U.S. Army TARDEC, 6501 E. 11 Mile Road, Bldg. 200A, RDTA-ST, Mail Stop #206, Warren, MI, 48397-5000.

70 Advancing Ground Vehicle Research and Development Michael D. Kaplun

74 Testing Facility Provides Clean Water Solutions for Soldiers Patrick Pinter

78 Keeping Warfi ghters Well-Hydrated — SDTF Delivers Optimal Water Purifi cation Systems Matthew Sablan

80 TARDEC Leads Fuel and Lubricant Technology Development and Design Patrick Pinter

86 Lab Puts Armor Under the Gun to Save Soldiers’ Lives Chris Williams

44 Fueling Development for Future Force Vehicles — TARDEC’s Fuels and Lubricants Laboratories Provide Leading-Edge R&D Matthew Sablan

48 EARL Runs Batteries Through Paces Chris Williams

50 TARDEC Engineers Advance Hybrid-Electric (HE) Technology and Systems Integration Chris Williams

54 Fueling Station and Maintenance Facility Keep Hydrogen Vehicles Powered Chris Williams

58 Optimized Combustion and Fuels Focus of Single Cylinder Test Cell Chris Williams

60 Systems Engineers Keep Vehicles on Track Chris Williams

64 TARDEC Turns Up Heat on Vehicle Testing Chris Williams

F O R C E P R O J E C T I O N

G R O U N D SYS T E M S S U R V I VA B I L I T Y

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CALL FOR ARTICLES

accelerate Magazine is seeking articles for upcoming issues. Are you researching new technologies? Have you faced and overcome

engineering challenges and created innovative designs that will aid Soldiers in theater? If you have, TARDEC, the Nation’s laboratory for advanced military automotive technology, wants to publish your story. Submit your article and photo images to: [email protected].

Inform your colleagues and community by writing for TARDEC’s monthly online news magazine, GVSET News. As a member of the ground systems enterprise, you have the opportunity to express your professional voice and engage the public by writing for GVSET News, which has a subscriber base of more than 3,000 readers. If you work in or around ground vehicle systems technology, engineering, robotics, survivability

or power and energy, your expertise would be of interest to our readership. Submit your article or photo images todayto [email protected]

114 Assessing Material and Microstructural Failures — Metallurgical and Failure Analysis Laboratory Provides Critical Analysis Michael D. Kaplun

116 Conducting M1A2 Software Maintenance and Enhancement — M1A2 System Integration Laboratory Michael D. Kaplun

118 DREN Provides TARDEC’s Computing Power Michael D. Kaplun

120 High-Performance Computing Center Delivers Proven Vehicle Solutions Patrick Pinter

122 Dynamic Structural Load Simulator Laboratory Bridges Capability Gaps (DSLSL)

Matthew Sablan

124 TARDEC Chief Scientist Helps Develop Army Ground Systems Technology Focus Michael I. Roddin and Chris Williams

90 Innovative Materials Bridge Partnership Between TARDEC and Lawrence Tech Matthew Sablan

94 Testing Capabilities Help Mitigate Explosive Damage Patrick Pinter

98 Laser Protection Research and Integration Laboratory — Protecting Soldiers’ Eyes and Optical Sensors Michael D. Kaplun

102 Total Immersion in Virtual Environments Leads to Engineering Innovation Patrick Pinter

106 A Virtual Environment Gets Soldiers Ready for Action Patrick Pinter

108 Ground Vehicle Simulation Laboratories Simulate Real-World Testing and Analytics Patrick Pinter and Matthew Sablan

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M O D E L I N G A N D S I M U L AT I O N

The U.S. Army Research, Development and Engineering Command (RDECOM) Tank Automotive Research, Develop-ment and Engineering Center (TARDEC) supports warfi ghters through research, development, engineering, integration and delivery of innovative technolo-gies. In executing this mission, TARDEC, in close collaboration with program, project and prod-uct managers, provides systems engineering and technology integration for all manned and unmanned ground systems.

At the heart of TARDEC’s science and technology (S&T) research, demonstration, devel-opment and full life-cycle engi-neering collaborative work are its laboratories. This special issue of accelerate Magazine highlights TARDEC’s cooperative work and world-class facilities, conveying how the RDECOM enterprise supports warfi ghters effi ciently and effectively.

Articles of particular interest in this edition include:

• People, Collaboration and NASA-Style Innovation — MG Justice’s Vision for RDECOM — an exclusive interview in which the new RDECOM Command-ing General MG Nickolas G. Justice discusses his philosophy and vision.

• Technology Integration for Unmanned Ground Vehicles — TARDEC’s Small Robotics Laboratory focuses on develop-ing and integrating technology advancements for unmanned ground vehicles, designing and analyzing advanced behavior control schemes for future ve-hicle implementation.• It's TARDEC-Funded West Point Robotics Lab Builds Future Engineers — TARDEC and the Robotic Systems Joint Project Offi ce led the construction of a robotics lab at the U.S. Military Academy, West Point, NY.• TARDEC Turns Up the Heat on Vehicle Testing — to improve vehicle mobility, TARDEC’s Ground Vehicle Power and Mo-bility team is rapidly testing and evaluating vehicles, ensuring they are optimally equipped to endure the harshest environments. • Keeping Warfi ghters Well-Hy-drated — SDTF Delivers Optimal Water Purifi cation Systems — the U.S. Navy’s Seawater Desalina-tion Test Facility (SDTF) enables the Army and U.S. Marine Corps to test and develop fi eld water purifi cation equipment to keep warfi ghters replenished and en-ergized in theater. • Innovative Materials Bridge Partnership Between TARDEC and Lawrence Tech — TARDEC entered into a partnership with Lawrence Technological University in October 2008 to

develop, install and operate an environmental/loading chamber to test advanced materials for vehicle armor and structural components.• Total Immersion in Virtual Environments Leads to Engi-neering Innovation — the Cave Automatic Virtual Environment (CAVE) is an immersive, virtual reality environment in which users view 3-dimensional graph-ics that show an object’s various sides and components.• TARDEC Chief Scientist Helps Develop Army Ground Systems Technology Focus — TARDEC Chief Scientist Dr. David Gorsich leads the center’s S&T portfolio to better equip and improve current and future Soldier operations.

These featured articles, and their companions, focus on the capabilities that TARDEC and its partners strive to deliver daily. Find out how collaboration with Army partners, industry and academia helps the Army and Department of Defense lead, innovate, integrate and deliver the most advanced technology and leading-edge solutions to our Nation’s warfi ghters.


Collaboration Yields Game-Changing Innovation for Our Warfighters

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RDECOM CG MG Nickolas G. Justice visited a number of technology displays while attending All-American Bowl Week festivities in San Antonio, TX, Jan. 7-9, 2010. RDECOM had a large technology display of its own at the annual event. (U.S. Army RDECOM photo.)

People, Collaboration and People, Collaboration and NASA-Style Innovation — NASA-Style Innovation —

RDECOM Commander RDECOM Commander SharesShares Vision Vision

Katherine H. Crawford

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In his New Year’s message to the 17,000-strong U.S. Army Research, Development and Engineering Command (RDECOM) workforce, Commanding General (CG)

MG Nickolas G. Justice directed his team to move out in triple time. “We provide America’s warfi ghters with strength through technology,” Justice declared. “There is no other or-ganization in the Army that does what we do, so we must all be fi rst-string players. We must be at the forefront of our expertise, striving to be world-class. Our Soldiers deserve no less. I’m sure you’ll agree. Your mindset must be — Fast. Furious. Now.”

During accelerate Magazine’s December 2009 interview with the new commander at RDECOM Headquarters in Gun Powder, MD, Justice was fi red up with plans for fusing Soldiers’ experi-ence with the RDECOM work-force’s knowledge and expertise to take science and technology (S&T) solutions to the next level.

Justice’s Philosophy and VisionJustice, a Soldier for more than 38 years, has served most of his career in electronic warfare communica-tions systems and software engi-neering. His most recent leader role was as Program Executive Offi cer, Program Executive Offi ce Command, Control and Commu-nications-Tactical (PEO C3T).

He breaks down everything that he does into four parts: people, purse (funding), problems and processes. To him, connecting these four parts correctly achieves optimal solutions. If you can team the people with the funding and then use processes to solve problems, you come out with a product that is better and more

sustainable. Justice believes that to improve RDECOM and the Army in general, we all need to work on processes and make them broader in scope to better solve opera-tional problems.

Justice asserted RDECOM should be defi ning the requirements and working with industry to fulfi ll those requirements rather than accepting industry-driven solu-tions. He stated that RDECOM has not been precise in express-ing itself and its needs, but that the engineers within RDECOM have the knowledge and exper-tise to drive innovations and articulate warfi ghter needs. By truly understanding systems and components and the way in which they work in the fi eld, as well as the research, development and engineering (RD&E) behind them, better solutions can be found. As Justice explained, “Be-ing able to put those understand-ings and real-world knowledge into the technologies we pro-duce allows us to shape how the problem is solved before we get a problem that has already been

shaped to an understanding of a certain solution.”

Power of Collaboration — Bringing Soldiers and Technical Experts TogetherJustice strongly believes in the concept of something being greater than the sum of its parts: “You can create more capabilities with syner-gies versus with individual compo-nents.” His goal is to partner do-main experts with those from each subject area and have them col-laborate so that their systems work together. “Look at the strength of what I’m doing: I’m taking those unique, one-of-a-kind experts, and I’m multiplying them to the power of the number of experts I put together, not just adding them together. It just becomes geometric in what you can accomplish.”

Another way in which Justice plans to build the strength of his organization’s people is to leverage the power of the mili-tary personnel within RDECOM. There are approximately 200 Sol-diers within RDECOM, and their insight and input is invaluable because they come to the problem with a different perspective. A fi rm believer in the idea that you can’t solve a problem until you

“We provide America’s

warfighters with strength

through technology. There is

no other organization in the

Army that does what we do.

We must be at the forefront

of our expertise, striving to

be world-class. Our Soldiers

deserve no less. Your

mindset must be —

Fast. Furious. Now.”

Justice (center) learns more about the TALON robot from TARDEC Robotics Engineers Bernard Thiessen (left) and Jeremy Gray at the RDECOM exhibit at the All-American Bowl. (U.S. Army RDECOM photo.)

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understand the problem, Justice is keen to harness the know-ledge and experiences of these service members who have been in the fi eld. “We’ve got noncom-missioned offi cers [NCOs] and offi cers here who have experi-ences that our folks with S&T and engineering backgrounds don’t have. These NCOs are just as valuable, if not more so, because that’s where the clarity of the problems will come,” he com-mented. Additionally, these mili-tary personnel can easily establish a network of people to work on a specifi c task, project or problem. “They’re used to moving around, and they have friends and associ-ates they’ve known on a personal basis around the Army, and they can easily establish a network of people because that network is already there.”

To this end, Justice plans to bring fi ve senior NCOs to the Army’s research, development and engi-neering centers to ask challenging questions of the engineers and

technicians working on the equip-ment that these NCOs’ fellow military personnel will be using in the fi eld. RDECOM’s Command Sergeant Major Hector Marin will be responsible for bringing in qualifi ed crewmembers who can operate as a unit rather than as individuals. The idea is to “bring the reality and the practice of what we do back into the labo-ratories to see it,” Justice stated, and “connecting the right people — the innovators and the user community — to create a product that is better than either could develop alone to make the Army the best in the world at solving particular problems.”

Power of Collaboration — Creating Common SystemsJustice applies this same strat-egy of networking to developing platform architectures. One of his major objectives is to bring commonality to everything — systems, components, platforms, etc. His ideal is an infrastructure that can host many components, the idea of “one-to-many versus many-to-many.” If various pieces of architecture aren’t compatible with one another, it just wastes time and money. “Commonality is incredible,” Justice explained. “It will reduce the costs in the contracts for components because you’ll be able to build components

RDECOM should be defining the requirements and

working with industry to fulfill those requirements

rather than accepting industry-driven solutions. By truly

understanding systems and components and the way in

which they work in the field, as well as the RD&E behind

them, better solutions can be found.

Justice visited the Detroit Arsenal to get an up-close look at the RD&E conducted by TARDEC. From left: TARDEC Executive Director of Re-search Dr. Paul Rogers, TARDEC Director Dr. Grace M. Bochenek, TARDEC Military Deputy COL Eric Fletcher and Justice speak with TARDEC Associate Dr. Mark Brudnak in TARDEC’s Ground Vehicle Simulation Laboratory. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

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to specifi cation and know that you’ve already got the infrastruc-ture to plug into.”

Currently, he noted, the Army’s usual practice is to replace a system and the whole infra-structure, which causes costs to skyrocket. Justice used a house-hold example to illustrate his point: “What if every time you replaced a TV in your house you had to replace all the elec-trical wiring, too? That sounds crazy for me to say that, right? But that’s oftentimes what the Army would do. We’d replace a system, but we’d have to replace the complete infrastructure. Not only the infrastructure, but the parts supply. We’d also have to replace the repair facilities. When you start doing that, your costs go orders of magnitude more than the actual capability you’re putting into the combat forma-tions. What we want to do is get down to where we are fund-ing those things that directly make a difference and make an improvement to combat forma-tions without having to replace complete infrastructures.”

Justice gave another household example to show that common-ality is possible, noting that we have standards for various specifi -cations in our homes. “Everybody knows exactly what the specifi ca-tion is for a 110-volt, 60-cycle power outlet on your wall. You know exactly how to plug it in and how it’s got to be wired, so anybody in the country who can produce electronics knows what the power that will be available for that device is, and they know how to confi gure it and have it ready for your home.” Justice seeks to bring this same type of standardization to Army equip-ment and platforms and have RDECOM set the standards for

industry and academia. “What we want to do is get into the position of setting those standards, defi n-ing them and being the under-writer’s lab equivalent for the Army, and that means focusing very heavily on the engineering component,” he observed.

Justice knows that this type of commonality can be achieved by bringing the right communities together and fostering collabora-tion. He spoke of witnessing, in his previous role, the communica-tions and electronics community and the vehicles and sensors com-munity getting together to “create a common driving infrastructure that allowed integration to occur.” Once a common platform was created, ultimately, “They created more capability than the individ-ual components had organic to themselves by creating synergies across the components.”

The other crucial consideration that RDECOM scientists and engineers must always take into account is product and system longevity. RDECOM must an-ticipate future requirements and design components that will have a long life cycle and can take on many potential systems. “One of the things I see us doing is design-ing components to use infrastruc-ture that we know will have a fairly long life cycle, and we need to fi nd touch points of modern-ization with that infrastructure that allow us to grow its capability and capacity to a potential capac-ity that we never realized in the initial fi eldings,” he emphasized. For example, “I want my commu-nications systems to be capable of 50 or 100 megabits per second, though I may fi eld them with fi ve megabits per second, and I want to be able to take small compo-nents of that and change them out. That will give me a doubling

Justice gets a driver’s-side view from the cab of a Mine Resistant Ambush Protected vehicle in TARDEC’s Prototype Integration Facility (PIF). PIF Associate Director Luis Hinojosa (front) describes vehicle components and platform-unique capabilities to him. Justice believes in bringing together experienced NCOs, researchers, developers and technicians to achieve great things for RDECOM and the Army as a whole. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

“What we want to do is get

down to where we are

funding those things that

directly make a difference

and make an improvement

to combat formations

without having to replace

complete infrastructures.”

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or a 10-times capability in that network but not have to replace everything there.”

Reaching to the Stars — Harnessing NASA’s Expeditionary MindsetJustice is always planning for the “Army after next,” seeking strategies to modernize and looking for long-term solu-tions. He fi rmly believes that RDECOM and the Army need to think longer-term and be better at anticipating future needs and technologies. “We want to plan things that fall over at least three generations of packaged capabil-ity — packaged capability is all the equipment in there — so that the infrastructure crosses mul-tiple generations of equipment. Don’t solve my problem today — solve my problem today that has legs to the future and the ability to be modernized,” he remarked. The Army needs to be able to see “disruptive” technologies coming, like cell phone technology was 10 years ago, and plan for it so that it’s not stuck with legacy systems that cannot be adapted or will be too expensive and time-consum-ing to modernize.

Standardizing equipment and ensuring that it is built for a long product life cycle also al-lows Soldiers to become more expeditionary. If you “standard-ize equipment so that the vehicle comes ready for plug-and-play kind of applications, then every piece of equipment that goes in that vehicle doesn’t have to have its own installation kit, its own installation crew to support that, its own maintenance, its own tail of supply that’s out there in the unit,” Justice observed. This allows the Army to lighten its load of parts and people, yield-ing a more mobile and agile force. “Being expeditionary means that

you need to lighten your load as quickly as possible,” he noted. “We want to empower our portion of that combat brigade with a smaller footprint, a much more sustain-able equipment set, so that those kits allow a unit to pack and move faster than they’re able to do today with very large supply tails.”

Justice views the Soldier as his or her own self-sustaining system that’s equipped and plugged into the network — each is his or her

own expeditionary force. The human as its own closed, self-sus-taining system is the same idea as an astronaut, and he’s looking to NASA for inspiration on ways of bringing this thinking to the Army.

Justice noted that all the future platforms the Army is moving to are for 2- or 3-men crews, which is similar to the Apollo program, and so it may be useful to see if there are any lessons that can be gleaned from history. “Some of the things that we achieved with NASA in the late 1950s and 1960s are the kinds of engineering that we want to do in this organization.

Justice receives the RDECOM colors from U.S. Army Materiel Command CG GEN Ann E. Dunwoody during a Dec. 4, 2009, Change of Command Ceremony. (U.S. Army RDECOM photo.)

“We have an insatiable

appetite for things that save

lives and make us more

effective, that close time and

distance problems, so you

see us in this same geometric

demand cycle for things

like bandwidth and energy

and many other things, but

bandwidth and energy are

two things that fall into the

big infrastructure pieces.”

Justice (center) examines the 3rd Infantry Division’s course to integrate PEO C3T equipment into its predeployment exercise at the National Training Center, Fort Irwin, CA, in August 2007. (U.S. Army RDECOM photo by Richard Mattox.)

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They’re directly related to what we do in the Army on the battlefi eld. The Soldier is the astronaut. The spacecraft becomes the combat vehicle — it’s tailored to a specifi c mission, it’s expeditionary.”

This collaboration with NASA is real and, in fact, Justice is talk-ing with Astronaut William M. Shepherd regarding potential opportunities for collaboration. This is just part of his forward-thinking strategy for bringing innovation and new partnerships to RDECOM to achieve techno-logical breakthroughs.

Justice used the NASA analogy during the U.S. Army All-Amer-ican Bowl held in January in San Antonio, TX. He escorted Secre-tary of the Army John McHugh through the Army Strong Zone, which demonstrated the Army’s future vehicle concepts, Soldier gear and technology. Standing next to a Soldier wearing com-posite armor, Justice explained, “This is the astronaut version of a Soldier. He can live in any envi-ronment. He can do anything. If I add the ‘Sense through Wall’ technology being demonstrated behind me, he can see through walls. He’s got X-ray vision.”

Exploring TARDECIn the past six months, Justice has visited U.S. Army Tank Automo-tive Research, and Development Center (TARDEC) four times, and he is learning more about other disciplines and domains, particu-larly “getting to work with the vehicles — that’s just exciting.” It is this type of hands-on interaction that he thrives on. Justice said he is thrilled to visit the various labs and see the innovative work being done fi rsthand. He is particu-larly impressed by the multitude of capabilities TARDEC offers. “It was interesting to look at the

wealth of test equipment that TARDEC has for measuring the stresses on vehicles — some of the shake, rattle, roll kind of devices that TARDEC has in its labs. I was surprised to fi nd a couple of supercomputers, and the kind of modeling and simulation they were doing, the fabrication facilities, how they were able to produce things — actually make components in its facilities — that’s just fascinating,” he exclaimed, adding, “This was the fi rst time I had a chance to go into those facilities and see what was going on.”

Justice also took note of the many young TARDEC associates, com-menting, “There are lots of bright, young kids up there who know what they’re doing.” TARDEC has done an exceptional job of build-ing its future workforce, and these “kids” comprise another piece of the collaboration puzzle — bring-ing diversity of age and experi-ence to tackling diffi cult chal-lenges. As Justice stated, “That’s the kind of thing we want to do: bring the power of networking, bringing the bright, talented people we have who are experts in the problem and experts in the sciences and experts in the en-gineering capability, bring those people together and see if we can’t solve some of these things.”

For the near-term, Justice will be focusing RDECOM’s innovative and collaborative resources on two critical challenges facing the Army — bandwidth and energy. “We have an insatiable appetite for things that save lives and make us more effective, that close time and distance problems, so you see us in this same geomet-ric demand cycle for things like bandwidth and energy and many other things, but bandwidth and energy are two things that fall into the big infrastructure pieces.” His main tool for tackling these challenges will be people. “It’s all about the people, and we’ve got the talent pool, we just need to get them into the network — the people with the problems — and get them out there working, and the power of people is amazing. Other than that, it’s all to be dis-covered, and that’s what I need to do,” he concluded.

Katherine H. Crawford is the

Managing Editor for TARDEC’s

GVSET News and accelerate Magazine

and a Senior Publications Manager

with BRTRC, providing contract

support to TARDEC’s Strategic

Communications team. She has a

B.A. in English from Boston College

and an M.A. in literature from the

University of New Hampshire.

Justice views equipment during a demonstration by a staff member at Tobyhanna Army Depot, PA, to PEO C3T on March 17, 2009. (U.S. Army RDECOM photo by Richard Mattox.)

INTELLIGENT GROUND SYSTEMS (IGS)

IGS RL engineers and tech-nicians primarily focus on researching and developing hardware, software and sensors. Development is being performed on a Velodyne Light Detection and Ranging (LIDAR) — a 360-degree, high-resolution laser range-fi nding sensor — Segway robots; 360-degree cameras; open architecture; Java-based robotic control software; and Joint Architecture for Unmanned

Systems-based software — among other projects.

These facilities also have networked computers (Windows and Linux) to support R&D efforts. Com-puter software includes Visual Studio, used mostly for C++ de-velopment; Eclipse, an integrated development environment for Java; modeling software, such as SolidWorks; and other, more specialized software.

Key recent IGS Robotics Labora-tory projects include:

• Velodyne LIDAR — performed advanced characterization of LIDAR performance, especially in detecting people; utilized

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“IGS Robotics Laboratory

initiatives, such as the

Velodyne LIDAR project and

the Segway Robotic Control

project, help enhance robotic

development in a time of ever-

growing technology.”T he Intelligent Ground Systems (IGS) Robotics Laboratories (RL) pro-vide the U.S. Army Tank Automotive Research, Development and Engi-

neering Center (TARDEC) with an extensive laboratory setup, compromising facilities, tools and equipment to design, inte-grate, test and validate diverse robotic systems to meet Soldier needs and requirements.

Intelligent Ground Systems (IGS) Robotics Laboratories — Finding

Robotics Technology Solutions Through Innovation

Michael D. Kaplun

UGV Current Operations Support Team Leader UGV Current Operations Support Team Leader Lonnie Freiburger (left) and Robotics Systems Lonnie Freiburger (left) and Robotics Systems Manager MAJ Seth Norberg install the TARDEC-Manager MAJ Seth Norberg install the TARDEC-developed Tanglefoot tripwire mitigation device to developed Tanglefoot tripwire mitigation device to a FasTac 510 PackBot. IGS Robotics Laboratories a FasTac 510 PackBot. IGS Robotics Laboratories engineers are at the forefront of TARDEC’s robotics engineers are at the forefront of TARDEC’s robotics R&D. (U.S. Army TARDEC photo by Bill Dowell.)R&D. (U.S. Army TARDEC photo by Bill Dowell.)

information from LIDAR to perform obstacle detection.

• M/A-COM Radar — performed radar characterization to deter-mine performance in detecting

people from 360 degrees around a vehicle; used radar to perform

obstacle detection and avoidance, focusing on smaller unmanned ground vehicles (UGVs).

• Segway robotic control — roboticized Segways and put

mannequins on systems to sim-ulate humans moving through hostile environments.

• Pressure-sensitive Membrane — utilized a material that changes resistance based on pressure to create a circuit capable for use on manipulator end-effectors.

• iPod Touch — used an iPod Touch to control the Omni-

Directional Inspection System-T3 vehicle and an iRobot PackBot.

• Electronic Ink (e-ink) — used the display to compare the day-light readability of e-ink versus other displays.

“IGS Robotics Laboratory initiatives, such as the Velodyne LIDAR project and the Segway Robotic Control project, help enhance robotic development in a time of ever-growing tech-nology,” remarked TARDEC Engineer Matthew Skalny. Through IGS associates’ R&D efforts, TARDEC has taken the lead in the advancement of vital robotics technologies, provid-ing state-of-the-art solutions to meet critical warfighter needs.

Michael D. Kaplun is a Writer/Editor

with BRTRC and provides contract

support to TARDEC’s Strategic Com-

munications team. He holds a B.A. in

English and media and society from

Hobart and William Smith Colleges. 15


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Pictured here is a Segway robot at TARDEC’s IGS Robotics Laboratories at the Detroit Arsenal in Warren, MI. System developments, such as the robot, are expanding TARDEC’s role in robotics innovation to augment Soldier capabilities. (U.S. Army TARDEC photo by Carrie Deming.)

UGV Current Operations Support Team Leader Lonnie Freiburger helps Robotics Systems Manager MAJ Seth Norberg strap on the Squad Support UGV (SSUGV) control pack. TARDEC is helping develop the SSUGV for the U.S. Marine Corps. (U.S. Army TARDEC photo by Bill Dowell.)

TSGT Jeffrey Wasik kneels next to a TALON explosive ordnance disposal (EOD) robot. Systems like the EOD robot help to defeat seen and unseen threats while minimizing Soldier vul-nerability in theater. (U.S. Army photo by MSG Brian Davidson.)

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VSIL Technology Test and VSIL Technology Test and Validation Center Provides Validation Center Provides

Systems Engineering Systems Engineering Integration CapabilityIntegration Capability

Carrie Deming

TARDEC Intelligent Ground Systems engineers collect data from recent VSIL tests. The VSIL testing and validation laboratory helps to formulate a common technical language for industry, academia and DOD robotics technologies. (U.S. Army TARDEC photo by Carrie Deming.)

The Robotics Vehicle Simulation Integra-tion Laboratory (VSIL) provides potential solu-tions to the universal challenge of developing

technology that can “plug and play” with other robotic tech-nology across the Department of Defense (DOD). The lab provides a test environment where industry members can evaluate new technology be-fore rolling it out. Technology still under development can be plugged into the VSIL testing system to validate its utility for Army and Marine Corps ground systems robotics.

Currently, the VSIL is working in conjunction with TARDEC’s Concepts, Analysis, System Simulation and Integration (CASSI) group on modeling mobility, arm manipulator components and providing a simulation environment for new robotic technologies. By using CASSI’s simulation environ-ment, the VSIL has the ability to apply modeling architecture for

technology, research and experimentation tools, which allows for robust partnerships with other U.S. Army Research, Development and Engineering Command organizations, as well as other military branches and academia.

Presently, the VSIL is collaborat-ing with the U.S. Army Night Vision and Electronic Sensors Directorate team on comprehen-sive munitions and sensor servers, which are used to model tactical unmanned ground sensors and electrooptical infrared sensors. The VSIL is also integrating tech-nology with the aviation mobility server for modeling unmanned air systems fl ight dynamics from the U.S. Army Aviation and Missile Research, Development and Engineering Center, as well as providing infantry warrior simulations for modeling infan-try behavior from the U.S. Army Natick Soldier Research, Develop-ment and Engineering Center.

Additionally, the VSIL is focused on building a cost-effective, integrated profile testing ca-pability for small unmanned ground vehicles (SUGVs). The capability would allow for a test bed for SUGVs that would sup-port the Robotics Systems Joint Project Office with modeling and simulation, demonstration and transfer assistance. “The VSIL is a continually evolving, virtual environment with the

end goal to provide interface testing for validating unmanned systems for industry controllers and to provide an environment for sensor hardware evaluations to aid autonomous navigation and human detection algo-rithms,” explained a TARDEC

Embedded Distributed Simula-tion team member.

The VSIL is funded by the TACOM Life Cycle Management Command’s Joint Center for Robotics (JCR) and is currently supporting Battlefi eld-Extraction Assist Robot (BEAR) testing at the Maneuver Battlefi eld at Fort Benning, GA. The testing objec-tive is to evaluate the need for robot assistance in recovering wounded Soldiers on the battle-fi eld. Through testing at the VSIL, the TARDEC robotics team can ensure that the mature technol-ogy they integrate today onto robotic platforms can provide a strong foundation upon which to build integrated solutions for tomorrow’s unmanned ground vehicle systems, DOD-wide.

Carrie Deming is a Writer with BRTRC

and provides contract support to

TARDEC’s Strategic Communications

team. She has a B.A. in creative writing

from The Evergreen State College. 17


“The VSIL is a continually evolving, virtual

environment with the end goal to provide interface

testing for validating unmanned systems for industry

controllers and to provide an environment for sensor

hardware evaluations to aid autonomous navigation

and human detection algorithms.”

A Future Combat Systems (FCS) Lead Sys-tems Integrator performed a bezel study on the FCS Robotics Common Controller. The study involved technologies developed as part of the TARDEC Robotic Vehicle Control Architecture program, and simulations were developed as part of the TARDEC JCR VSIL. Soldiers evaluated different bezel placements and alignments using reconfi gurable touch screen technologies for controlling the FCS SUGV performing an urban area search. SUGV functionality and the virtual urban environment were modeled using VSIL technologies. (U.S. Army TARDEC image courtesy of Paul Bounker.)

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The U.S. Army Tank Automo-tive Research, Development and Engineering Center’s (TARDEC’s) Intelligent Ground Systems (IGS) and the Joint Center for Robot-

ics (JCR) serve as robotics research hubs for the Department of Defense (DOD). Reducing Sol-dier workloads and increasing Soldier safety is at the fore-front of their missions. To test

robotic systems’ applicability and Soldier-machine interfaces with emerging technologies, many systems are tested at TARDEC’s Robotics SIL. The SIL houses two major com-ponents for testing: a vehicle behavior simulator and mod-eling and simulation (M&S) equipment that can work in concert or independently of one another.

Behavior SimulatorThe behavior simulator pro-vides an initial look at human performance when using certain technologies that would exist as part of a Soldier-machine inter-face on a crew station, such as a route planning aid. Scott Lohrer, a TARDEC Engineer with the Embedded Distributed Simula-tion team, explained, “The M&S environment provides battlefi eld

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TARDEC TARDEC Robotics Systems Robotics Systems Integration Lab (SIL)Integration Lab (SIL)

TARDEC engineers test and validate emerging technologies by using the crew station in the Robotics SIL. Currently, IGS is reducing Soldier workload for both manned and unmanned systems through the development of products such as autonomous driving aides. The driving aides allow for vehicles to drive in autonomous mode, thereby freeing Soldiers to perform other tasks. (U.S. Army TARDEC photo by Carrie Deming.)

Carrie Deming

stimuli to stress the Soldier as if he or she were in battlefi eld con-ditions. One of the capabilities we try to expand on is what type of Soldier tasks can be automated so that they can perform other [higher order] tasks.”

Currently, IGS is reducing Sol-dier workload for both manned and unmanned vehicles. One example of task automation is

autonomous driving aides, which allow vehicles to drive in autono-mous mode, thereby freeing the Soldier to perform other tasks, such as scanning for local situ-ational awareness.

M&SThe SIL’s M&S component assists in developing software by providing stimulation to different subsystems

that must be controlled by the crew station. “The crew station must be able to control the driv-ing for manned and unmanned systems,” IGS Engineer Paul Bounker related. “M&S provides models of vehicles moving within a virtual world so that the driving control software can be tested and debugged as needed in the lab set-ting. This saves time and funding and reduces safety concerns with the development of new software.”

By capturing simulated and modeled tactical behavior for platforms and human actions through a tasking network, IGS engineers can test new technolo-gies and see how those technolo-gies may affect the performance of a vehicle or Soldier interface simply by running a program through the SIL laboratories.

Through the TARDEC IGS SIL’s capabilities, robotic engineers can more successfully test robotic technologies’ systems-of-systems, predict how the technology will affect Soldiers and determine how new technologies can be in-tegrated into existing platforms and software.

Carrie Deming is a Writer with BRTRC and provides contract support to TARDEC’s Strategic Communications team. She has a B.A. in creative writing from The Evergreen State College.

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TARDEC Robotics Systems Integration Lab (SIL)

“M&S provides models of

vehicles moving within a

virtual world so that the

driving control software can

be tested and debugged as

needed in the lab setting.”

JCR and TARDEC’s IGS serve as robotics research hubs for DOD. The IGS mission for crew station development is to maximize Soldier-system effectiveness, reduce warfi ghter training burdens and increase control of a variety of unmanned systems. (U.S. Army TARDEC photo by Carrie Deming.)

Many robotic systems are tested at TARDEC’s Robotics SIL, including the Multi-Mission Work Station (MMWS). Soldiers in the back of a Stryker Fire Support Vehicle navigated an experimental unmanned vehicle robot in autonomous mode around obstacles just by moving a set waypoint using the MMWS touch screen, which was tested at TARDEC’s SIL. (U.S. Army TARDEC photo by Larry Siegh.)

Technology Integration for Unmanned Ground

Vehicles Michael D. Kaplun

TThe U.S. Army Tank Automotive Research, Development and Engineering Center’s (TARDEC’s) Small Robotics Laboratory (SRL) is focused on developing and integrating technology ad-vancements for unmanned ground vehicles (UGVs), such as the PackBot and TALON. UGV laboratory work includes designing and analyzing advanced behavior control schemes for future

vehicle implementation. The facility, which serves as a System Inte-gration Laboratory for implementing internal and external sensor packages, also provides for indoor mobility testing, sensor/payload integration and testing, platform characterization and training.

An explosives ordnance disposal technician maneuvers a robot to disarm a mock improvised explosive device (IED) during a training exercise. Robotic systems are advancing to better protect warfi ghters on a diverse battlefi eld. (U.S. Armed Forces photo by CPT David Faggard.)

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Intelligent Ground Systems (IGS) personnel, particularly the UGV Operations Support team, provide support to orga-nizations such as the Robotic Systems Joint Project Offi ce (RS JPO) by creating, acquiring and evaluating diverse robotic payloads. Recently, the team led an effort to integrate and test a payload called “Tanglefoot” in response to an operational fi eld request. The SRL is also used for characterizing and testing new platforms. Periodically, IGS will receive new platforms from Small Business Innova-tion Research Programs, and the platforms’ initial evaluations occur in the SRL.

Another signifi cant laboratory aspect is its ability to provide infor-mation for platforms or sensors/payloads. If a robotics organization, such as RS JPO, needs technical information on a particular plat-form, the SRL serves as the information source.

Currently, TARDEC is building the Squad Support UGV (SSUGV) in the SRL. Addition-ally, IGS and contractor personnel are working

together to build subassemblies while also preparing to perform full SSUGV assembly and testing once the system is built.

“The SRL’s various system developments will continue to expand TARDEC’s role and ca-pabilities in the fi eld of robotics as well as increase our in-house expertise,” remarked TARDEC Acting Administrator for IGS Jeff Jaster. TARDEC’s SRL future de-velopment and integration efforts are improving future UGV capa-bilities for our Soldiers today.






Hobart and William Smith Colleges.21


“The SRL’s various

system developments

will continue to

expand TARDEC’s role

and capabilities in the

field of robotics.”

IGS engineers at TARDEC’s SRL integrate robotic technologies for small and medium platforms for IED removal and an ever-expanding range of operational capabilities. IGS personnel provide support to organizations, such as RS JPO, by acquiring, creating and evaluating payloads. (U.S. Army TARDEC photo by Carrie Deming.)

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The Multi-function, Agile, Remote Control Robot (MARCbot) is one piece of technology helping in the fight against IEDs in the theater of operations. The MARCbot is one of several robotic systems that can be used to safely disengage threats without putting Soldiers in harm’s way. (U.S. Armed Forces photo.)

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Integrating Systems Integrating Systems Engineering for Robotic Engineering for Robotic Battlefield Deployment — Battlefield Deployment — Intelligent Ground Systems (IGS) Intelligent Ground Systems (IGS) Laboratory and Vehicle BayLaboratory and Vehicle BayMichael D. Kaplun

The U.S. Army Tank Automotive Research, Development and Engineering Center’s (TARDEC’s) IGS Laboratory and Vehicle Bay integrates component technologies, such as perception systems, human detection and intent analysis hardware/software, onto unmanned ground vehicle (UGV) platform components, while also integrating these component technologies onto platforms for testing and evaluation. TARDEC engineers and industry partners perform critical research, development and engineering in the IGS Laboratory to enable better transition of components and subsystems to

the complex designs, systems, integration and test phases for UGV platforms. The facility’s components and subsystems are assembled and integrated onto platforms to be tested in relevant operational scenarios in the fi eld.

The MARCbot is a result of TARDEC’s IGS Laboratory and Vehicle Bay’s component technology integration efforts. The MARCbot is a lightweight robot that provides warfi ghters with remote, look-only capabilities. This MARCbot can look around a corner while a warfi ghter observes from a safe standoff distance. (Photo courtesy of American Reliance, Inc.)

The high bay houses small- to mid-sized robots that are cur-rently in theater or getting ready to be fi elded or deployed. Presently, through a Robotic Systems Joint Project Offi ce (RS JPO) charter, IGS engineers ensure upgrades are implemented to improve reliabil-ity, maintainability and ease of tactical UGV use in the theater of operations. By building the system to better standards and ensuring the drawing package is production-quality, facility engineers are cur-rently assembling and integrating a teleoperated, 2,600-pound Squad Support UGV (SSUGV), which is capable of being integrated with a remote tactical capabilities.

The UGV assembly involves TARDEC IGS, a local automotive supplier’s research, development, design and fabrication expertise, the participation of other cross-disciplinary TARDEC personnel and the RS JPO. “Working with RS

JPO continues to be a productive relationship, and TARDEC remains excited to work so closely with its customer,” remarked TARDEC’s Shanna Render, UGV Current Op-erations Support Engineer.

IGS technicians and engineers solve battlefi eld and operational challeng-es that call for intelligent, automated ground vehicle systems capable of engaging threats while interact-ing with and through their Soldier operators. Through autonomous perception and navigation, intel-ligent tactical behavior, command and control, IGS further develops the Army’s signifi cant capability to deliver near real-time situational awareness, and foresee and diagnose potential battlefi eld threats.

From small robotic systems, such as the Omni-Directional Inspec-tion System and Multi-Function Agile Remote Control Robot (MARCbot) surveillance system, to the full-size Autonomous Platform Demonstrator (APD), TARDEC researchers and engi-neers are pushing the boundaries of robotic technologies to provide our warfi ghters more safety and an operational advantage.

Michael D. Kaplun is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Com-munications team. He holds a B.A. in English and media and society from Hobart and William Smith Colleges.

23


TARDEC’s IGS Laboratory and Vehicle Bay integrates systems to enhance Soldier capabilities on the battlefi eld. Systems like the APD are an example of successful integration efforts. The APD can reach speeds of up to 50 miles per hour and can operate at 113 degrees Fahrenheit. (U.S. Army TARDEC photo.)

TARDEC’s Shanna Render, UGV Current Operations Support Engineer, helps TARDEC’s IGS Laboratory and Vehicle Bay integration op-erations, increasing the center’s role in robotics technologies. The 2,600-pound SSUGV is cur-rently undergoing assembling and integration with a remote tactical capabilities. (U.S. Army TARDEC photo by Bill Dowell.)

TARDEC Engineer Sean Hadley works on an SSUGV robotics system in TARDEC’s IGS Laboratory and Vehicle Bay. At the facility, component technologies, such as perception systems, human detection and intent analysis hardware/software and unmanned ground vehicle platform components, are developed and integrated. (U.S. Army TARDEC photo by Carrie Deming.)

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TARDEC’s B TARDEC’s Battlefattlefield Observation Room (BOR) ield Provides Leading-Edge Teleoperation Provides Leading-Edge and Data-Sharing Capabilities and Data-Sharing

The BOR, a facility operated by the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC), was originally established in 1994 to complete simulations for TARDEC. Simulations were performed off-site throughout the Nation and were linked through the Systems Integration Lab (SIL). Each loca-tion had the capability to virtually control simulated assets.

Matthew Sablan

25


TARDEC’s Battlefield Observation Room (BOR) Observation Room (BOR) Provides Leading-Edge Teleoperation Teleoperation and Data-Sharing CapabilitiesCapabilities

A 4th Infantry Division Soldier communicates via A 4th Infantry Division Soldier communicates via radio while a Bradley Fighting Vehicle crew pro-radio while a Bradley Fighting Vehicle crew pro-vides site security. TARDEC engineers routinely vides site security. TARDEC engineers routinely use the BOR to help spiral unmanned ground ve-use the BOR to help spiral unmanned ground ve-hicle technology into Bradley and Stryker vehicle hicle technology into Bradley and Stryker vehicle platforms. (U.S. Army photo by SPC John Crosby.)platforms. (U.S. Army photo by SPC John Crosby.)

The BOR is becoming a central hub of powerful audio and video capabilities to remotely view tests as they are conducted at training centers and labs around

the country. “The planned BOR upgrade will use a sophisticated control system that allows the user to select input data from multiple sources and route those

inputs to various destinations, both internal and external,” remarked TARDEC Computer Science Specialist Matthew DeMinico. After routing this information, the BOR also will be able to act as a central hub for viewing various tests and pull data from any of its sources. The SIL is one of these data sources, and, in the future, these sources could include facilities anywhere around the world.

“The BOR will serve as an observation and control facility for vehicle testing,” DeMinico explained. The BOR will also allow remote viewing of robotics tests alongside manned

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“The BOR is available for use by

any organization within TARDEC

that requires its observation and

control functions.”

The BOR serves as an observation and control facility for vehicle testing. Images, data and videos are displayed to allow TARDEC engineers immediate access to fi eld data. (U.S. Army TARDEC photo by Carrie Deming.)

A TALON and MARCbot are displayed during the TARDEC Ground Systems Power and Energy Laboratory Tour, Aug. 17, 2009. TARDEC’s BOR has been used to test various robotic plat-forms that Soldiers use to assist with dangerous tasks in theater. As the technology and operator systems mature, unmanned ground vehicle systems will be rapidly fi elded to support ground combat operations. (U.S. Army TARDEC photo by Carolyn Baum.)

platform test observation. In combination with the SIL, the BOR will observe robots during testing at external locations, while operators in the SIL control the robots. In the future, crew stations will allow remote operation of robots, with the BOR serving to route data between the operator and assets at the test facility.

While testing these robots, the BOR will allow TARDEC’s engineers to remotely gather data. TARDEC associates could then analyze this data to fi nd and solve potential engineering or design problems with the technology before fi elding it,

providing the Army with cost savings and better preparing warfi ghters in the fi eld.

The BOR continues to expand its capabilities and support TARDEC’s mission. “The BOR is available for use by any organization within TARDEC that requires its observation and control functions,” DeMinico offered. “Due to the BOR’s large size and powerful audio/video capability, it is also capable of serving as a meeting or conference facility when it is not in use as a lab.”

Matthew Sablan is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Communications team. He has a B.A. in English and history from Marymount University in Arlington, VA.

27


“The planned BOR upgrade

will use a sophisticated

control system that allows

the user to select input data

from multiple sources and

route those inputs to various

destinations, both internal

and external.”

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A crew station operator in the SIL can teleoperate a robot from the BOR. In the future, crew stations will allow remote operation of robots, with the BOR routing data between the operator and assets at external test facilities. (U.S. Army TARDEC photo.)

Vehicles proceed along a test course. Every day, TARDEC engineers and scientists bring remote teleoperation closer to reality through concentrated research and development, modeling and simulation, and a rigorous fi eld test schedule. (U.S. Army TARDEC photo.)

TARDEC-Funded TARDEC-Funded West Point Robotics Lab West Point Robotics Lab Builds Builds FuFuture Engineersture Engineers Patrick PinterPatrick Pinter

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TT he battlefi eld is an ever-changing environment that constantly presents new threats to Soldiers. Developing new innovative technologies to protect Soldiers’ lives is something engineers and scientists are working around the clock to accomplish. To keep Soldiers out of harm’s way, one key area the U.S. Army is focusing its research and development (R&D) resources on is robotics.

West Point cadets show off some of their robotic skills while operating an iRobot PackBot. This lab’s development led to robotic platform integration throughout the electrical engineering curriculum.(U.S. Army TARDEC photos by Patrick Pinter.)

29


Realizing the value of advanc-ing this emerging capability, the U.S. Army has taken an aggres-sive stance in developing robotic technologies. Toward this end, the U.S. Army Tank Automotive Research, Development and En-gineering Center (TARDEC) and the Robotic Systems Joint Project Offi ce (RS JPO) took lead roles in constructing a robotics lab at the U.S. Military Academy (USMA), West Point, NY. “There is a mu-tual operating agreement with RS JPO, which is the acquisition authority for the lab,” explained TARDEC Joint Center for Robot-ics (JCR) Deputy Director Dr.

Greg Hudas. “RS JPO is directly in-volved, too. They provided us with the setup and insights on what they would like this lab to do. RS JPO knows this is necessary. This effort is going to help out in the area of generating future robotic requirements. We want to create future robotic experts here.”

In 2008, TARDEC’s JCR initiated the effort to construct a state-of-the-art, fully instrumented and reconfigurable experimen-tation facility centrally located at USMA so faculty and cadets would have access to a world-class facility. The robotics lab,

funded by the JCR, is a way to increase robotic educational and research opportunities. The lab allows future U.S. Army sci-entists and engineers to become more familiar with robotic sys-tems and to conduct research. “We need cadets to drive these requirements. We want cadets to be aware of the technologies that are out there,” remarked Hudas. “We don’t want them to be shell shocked when they get out and see these platforms for the first time.”

Since the project’s initiation, the USMA Electrical Engineering and Computer Science Department renovated an old small-ballistics laboratory and converted it to a dedicated support facility that contains educational and fi elded

“We want cadets to be aware of the technologies that are out

there. We don’t want them to be shell shocked when they get out

and see these platforms for the first time.” 30

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West Point faculty member Dr. John Rogers shows TARDEC Robotics Systems Manager MAJ Seth Norberg a battery from a small robot his cadets recently completed.

robotic platforms. “A large part of the research done here in robot-ics is in the capstone projects done by the seniors,” commented LTC Robert McTasney, Assistant Professor at USMA. “They use robotic platforms to explore navigation and safety, as well as a number of other topics. Here, with this lab, we are just trying to leverage everybody’s strengths to reach certain goals. A large part of funding is coming from TARDEC, which has allowed us to do some great things here.”

The idea for a dedicated robot-ics lab took shape in 2003 when Army leaders realized that there was a defi nite need to apply more focus to the robotics fi eld. To do that, USMA restructured its electrical engineering major to offer more in-depth courses in robotics, which led to integrating robotic platforms throughout the electrical engineering cur-riculum. “We started thinking

about ways to enhance learning in the robotics fi eld,” commented McTasney. “We were working to

integrate robotics in computer sci-ence and information technology. Once we got things off the ground, cadets were showing that they really liked the robotic programs here. It has been a good vehicle to tie everything in engineering together within a single program.”

Since then, the use of robotics as a common educational platform has increased dramatically. In

2006, USMA established a Co-operative Autonomous Robotics for Military Applications work-ing group consisting of nearly 20 faculty and staff from several academic disciplines interested in robotics research opportunities. That spirit of collaboration in which the lab was begun contin-ues today. “We want to make sure all departments are coordinat-ing with each other and working together. This is systems engi-neering technology,” commented Hudas. “Now that we have this

lab, we want to start funding specifi c ex-periments. We want to bring in original equipment manufacturers and have their platforms integrated into the curriculum. I want them to be working on relevant platforms.”

The Army’s use of robotic systems in Iraq and Afghanistan has demonstrated these systems’ ability to assist Soldiers in a range of missions. Robotic systems pro-duce the capability to conduct reconnais-sance, surveillance and mine mitigation. With continued study and applied R&D in this technology area,

robotics may enable the Army to discover entirely new capabilities.

Patrick Pinter is a Writer/Editor with

BRTRC and provides contract support

to TARDEC’s Strategic Communica-

tions team. He has a B.A. in journalism

and political science from Western

Michigan University.

A cadet operating a robotic controller attempts to pick up a pen with a PackBot’s articulating arm and pincers. The robotic technologies that cadets are using in the laboratory are the same ones that are being used in the field by Soldiers today.

“Now that we have this lab,

we want to start funding

specific experiments. We

want to bring in original

equipment manufacturers and

have their platforms integrated

into the curriculum.”

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POWER AND MOBILITY

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TARDEC Associates ARDEC

Chris Williams

Representatives from two U.S. Army research facilities held a “meeting of the minds” and discussed future collaborative opportunities during a recent tour of the U.S. Army Tank Automotive Research, Development and Engineering Center’s (TARDEC’s) facilities at the Detroit Arsenal, in Warren, MI.

ARDEC representatives visited TARDEC in December 2009 to tour the labs and see the test equipment in operation to gain a better understanding of TARDEC’s R&D capabilities. TARDEC’s Team Leader for Motion Base Technologies Harry Zywiol (left) describes TARDEC’s modeling and simulation capabilities to ARDEC Senior Associate for Future Weapon Concepts and Business Development Mike Zecca (right) in TARDEC’s Ground Vehicle Simulation Laboratory. (U.S. Army TARDEC photos by Elizabeth Carnegie.)

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Three associates from the U.S. Army Armaments Research, Development and Engineering Center (ARDEC) at the Picatinny Arsenal, NJ, visited the Detroit Arsenal. ARDEC Senior Associ-ate, Future Weapon Concepts and Business Development Mike Zec-ca, Program Integrator for Small and Medium Caliber Armaments and Remote Robotic Armaments

Vince Matrisciano and ARDEC’s Enterprise and Systems Integra-tion Center (ESIC) Director COL Scott Flynn toured TARDEC’s facilities and received an up-close look at the organization’s facilities and capabilities.

During the visit, TARDEC associ-ates shared how they are using their expertise to deliver advanced

technology solutions to improve the Nation’s ground vehicle fl eet. The tour highlighted the Detroit Arsenal’s state-of-the-art mod-eling and simulation facilities, including the three-dimensional video and audio Cave Automatic Virtual Environment (CAVE), the Vehicle Inertia Properties Evaluation Rig and Ride Motion Simulator. Engineers from

Display Capabilities to Visitors

TARDEC’s Ground Vehicle Power and Mobility (GVPM) Team highlighted the critical role TAR-DEC is playing in the progression of advanced automotive batteries, hybrid-electric technology and track and suspension. GVPM associates also highlighted the capabilities of TARDEC’s fu-ture Ground Systems Power and Energy Laboratory, which opens its doors in September 2011 with eight state-of-the-art laboratories in one building.

As robotic systems continue to play a crucial role in keeping warfi ghters out of harm’s way, both TARDEC and ARDEC are seeking ways to utilize the

CGVDI engineers and technicians provide systems engineering integration for all of the Army’s combat and tactical ground vehicle fl eets. The CGVDI integrates vehicle technologies that increase battlefi eld survivability and systems performance. ARDEC team members were duly impressed by TARDEC’s unprecedented ground vehicle engineering capabilities and capacity.

From left: Mike Zecca, Vince Matrisciano and TARDEC Team Leader for Lightweight Structures – Survivability Donald Ostberg discuss armor solutions in TARDEC’s CGVDI, formerly the Prototype Integration Facility.

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capabilities of those systems. Associates from TARDEC’s Intelligent Ground Systems (IGS) detailed the work being conducted in their technical areas. The tour also included a visit to TARDEC’s newly formed Center for Ground Vehicle Development and Integration (CGVDI), which merged the capabilities of the Prototype Integration Facility and Ground Vehicle Integration Center to align and expand research and development (R&D) activities and establish a new military nucleus for public-private ground vehicle systems collaborative partnerships. In the CGVDI, ARDEC associates were shown TARDEC-developed auxiliary power units and received a demonstration of how armor is integrated onto a ground vehicle platform.

ARDEC is an internationally acknowledged hub for the

advancement of armaments technology and engineering in-novation. As one of the special-ized research, development and engineering centers within the U.S. Army Materiel Command, ARDEC has the responsibility for meeting this critical demand. ARDEC’s workforce provides life-cycle support for nearly 90 per-cent of the Army’s lethality used every day by the U.S. warfi ghter. Last October, TARDEC Director Dr. Grace M. Bochenek and her ARDEC counterpart Dr. Joseph Lannon hosted a joint panel at the National Defense Industrial Association’s Ground Combat Vehicle Conference, where they emphasized the importance of collaboration between the Army’s Research, Development and Engineering Centers and industry partners.

The ARDEC visitors remarked that the time spent at TARDEC provided an eye-opening look

at the work being done by the organization and opportunities for future collaboration. “During our visit to TARDEC it quickly became apparent that the orga-nization has made great strides in its efforts to further develop core competencies, including new areas such as the robotics team,” remarked Flynn. “I com-mend TARDEC leadership on the outstanding improvements to its facilities and, more impor-tantly, to its renewed operational focus. I am very excited about the tremendous opportunities for ARDEC and TARDEC to expand our collaboration in armaments integration for both manned and unmanned platforms, as well as in systems engineering.”

Chris Williams is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Communica-tions team. He has a B.A. in communi-cation from Wayne State University in Detroit, MI, and has previously written for The Source newspaper in Shelby Township, MI, and The Macomb Daily and C & G Newspapers in Macomb County, MI.

“I am very excited about the tremendous opportunities for

ARDEC and TARDEC to expand our collaboration in armaments

integration for both manned and unmanned platforms, as well

as in systems engineering.”

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Foreground: TARDEC Engineer Jonathan Aboona (left) and TARDEC CGVDI Associate Director Luis Hinojosa (right) give an overview of the work conducted in the CGVDI to (back row, from left): Acting Associate Director for IGS Jeff Jaster, Mike Zecca, Vince Matrisciano and ESIC Director COL Scott Flynn.

From left: ARDEC Program Integrator for Small and Medium Caliber Armaments and Remote Robotic Armaments Vince Ma-trisciano; ARDEC Senior Associate for Future Weapon Concepts and Business Development Mike Zecca; TARDEC GVPM Testing, Evalu-ation and Assessment Team Leader Michael Reid; TARDEC Deputy Associate Director for Platform Mobility Michael Blain; and TARDEC Deputy IGS Associate Director Terry Tierney tour TARDEC’s GVPM test cells.

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Designing a Unique Lab for Advanced Military VehiclesDesigning a Unique Lab for Michael A. Kluger and Felt A. Mounce

A new Army facility will support warfi ghters with next-generation ground vehicles.

A Combat Tactical Vehicle Technology Demonstrator, a test bed for the Joint Light Tactical Vehicle family of vehicles, under-goes testing at the Nevada Automotive Test Center in Carson City, NV. TARDEC’s new GSPEL will support the Army with engineering systems integration for next-generation ground vehicles and equipment. (U.S. Navy photo by John F. Williams.)

The pace at which cutting-edge vehicle technologies are being devel-oped to support warfi ghters’ needs continues to increase dramatically. Vehicles are being designed with experimental engines, alterna-tive fuels, nontraditional power-trains, high-density energy storage capabilities, high-voltage electrical systems, armor plating, high-density electronics and navigational systems

with complexity rivaling that of a fi ghter jet, and sophisticated battle-fi eld communications, command and control.

Evaluating those systems and integrated vehicle platforms requires development, validation and commissioning so they are battle-ready and highly reliable. These qualities are critically im-

portant and extremely challeng-ing to deliver. The challenges are further compounded by the fact that military vehicles are operated at extremely high power levels, must be tested at extreme condi-tions and typically contain new and experimental technologies.

To meet these challenges, the U.S. Army determined it needed a

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Designing a Unique Lab for Advanced Military VehiclesAdvanced Military Vehicles

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one-of-a-kind, fully integrated test facility, the likes of which had not been attempted before. The fi rst step toward creating such a facility, to be located alongside the Army’s existing U.S. Army Tank Automo-tive Research, Development and Engineering Center (TARDEC) laboratories in Warren, MI, was to prepare a specifi cation defi ning the different laboratories and their testing equipment, operational requirements and facility infra-structure requirements.

To create the specifi cation, the Army sought a collaborating research organization that would have:

• A strong vision of where future vehicle technology is headed.

• A broad awareness of current vehicles and drivetrain systems.

• A deep grounding in vehicle and component testing and laboratory test equipment.

• The ability to integrate multiple engineering requirements asso-ciated with mechanical, electri-cal and electronic systems.

• The ability to complete speci-fi cations under a demanding,

rigid schedule to be eligible for congressional funding.

Ground Systems Power and Energy Laboratory (GSPEL)The new GSPEL is expected to require two years to construct and will become operational by Sep-tember 2011. The Army engaged Southwest Research Institute (SwRI), which has been involved with advanced and unique engine, vehicle and emissions research laboratories over many years, as a consultant to rapidly provide engineering support services for GSPEL.

The Army had a concept in mind but sought out SwRI to develop the demanding equipment and

facility specifi cations necessary to embody the centralized, state-of-the-art facility containing eight engineering laboratories. The goal was to create a facility to evalu-ate light transport, such as High Mobility Multipurpose Wheeled Vehicles (HMMWVs), to heavy combat vehicles, such as military tanks with hybrid-electric (HE) and fuel cell confi gurations, and to evaluate components, such as engines, transmissions, axles, electric motors, batteries, ul-tracapacitors, engine auxiliary systems, air fi lters, radiators and heat exchangers. To develop the specifi cations, SwRI assembled a team of 31 engineers with a wide variety of backgrounds.

For more than six decades, SwRI has operated the Army-owned TARDEC Fuels and Lubricants Research Laboratory on the SwRI grounds in San Antonio, TX. TARDEC Ground Vehicle Power and Mobility operates its primary facility at the Detroit Arsenal in Warren, MI, where engines and vehicles are evaluated on dyna-mometers under extreme envi-ronmental conditions.

The team, drawn from SwRI’s automotive engineering divisions, began by consulting with TARDEC engineers to gain an understand-ing of the vision for the laboratory, conceptualizing many options and eventually arriving at a preferred solution for each of the laborato-ries. Estimates of electrical, water,

SwRI provided this artist’s rendering of TARDEC’s GSPEL. The specifi cation for the GSPEL facility contains a number of unique components, including this environmental chamber with wind and solar simulators (orange, at center). (Image courtesy of SwRI.)

The goal was to create a facility to evaluate light transport,

such as HMMWVs, to heavy combat vehicles, such as military

tanks with HE and fuel cell configurations, and to evaluate

components, such as engines, transmissions, axles, electric

motors, batteries, ultracapacitors, engine auxiliary systems, air

filters, radiators and heat exchangers.

steam and gas utility requirements were developed for the overall building specifi cation. Detailed projections based on expected utilization, equipment and discus-sions with TARDEC engineers re-vealed opportunities for effi ciency gains as the team created a set of facility requirements. The require-ments were provided to the U.S. Army Corps of Engineers to aid in the preparation of a bid request.

Green Laboratory MandateBeyond the effi ciency gains that would be expected from a new laboratory, the Army today mandates that all new construc-tion be certifi ed under the “Silver” category of the U.S. Green Build-ing Council’s Leadership in En-ergy and Environmental Design (LEED) Green Building Rating System. LEED is a third-party cer-tifi cation program that encour-ages sustainable “green” build-ing and development practices through universally accepted tools

and performance criteria. Further-more, GSPEL will help expedite the integration of state-of-the-art HE and fuel cell technologies into advanced military vehicles to reduce fuel consumption, improve overall vehicle operation and em-ploy the most effi cient use of energy sources.

The new laboratory design ex-pands the Army’s technological thrust into cutting-edge power and energy management technol-ogy. The proposed facility will have labs and offi ces and related spaces for a staff of more than 60. Laboratories are provided for vehicle environment, power, elec-

trical power architecture systems integration, electric components, pulse power and directed energy, thermal fl uids, fuel cells and air fl ow fi ltration. Taken as a whole, the laboratory will be able to ex-amine various vehicle systems as well as the entire vehicle.

Some of the selected equipment features include:

• Eleven alternate current electri-cally regenerative dynamom-eters with ratings from 2,500 foot-pounds (ft-lb) of torque and 14,000 revolutions per minute (rpm), up to 26,500 ft-lb and 1,000 rpm.

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The team, drawn from SwRI’s automotive engineering divisions,

began by consulting with TARDEC engineers to gain an

understanding of the vision for the laboratory, conceptualizing

many options and eventually arriving at a preferred solution for

each of the laboratories.

M1151 up-armored HMMWVs sit inside the 1st Battalion, 401st Army Field Support Brigade vehicle maintenance facility at Camp As Sayliyah, Qatar, Oct. 10, 2009. The state-of-the-art GSPEL will contain eight engineering laboratories to create a facility to evaluate light transport, such as HMMWVs. (U.S. Army photo by Dustin Senger.)

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• A full-size vehicle chamber with environmental controls for temperature, humidity

and solar simulation.• Seven environmental chambers.• Three extremely high-voltage

and current power supplies.• One of the world’s largest calo-

rimeters for testing radiators, engine coolers and transmis-sion coolers.

• Four air fi lter test stands of various sizes with combined

dust media insertion.• Four fuel cell test stands.

The design team projected the facility’s electrical usage over 30 years, based on various dyna-mometer operating schedules, environmental chamber thermal cycles, power supply duty cycles, calorimeter test procedures and air fi ltration testing requirements. The projected electrical service was determined to be 4.7 megawatts

with yearly power consumption of more than 2 million kilowatt-hours. Cooling water needs were projected at 2,500 gallons per month. Power supplies to the facility will be rated to 800 volts direct current and 1,000 amps. The environmental air han-dling system will be able to fl ow 175,000 cubic feet per minute with 90 tons of heating and cool-ing to control air temperature and humidity.

Meeting LEED certifi cation stan-dards for such a facility is extremely challenging. Therefore, the SwRI engineering team created methods for quantifying LEED improve-ments, enhancements and solu-tions and for exploring multiple equipment- and energy-related issues. Some of those issues involved different dynamometer operating power scenarios during electrical motoring and regenerative operat-ing modes; dynamometer energy recovery; electrical motor operation in off-peak conditions; and preci-sion power supply charge-discharge cycles. For each lab within the facil-ity, the dominant energy-consum-ing or energy-producing items were selected for individual study. For example, dynamometer effi ciency was studied at various partial-load conditions to produce accurate electrical consumption estimates for the facility.

The authors stand behind a scale mock-up of TARDEC’s GSPEL. Felt A. Mounce (left) assisted with the specifi cation design, build and installation of dynamometer test stands. Michael A. Kluger leads SwRI’s effort for automotive-related test stand development for applications with high-power and high-speed requirements. (Photo courtesy of SwRI.)

GSPEL will help expedite the

integration of state-of-the-art

HE and fuel cell technologies

into advanced military

vehicles to reduce fuel

consumption, improve overall

vehicle operation and employ

the most efficient use of

energy sources.

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Broad-Based Design CapabilitiesThe creation of a specifi cation for a facility as broad and far-reach-ing as the GSPEL was an extremely challenging task. The GSPEL facility requires equipment to work at levels that are unprec-edented in today’s engineering laboratories and, in many cases, will represent the largest such capabilities in the world. Satisfy-ing such capabilities is a require-ment to allow for testing of future military vehicles that will have performance well beyond that of current vehicles. The SwRI team was able to help the Army defi ne, and then integrate, a wide range of laboratories and equipment into a single facility that will allow vehicle testing and development across demanding test conditions and in dramatically reduced time. This, in turn, will allow the Army to continue the development of future generations of military vehicles, integrating current and alternative vehicle propulsion, power generation, energy storage, power management and control systems for current and emerg-ing classes of vehicles that are both wheeled and tracked, and manned and unmanned.

The SwRI team defi ned and prepared this specifi cation using its broad experience in testing engines, transmissions, axles, elec-trical power components and ve-hicles over the past 60 years. This experience has been enhanced with real-world knowledge based on operating more than 240 dynamometers at its San Antonio facility, which is believed to be the largest dynamometer grouping of its kind in the world. In addition, much of this testing is extremely challenging, as it involves the next generation of powertrain components and vehicles that typically incorporate advanced

technologies. Testing these types of components requires the use of intensive engineering to pro-vide creative and innovative approaches and solutions, whether by modifying existing testing equipment or fabricating custom equipment.

GSPEL specifi cation develop-ment involved the generation and integration of massive amounts of information associated with extremely high-power electrical equipment, high-speed rotating equipment, very high voltage and amperage levels, extreme heating and cooling, humidity control, and massive airfl ow. Comple-menting this equipment was an extensive suite of instrumentation for measuring torques, speeds, pressures, fl ows and temperatures.

Acting as the client’s advocate by creating test stand and test facility specifi cations is a long-standing service that SwRI has provided for more than 30 years. By its very nature, it is a challenging and de-manding discipline because of the breadth of technologies and oper-ating conditions that engineering testing involves. Because of the many types of components SwRI is involved with on a daily basis, it provides such specifi cations and test stands for applications involv-ing the next generation of heavy lift helicopter gearboxes, subma-rine propulsion systems, advanced engines used in military vehicles, drilling motors used in oil rigs, transmissions used in 18-wheel trucks and precision hydraulics used in high-pressure applications.

The document SwRI prepared was integrated into a request for proposal by the Army and adver-tised for a design-build contract to construct the GSPEL labora-tory. Multiple bids were received and were reviewed to determine if they met the specifi ed facility and equipment requirements. A construction contract was award-ed by the Corps of Engineers and construction has already begun.

Editor’s Note: This article was previously published in the Spring 2009 issue of Technol-ogy Today. The article is reprinted with the authors’ permission and has been edited for style and to bring the content up to date.

Michael A. Kluger is a Senior Program Manager in the Fuels and Lubricants Research Division at SwRI, where he leads the organization’s efforts for automotive-related test stand develop-ment, with an emphasis on unique and novel test stands for applications requiring high-power and high-speed requirements. Kluger holds a B.S. in mechanical engineering from Arizona State University, and he is a Registered Professional Engineer, State of Arizona.

Felt A. Mounce is a Research Engineer in the Fuels and Lubricants Research Division at SwRI, where he supports the development of broad-based, inte-grated test stand fabrication and facility specifi cations involving the integration of mechanical, electrical and electronic components and systems. Mounce holds a B.S. in mechanical engineering from New Mexico State University and is a member of the American Society of Mechanical Engineers and Society of Automotive Engineers.

The SwRI team was able to help the Army define, and then integrate, a

wide range of laboratories and equipment into a single facility that will

allow vehicle testing and development across demanding test conditions

and in dramatically reduced time.

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Fueling Development for Fueling Development for Future Force Vehicles — TARDEC’s Fuels and TARDEC’s Fuels and Lub ricants Laboratories Provide Leading-Edge R&D

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A History of Innovations: The TARDEC Fuels and Lubricants Research Facility (TFLRF) supports battlefi eld fuel and lubricant needs for the Army and the other services. Its unique location draws on Southwest Research Institute’s (SwRI’s) interdisciplinary approach to problem solving among its 11 on-campus technical divisions. (U.S. Army TARDEC image courtesy of the TFLRF.)


Fueling Development for Future Force Vehicles — Future Force Vehicles — LubTARDEC’s Fuels and Lub ricants Laboratories ricants Laboratories

Provide Leading-Edge R&DProvide Leading-Edge R&D

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Matthew Sablan

The Crossroad for Fuels and Lubricants Research and Development (R&D)The TFLRF occupies more than

29,000 square feet on fi ve acres of

land. The facilities are government-

owned and contractor-operated,

and SwRI itself is an independent,

nonprofi t applied R&D organization.

SwRI’s grounds place the laboratory

in a “hub and crossroads of fuels

and lubricants research,” stated Steve

Marty, TFLRF Director. “SwRI is the

largest independent, nonprofi t fuels

and lubricants lab in the world.” The

work done here considers all aspects

that impact the performance of pow-

ertrain products.

Various technologies all impact the

automotive engine — combustion,

lubricant composition, fuel composi-

tion and hardware design all must be

considered. Changes in any of these

can impact other areas, and having a

facilities hub collocated with all these

technical areas together is a signifi -

cant benefi t for the Army. SwRI’s

location and expertise in these techni-

cal areas are available at one location,

not spread across the country. Better

still, the lab is dedicated to Army work.

The commercial laboratories sur-

rounding the TFLRF allow TARDEC

to work in an R&D complex focused

solely on relevant projects. Facil-

ity personnel have instant access to

a variety of experts in automotive

and other technology areas to ad-

dress unique problems. TARDEC can

access these experts and correspond-

ing data as soon as they are needed

using a variety of means. “Being in the

middle of this complex lets us lever-

age world-renowned people to solve

problems,” Marty explained. “We have

access to resources that just wouldn’t

be available elsewhere. Sometimes, if

we’re having a problem, rather than

hunt down a Ph.D. across the country,

I can go fi nd, or bump into, the needed

expert at the cafeteria.”

“SwRI is the largest

independent, nonprofit fuels and

lubricants lab in the world.”

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After World War II, the Army noted fuels and lubricant problems that occurred in vehicles operating in harsh environments. To fi nd solutions to these engineering problems, the Army established the Army Fuels and Lubricants Laboratories on May 9, 1957. Over the years, the lab has evolved into a world-class research facility with a much-expanded mission. Now known as the U.S.

Army Tank Automotive Research, Development and Engineering Center (TARDEC) Fuels and Lubricants Research Facility (TFLRF), it is located on the Southwest Research Institute (SwRI) campus in San Antonio, TX. The SwRI location was already well-established with well-known experts in the automotive and fuels and lubricants areas, so it was an obvious choice for the Army to move its research, development and testing focus to the facility. Today, the TFLRF offers unprecedented synergy that brings unique strengths to TARDEC.

An SwRI associate conducts an experiment. SwRI has established subject-matter experts (SMEs) in the automotive and fuels and lubricants areas, and their resources and facilities provide numerous opportunities for TARDEC to leverage their expertise. (U.S. Army TARDEC photo by Bill Dowell.)

State-of-the-art equipment is available from SwRI for TARDEC’s use. The equipment pictured here — combined with SwRI SME expertise — gives TARDEC unparalleled access to fuels and lubricants knowledge and test results. (U.S. Army TARDEC photo by Bill Dowell.)

Conducting One-of-a-Kind TestingThe TFLRF’s mission is to support the Current Force’s vehicle fl eet. However, the lab keeps an eye to the future. The future mission involves being able to move away from conventional fuels and lubricants, while making sure that new and current vehicles can use the newly developed fuels, lubricants and synthetics fuels. By keeping the new technologies backwards-compati-ble, the laboratory can prepare the way for Future Force vehicles while fulfi lling its Current Force mission. Additionally, SwRI assists TAR-DEC’s National Automotive Center with hybridization and alternative fuel research.

To accomplish the mission, the

laboratory makes use of vari-

ous capabilities and equipment.

Alongside the facility’s engine test

cells is the combustor facility, which

simulates the fi rst stage of a jet tur-

bine. It generates high temperatures

and airfl ow, making the facility able

to conduct tests that are impossible

elsewhere, such as fuel nozzle fouling

tests. The laboratory's on-grounds

ballistics test site allows SwRI to test

whether fuels or other technologies

can withstand specifi c threats. Unique

air and liquid fi ltration systems and

fog-producing effects round out the

facility’s equipment.

The TFLRF, alongside TARDEC’s

Fuels and Lubricants Technology

Team, is currently researching the

Single Common Powertrain Lu-

bricant (SCPL). SCPL will work in

engines and replace other vehicle

lubricants as well. “Think logistics,”

Marty explained. “If this one lubri-

cant works in engines and gears, then

we can reduce supply chains. But,

think further. Wouldn’t it be neat

if it worked in the Arctic and the

desert?” A product that can tolerate

these extremes without requiring an

oil change will enhance posture and

readiness. The SCPL would also allow

the Army to reduce costs, as the SCPL

would be using a synthetic and less

viscous base stock that will, ultimate-

ly, reduce fuel consumption.

Marty sees the laboratories as “a

TARDEC facility, but also a Depart-

ment of Defense support facility for

fuels and lubricants.” The Air Force,

Navy, Marine Corps and Coast Guard

also have run projects through the

laboratories. Additionally, the facility

can assist in commercial work when

assets are not required for military

research. “This lets the facility see

activity on both sides of the fence,”

Marty stated. “This is only possible

because of our location.”

The Army has always been a driving

force behind commercial fuels and

lubricants, often initiating the gold

standard for lubricants’ performance

in the most challenging operational

environments. “If you go into [a mar-

ket] and buy a quart of engine oil, the

technology used in it was at one point

a military standard,” Marty remarked.

The TFLRF at SwRI continues to

provide valuable R&D unobtain-

able from any other location in the

world. As they have for more than 50

years, these labs continue support-

ing TARDEC’s mission, providing

cutting-edge research for supporting

America’s current and future tactical

and combat ground vehicle fl eets.

Matthew Sablan is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Com-munications team. He has a B.A. in English and history from Marymount University in Arlington, VA.

“Being in the middle of this

complex lets us leverage world-

renowned people to solve

problems. We have access to

resources that just wouldn’t be

available elsewhere.”

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Soldiers from 1st Battalion, 401st Army Field Support Brigade, test drive a Stryker medical evacuation variant on a test track outside the Stryker battle damage repair facility at Camp As Sayliyah, Qatar, Sept. 21, 2009. Research at SwRI ensures that the Soldiers mounted in Strykers and other vehicles have more fuel-efficient and safer tactical vehicle platforms. (U.S. Army photo by Dustin Senger.)

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Located at the Detroit Arsenal in Warren, MI, the U.S. Army Tank Automotive Research, Develop-ment and Engineering Center’s (TARDEC’s) Electrochemical Analysis and Research Labora-tory (EARL) exists to increase the Army’s understanding of advanced batteries and how they can be in-tegrated into GVS. The laboratory selects research and development undertaken by Army engineers and industry partners and applies it to Army technologies.

Understanding CapabilitiesTARDEC’s Energy Storage Team works with partners in industry and academia to develop advanced batteries for Army ground vehicles. The EARL’s major function is to

understand the battery cell capa-bilities and modules provided by those partners and determine how they can be integrated into vehicle systems. “Part of our job is to per-form the screening process on these cells and batteries to say, ‘Yes, that’s good,’ or, ‘Let’s not pursue that any further.’ Typically we perform a series of characterization tests, where we make sure the battery or cells operate to the manufacturer’s claims,” explained TARDEC Battery Test Engineer Ted Olszanski.

The team works with a variety of chemistries and battery types, in-cluding lithium ion (Li-ion), which lasts longer, weighs less and has greater energy and power densities, than standard lead acid batteries.

The team also is exploring vari-ous Li chemistries and nickel-zinc (Ni-Zn) batteries. “In the advanced Li-ion area, we’re evaluating dif-ferent batteries that will provide higher energy and higher power capability,” Olszanski stated. “We’re also looking at Ni-Zn as a poten-tial backup, which is a low-cost, water-based electrolyte system. We are also continuing to research advanced lead acid systems.”

Testing Equipment The TARDEC laboratory utilizes various programmable cyclers to test batteries, which allow characterization of the units

As the U.S. Army and its partners pursue new developments in alternative energy, advanced energy storage systems have become a crucial focus area for improving fuel effi -ciency and providing improved power to vehicle systems. With the addition of new electronic equipment leading to increased power requirements and the Army continuing

its pursuit of "silent watch" capabilities, advanced batteries have become a critical tool in powering the Army’s current and future ground vehicle systems (GVS).

EARL Runs Batteries Through Paces

Chris Williams

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A TARDEC engineer tests a Li-ion battery module. Lithium chemistry batteries provide higher energy and longer life cycles than lead acid batteries. (U.S. Army TARDEC photo courtesy of Ted Olszanski.)

The Advanced Reconfi gurable Spaceframe (AReS) combat vehicle features a hybrid-electric propulsion system integrated into an advanced space frame hull structure. Work conducted in TARDEC’s advanced battery lab-oratories is dedicated to improving the power and capabilities of advanced power storage systems to power hybrid-electric vehicles like the AReS. (U.S. Army TARDEC photo.)

under various operational and environmental conditions. Associates also measure resistance and power through a Hybrid Pulse Power Characterization test. “This allows us to characterize the resistance and the power at various states of charge,” Olszanski stated. “Ultimately, we’ll be doing life-cycle testing to see how long these cells last and what their fade characteristics are.”

The team utilizes an impedance spectrometer to measure a cell’s im-pedance at various frequencies. The tool allows TARDEC researchers to understand how one cell performs when compared to another, the effect of current collection and the way it is manufactured. “It’s a diag-nostic tool,” Olszanski clarifi ed. “It’s used for identifying areas that need to be improved or improvements that someone may have made as they provide us with different types of cells. Impedance and resistance help us determine how much power a cell will provide.”

Environmental conditions can im-pact the amount of power batteries can provide. To better understand how cells and modules are affected by environmental changes, char-acterization tests are conducted at room temperature, as well as at high- and low-temperature extremes. “At lower temperatures the batteries do not provide as high a capacity, and at some point they won’t operate,” Olszanski illustrat-ed. “Below -25 degrees Fahrenheit seems to be the critical number where we know we need to improve upon and develop a thermal man-

agement system. It’s harder for the battery to actually give up or accept energy at lower temperatures. In the high-temperature range, how-ever, the batteries wear out faster and yield less energy over time, giving them a lower cycle life.”

The Call for More Power As the demand for increased bat-tery capability grows, TARDEC’s Energy Storage Team faces a num-ber of challenges. New technol-ogy drives up energy demands on vehicles and takes up space, leaving engineers with the task of develop-ing batteries with greater energy and power densities. “We’re trying to hit a moving target in terms of what the power and energy require-ments are because it keeps moving in an upward direction,” Olszanski revealed. “There’s never enough available power, energy or space on a vehicle.”

The team is currently studying the application of advanced batteries in electric and hybrid-electric-powered vehicles. More impor-tantly, however, is the capability advanced batteries may provide in powering vehicle equipment and providing Soldiers with silent watch capabilities, a must-have on the battlefi eld. “The push is to provide more power to the Army’s ground vehicles,” Olszanski emphasized. “Batter-ies are needed to provide power, especially in silent watch or

starting, lighting and ignition applications.”

The EARL is currently located intwo buildings at the Detroit Arse-nal, and both laboratories will be incorporated into the new Ground Systems Power and Energy Labora-tory (GSPEL), which celebrated its groundbreaking at the Detroit Arsenal in August 2009. The GSPEL location will provide greater testing capabilities, including the ability to test the actual battery packs that are used to power vehicles. “Right now, we’re testing cells and modules, but modules are what ultimately get put onto a battery pack, and the battery pack is what ultimately goes on a vehicle. So we’re moving toward increasing the capability of the lab to test battery packs,” Olszanski remarked. “Within the GSPEL, we will be able to test cells, battery modules and battery packs, which can provide 300–600 volts.”

The Army’s fl eet of ground vehicle’s energy and power needs continue to grow in order to allow Soldiers to safely and effi ciently complete mis-sions in the fi eld and keep the fl eet moving. With the addition of the new GSPEL facility and its ability to allow testing of larger batteries safe-ly, along with the existing EARL, the TARDEC Energy Storage team will be capable of performing research, development and testing of batteries up to pack size and thus help meet the many energy challenges facing today’s Army vehicle fl eet.

Chris Williams is a Writer/Editor with


to TARDEC’s Strategic Communications

team. He has a B.A. in communication

from Wayne State University in Detroit,

MI, and has previously written for The

Source newspaper in Shelby Township,

MI, and The Macomb Daily and C & G

Newspapers in Macomb County, MI.49


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“Part of our job is to perform

the screening process on these

cells and batteries to say, ‘Yes,

that’s good,’ or, ‘Let’s not pursue

that any further.’”

A TARDEC engineer conducts tests on a battery module. TARDEC’s Power Storage Team conducts several tests to understand advanced battery characteristics, capabilities and life cycle duration. (U.S. Army TARDEC photo courtesy of Ted Olszanski.)

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TARDEC Engineers Advance Technology and Systems

Increased fuel effi ciency requirements and power demands have made HE power an integral component for developing the Army’s future ground vehicle fl eet. TARDEC, as the Army’s ground vehicle systems integrator, tests HE components and systems for future implementation on a range of wheeled and tracked vehicles using the HE Reconfi gurable Movable Integration Test (HERMIT) bed. (U.S. Army TARDEC photos provided by Ghassan Khalil.)

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Hybrid-Electric (HE) In tegration

Chris Williams

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As automakers face new fuel-effi ciency requirements and the U.S. Army develops new ways to power vehicles, the role of HE vehicles (HEVs) has become more prominent. To further the Army’s development of HE technology, the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC) operates two laboratories that specialize in devel-

oping, testing and optimizing HE systems.

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Electric Component Evalua-tion Laboratory (ECEL)The Army’s demonstrator HEVs require advancing some enabling electrical component technolo-gies for the vehicles to meet their performance objectives. Located at the Detroit Arsenal in Warren, MI, TARDEC’s ECEL technicians and engineers test and verify the performance of new HE compo-nent concepts for acceptable and safe operation.

“It’s a very important capability to have because there are some technical challenges that need to be resolved before we can imple-ment HE technologies,” explained Ghassan Khalil, TARDEC HE Team Leader. “We have to mature the technology, and we do that through testing and evaluation and further development at the system level.”

The ECEL includes capabilities to test all electrical components that make up an HE system, including electric motors and their controllers, power condi-tioning converters and advanced batteries. An alternating cur-

rent dynamometer is used to test motors and generators up to 350 kilowatts to provide an understanding of the test items’ power, torque, efficiency and thermal management.

The laboratory provides TARDEC associates with the ability to understand electric component capabilities prior to integrating them into a system, a crucial fac-tor in developing vehicle systems. “The importance is to verify the component’s predicted and advertised performance,” stated Khalil. “When you buy a machine, it comes with certain ratings re-lated to torque, power, speed and an advertised effi ciency. Effi ciency varies with speed, load, power and torque, and we need to verify that these ratings are correct and

then characterize the machine by measuring its effi ciency at several points to create an effi ciency map.”

Power and Energy (P&E) Systems Integration Laboratory (SIL) Once electrical components have been tested on their own, they must be evaluated as part of an integrated system. TARDEC’s P&E SIL, initially located in Santa Clara, CA, now has a large por-tion of the facility’s equipment moved to TARDEC. This allows on-site researchers to understand how a component’s capabilities are affected when it is connected to a system. “Even though we test individual components and understand their performance, we need to gain an understanding of how they behave when they are integrated together,” remarked Khalil. “How are they connected together, how does one system affect another system, what’s their burden for integration purposes, how many cooling circuits will they require and what are the different temperatures that need to be maintained for each com-ponent? All of these things are

“Even though we test individual

components and understand

their performance, we need to

gain an understanding of how

they behave when they are

integrated together.”

The HERMIT is a critical tool in TARDEC’s Hybrid P&E labs. Recently moved to the Detroit Arsenal in Warren, MI, from Santa Clara, CA, the HERMIT provides engineers with the capability to test integrated systems on a vehicle platform.

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extremely critical before com-ponents are integrated into the vehicle, and the SIL gives us the capability to understand those issues,” Khalil explained.

A component’s performance can be drastically affected when it’s connected to another compo-nent. A motor may operate at 97-percent effi ciency on its own, but that effi ciency will decrease when controllers, fans or other components are attached to it. The work conducted in the P&E SIL allows TARDEC engineers to connect the components together in one room and understand the system’s performance capabilities, allowing them to discover problems and challenges before the system is integrated into a vehicle for fu-ture fi elding. The measurements gained through testing in the SIL rapidly and cost-effectively validate and transition advanced electrical technology to a ve-hicle and provide a cost-effective means to develop and evaluate

a combat vehicle architecture’s effectiveness. “When you test these components as part of an integrated system, things start appearing,” Khalil revealed. “You may learn that a component works fi ne by itself, but there’s an issue when it’s combined with other components. The SIL allows us to discover and fi x these issues before the vehicle is fi elded, when it would be too late.”

One key P&E SIL test tool is the HE Reconfi gurable Movable Inte-gration Test bed (HERMIT). The HERMIT provides engineers with the capability to test the integrat-ed systems on a vehicle platform. The HERMIT allows TARDEC associates to understand how the system performs when compo-nents are connected under the

constraints of a system, where electrical interference and space and weight restrictions may affect the system’s overall capabilities.

“The idea is to see how tight the space is going to be when you put all these components to-gether and see if you have enough space available for what you have designed,” Khalil noted. “There are many constraints in integrat-ing a vehicle, and you never know how a system reacts to those constraints until you package the different subsystems into the vehicle platform. The SIL can operate without a vehicle plat-form because we can put different components in different places and fi ll up an entire room. With the HERMIT, we bring them all into this small space to gain an understanding of how they all work together,” Khalil concluded.

Chris Williams is a Writer/Editor with


to TARDEC’s Strategic Communications

team. He has a B.A. in communication

from Wayne State University in Detroit,

MI, and has previously written for The

Source newspaper in Shelby Township,

MI, and The Macomb Daily and C & G

Newspapers in Macomb County, MI.

The HERMIT can be reconfi gured to allow for the placement of systems through-out the platform, allowing engineers to test integrated systems for any vehicle.

“There are many constraints in

integrating a vehicle,

and you never know how

a system reacts to those

constraints until you package

the different subsystems into

the vehicle platform.”

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Fueling Station and Fueling Station and Maintenance Facility Keep Maintenance Facility Keep

Hydrogen Vehicles PoweredHydrogen Vehicles PoweredChris Williams

As the U.S. Army pursues advancements in alternative energy, hydrogen has proven to be a potentially viable fuel source for many smaller ground vehicles. As the Nation’s energy security hub, the U.S. Army Tank Automotive Research, Development and Engineering Cen-

ter’s (TARDEC’s) National Automotive Center (NAC) oversees two facilities that support the Army’s fl eet of hydrogen-powered vehicles.

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Hydrogen Fueling Station One challenge to the acceptance of hydrogen-powered ground vehicles is the lack of a robust infrastructure for fueling those systems. The Hydrogen Fuel-ing Station, located at the Self-ridge Air National Guard Base (SANGB), MI, provides a location for that task and serves as an ex-ample to the automotive industry

as it works to create a nationwide fueling infrastructure for hydro-gen vehicles. “We’ve had a couple of different offi cials from the auto industry come out here recently to take a look,” stated Steven Eick, a TARDEC hydrogen projects engineer. “They were looking not just at the station, but at how alternative energy as a whole fi ts into a military base.”

The station’s dispenser, which is designed after a basic gasoline pump, uses a specialized locking mechanism to ensure that neither the vehicle nor station will suffer leaks during fueling. Designed in accordance with the California Fuel Cells Partnership (CFCP) designs, the nozzle also features a data connection between the vehicle and dispenser that

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The sports utility vehicle, seen here at the 2009 Memorial Day Parade in Dearborn, MI, was developed by TARDEC’s NAC in partnership with outside organizations. The vehicle is one of 10 converted hybrid-electric sports utility vehicles to operate on compressed hydrogen. (U.S. Army TARDEC photos by Chris Williams.)

monitors tank size, temperature and pressure, factors essential to an accurate fi lling. “When you’re dealing with gaseous fuels, you have to be a lot more careful about temperature and pressure because it relates to how much volume

and mass you get,” Eick explained. “With liquid fuels like gasoline, it doesn’t vary that much — you heat it up, and it expands just a lit-tle bit. If you heat up a little bit of hydrogen, it drastically increases the pressure and adds additional

strain. The reason you want that communication between the ve-hicle and station is to adequately control that relationship between temperature, pressure and volume during refueling.”

In partnership with Chevron, the facility formerly generated its own hydrogen using a steam natural gas reformer. The part-nership is currently in the fi nal stages, with the reformer in the

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TARDEC’s Hydrogen Fueling Station, located at SANGB, provides a location to fuel the Army’s growing fl eet of hydrogen-powered ground vehicles.

“They put together an organization for vehicle

manufacturers, gasoline retailers and energy retailers and

developed a protocol that would fit with both groups and

said, ‘This is what we’re going to do.’”

process of being removed. “It was a steam-methane reformation process. It takes steam and natu-ral gas and breaks the natural gas down into carbon dioxide and hy-drogen. From there, the hydrogen is separated out, compressed and then put into storage banks,” re-vealed Eick. “Now when we need hydrogen, we have a hydrogen company deliver a full tube trailer and use the same compressor to back feed into the tanks. When it starts to get low, we order another tube trailer.”

By adhering to CFCP standards, the station serves as a model for how consumers may eventually fuel their own hydrogen-powered vehicles. Under the partnership’s standards, similar dispensers would be used throughout the country, ensuring a common infrastructure for refueling hy-drogen vehicles. “California was the forerunner with hydrogen in terms of infrastructure and refueling,” Eick remarked. “They put together an organization for vehicle manufacturers, gasoline retailers and energy retailers and developed a protocol that would fi t with the groups and said, ‘This is what we’re going to do.’ As other states start to develop a hydrogen capability, they will likely follow the same protocols. The benefi t is that you have the standardization in place to help companies work together instead of fi ghting.”

Hydrogen Maintenance FacilityThe Hydrogen Maintenance Fa-cility, also located at SANGB, of-fers a safe, state-of-the-art facility for repairing the Army’s fl eet of

hydrogen ground vehicles. While much of the work conducted on the vehicles is similar to work done on conventionally powered systems, the high pressures and sensitive nature of working with hydrogen require specialized precautions to prevent potentially dangerous leaks. The facility, which meets all federal, state and local requirements for conduct-ing maintenance on hydrogen vehicles, is equipped with hydro-gen and fl ame detectors that will sound an alarm and evacuate the gasses in the event of a leak. “The main danger comes from han-dling high-pressure gasses,” Eick expounded. “The hydrogen itself is actually no more dangerous than gasoline, but the fact that it’s at very high pressures makes it a little more diffi cult. It’s like deal-ing with a high-pressure propane tank or a compressed natural gas tank, where the high pressure has to be handled in a specifi c way because any weakness in the sys-tem can cause a leak. The systems are designed to withstand and avoid problems like that.”

Currently, contractual obligations require that the hydrogen vehicles be maintained by vehicle manufac-turers. In the future, Eick believes that TARDEC associates will be more involved in hydrogen vehicle maintenance as their knowledge of the systems increases and that the presence of manufacturers on the base provides the opportunity for a strong working relationship between the Army and its industry partners. “It benefi ts them because they get the hands-on experience of fi xing problems and dealing with user problems,” he stated.

“It helps us in the sense that we know what problems to look for or design to in the future if we want to do a beta version or second prototype. It benefi ts us, and it benefi ts the auto industry because they know, based on our research, what to do, what changes to make and how to make this move even closer to commercialization, which is their end goal.”

Hydrogen’s FutureHydrogen vehicles are still rela-tively new to the Army. Only a handful of bases currently have hy-drogen fueling stations, and most are still considered demonstrators. Only a few vehicles, such as the Ford Escape Internal Combus-tion Engine (ICE) and hydrogen-powered forklifts, are currently on the bases, although Eick believes the technology will increase in the future. “I think it’s a viable source because the vehicles are centrally fueled and have well-known usage profi les,” he acknowledged. “The earliest implementation areas right now, that I see, are basically fork-lifts and tow tractors, because the power required for them is a lot less than a standard vehicle. Their speeds are lower, their weights are lower and the fl eet is isolated to one location. Even though they’re lifting and towing, they don’t require an 80-kilowatt (kW) fuel cell to do it. They need, maybe, a 15-kW cell, and that decreases fuel costs, which makes it a lot easier to implement,” Eick concluded.

Chris Williams is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Communications team. He has a B.A. in communication from Wayne State University in Detroit, MI, and has previously written for The Source newspaper in Shelby Township, MI, and The Macomb Daily and C & G Newspapers in Macomb County, MI.

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“The earliest implementation areas right now that I see are

basically forklifts and tow tractors, because the power required

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Isolating the Phenomenon The laboratory features a state-of-the-art, high-output, single-cylinder research engine that provides researchers with the capability of isolating engine combustion, allowing them to gain greater insight through low-speed and high-speed parameter measure-ments that evaluate overall engine performance and in-cylinder combustion behavior. “We have measurements that you wouldn’t fi nd when we set up a multi-cylinder engine,” explained

TARDEC Senior Research Engineer Dr. Peter Schihl. “For ex-ample, we measure the in-cylinder pressure, which we normally don’t do when we test a multicylinder engine. We measure what’s go-ing on with the injection system precisely — measurements that you wouldn’t fi nd in production. This allows us to really study the combustion event in an engine.”

The research engine has been modifi ed with a fl exible prototype injection system and an associated

fl exible engine controller. Engi-neers control the entire testing process, including fuel rate, en-gine operating condition, coolant system and oil system. “Every-thing is controlled precisely on that engine,” Schihl remarked. “We take measurements that allow us to indirectly measure what’s going on in the cylinder with the combustion event and thus the fuel spray.”

Studying Combustion BehaviorCurrently, the laboratory is being used to test a variety of poten-tial military alternative fuels to understand how they impact engine systems. The process for such testing begins with gather-ing a baseline, in which North American diesel fuel is run at several different operating points through the engine, which is

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Optimized Combustion and Fuels Optimized Combustion and Fuels Focus of Single CFocus of Single Cylinylinder Test Cellder Test Cell

Chris Williams

Engine combustion is a complex phenomenon. Understand-ing it is crucial to effectively and effi ciently powering the U.S. Army’s fl eet of ground vehicles. The U.S. Army Tank Automotive Research, Development and Engineering Center’s (TARDEC’s) Single Cylinder Test Cell and Evaluation Laboratory, located at the Detroit Arsenal in Warren, MI, is dedicated to studying com-

bustion phenomena and increasing the Army’s understanding of how various factors may affect vehicle engines and performance.

A mechanic checks each part of a new engine on a Mine Resistant Ambush Protected vehicle at Camp Liberty, Baghdad, Iraq. TARDEC’s mobility labo-ratories research engine performance and combustion phenomena to provide Soldiers with reliable and safe ground vehicle systems in tremendously challenging operational environments. (U.S. Army photo by SPC Howard Alperin.)

calibrated to give the best fuel economy and highest thermal effi ciency at a given torque. “We start with the baseline, and we un-derstand that very well, meaning that we have a certain torque we want, and we’ve optimized it for effi ciency or fuel economy,” Schihl explained. “Then we very carefully study the combustion behavior.”

With the baseline gathered, engi-neers start running various fuels through the system to understand how and why the measurements change. “We’ve run a 50-50 blend of jet propellant-8 (JP-8) and synthetic JP-8, a 100-percent pure synthetic JP-8, and we have other samples of fuels that we’ve been running that are possible synthetic JP-8s,” Schihl described. “We start evaluating these different fuels with the same control strategy, document what the torque differences are and then study the combustion event to fi gure out why the change occurred. We’re in the process right now of fi nishing up the fi fth fuel. We’ll be making some special blends to adjust the ignition quality of the fuel and probably run another four or fi ve fuels through-out the remainder of 2009.”

Benefi ts “The information gleaned from the testing that occurs within the Single Cylinder Engine Test Cell can provide benefi cial informa-tion to Army engine suppliers and Army engineers when develop-ing engines and considering new

fuels for future ground vehicle systems,” Schihl stated. “It pro-vides an understanding of what’s going on in that cylinder as you vary combustion affecting fuel properties,” he explained. “This is important in the case of new engine development because as you look to the future, especially engines that the Army would like to have the capability to be more fl exible with the fuel, you’ll have information upfront that allows you to come up with a combus-tion strategy that is more tolerant of these various fuels.”

The research also prepares TARDEC engineers for questions that may arise in the fi eld, allowing them to quickly and effectively meet Sol-diers’ needs. “As you run into prob-lems with engines in the fi eld, you already have an idea of what might be causing it, or you have a quick way to study it,” Schihl stated. “I’m a big advocate for the more you understand about that situation, the better chance you have helping the Army or a program manager resolve a given engine issue.”

Chris Williams is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Communica-tions team. He has a B.A. in communi-cation from Wayne State University in Detroit, MI, and has previously written for The Source newspaper in Shelby Township, MI, and The Macomb Daily and C & G Newspapers in Macomb County, MI. 59


TARDEC’s Single Cylinder Engine Laboratory allows researchers to isolate cylinder combustion to better understand engine performance and behavior. Researchers are currently studying data gathered in the laboratory to understand how alternative fuels react during combustion events. (U.S. Army TARDEC photo courtesy of Laura Hoogterp.)

SSG Ronald Gasper, a fuels lab technician assigned to the 379th Expeditionary Logistics Readiness Squadron, fi lls a bottle with JP-8 fuel to perform a bottle method test, which is used to test a fuel truck's fi lter separator and measures the amount of impurities in the fuel. Testing at TARDEC’s Single Cylinder Engine Laboratory is currently studying the effects of JP-8 and alternative fuels on vehicle engines to improve engine performance, fuel effi ciency and economy. (U.S. Army photo by TSGT Michael Boquette).

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SSysystems Engineers Keep Vehicles on Tracktems Engineers

Track for the U.S. Army’s fl eet of tracked vehicles is expensive to replace, and, if it fails, the vehicle and crew can potentially be stranded in hostile territory. To keep warfi ghters safe and prevent costly failures, the U.S. Army Tank Automotive Research, Development and Engineering Cen-ter (TARDEC) operates two labs that study the performance of tracked vehicle components.

An M1A1 Abrams Main Battle Tank provides covering fi re during a clear, hold and build exercise. The Elas-tomer Improvement Program (EIP) has established baseline hyperelastic data that successfully developed, optimized and delivered an Abrams T-158LL bushing model so warfi ghters have the reliability they depend on for maneuverability and battlefi eld survivability. (U.S. Marine Corps photo by LCPL Kelsey J. Green.)

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Center Guide Wear Simulator Center guides are small compo-nents that play a major role in keeping tracked vehicles on track. The component is part of the vehicle’s track shoe and runs be-tween the road wheels to keep the track aligned and on the vehicle. During the vehicle’s operation, the center guide’s contact with other tracked components causes wear and degradation.

To understand how the compo-nents interact before they are

integrated into a vehicle, TARDEC offi cials test the components on the Center Guide Wear Simulation Machine located at an off-site aca-demic research center. “You tend to get a lot of side load, friction and wear between the center guide and the back of the road wheel,” explained Eric Blash, a mechani-cal engineer on TARDEC’s Track and Suspension Team. “The Center Guide Wear Simulation Machine is basically a large drum. We fasten center guides to it and spin it around, simulating a

vehicle moving at 20 mph. The center guides ride against the wear surface of a road wheel with a specifi ed contact load between the components. It’s a quick and cost-effective way to see if a mate-rial is suitable for the application before we spend a lot of money on vehicle testing.”

As the Army develops lighter vehicles, the simulator plays an essential role in testing new mate-rials and components. Track shoes are traditionally made from steel.

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Systems Engineers Keep Vehicles on TrackKeep Vehicles on Track Chris Williams

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In an attempt to decrease vehicle weight, the Army has experi-mented with various lightweight materials, including aluminum metal track with silicon carbide inserts that were placed on the center guides and a diverse array of materials and coatings for wear rings and road wheels.

When new materials and compo-nents are added to the test shoe, the simulation machine is used to gauge how quickly the components will wear. “When you use a lighter-weight aluminum road wheel, you typically have a steel wear ring attached to it,” explained Blash. “That wear ring is going to be what actually contacts the center guide. It’s expensive to build that wear ring and then fasten it to the road wheel. There’s been experimentation with different coatings that improve the wear properties of the aluminum wheel. So, we can use the simulation machine to test the center guide material itself, or we can test new materials for the wear ring or the road wheel.”

The testing provides TARDEC engineers with an understanding of how the components interact with each other when in use, a capability that stand-alone component testing cannot provide. The simulation machine also allows researchers to understand the wear properties of various materials, properties that would be diffi cult to gauge with-out physical tests. “Wear is a funny beast,” Blash remarked. “We can do a standardized wear test that compares materials, but until you simulate the actual working condi-tions you won’t know exactly how those two materials are going to interact with each other.”

The simulation machine does not replace Army qualifi cation standards but, rather, is used to understand tracked vehicle com-ponents as they interact before they are integrated into a vehicle system. “We really utilize it for the cost-savings benefi t,” Blash revealed. “It’s not a qualifi ca-tions test — it’s an engineering evaluation. It basically provides another data point for us to make the decision of whether or not we should spend the money on a fi eld test.”

Bushing Testing and Evaluation The most common track failures stem from the system’s elastomeric

components, such as bushings, which hold essential pins in place to keep tracks aligned. TARDEC’s Elastomer Improvement Program (EIP), a state-of-the-art research and development (R&D) facil-ity designed for testing, catego-rizing and improving rubber compounds for tracked vehicle systems at the Detroit Arsenal, features a bushing tester, which allows engineers to understand bushing properties without incur-ring the cost of a vehicle test.

“The EIP exists to come up with more relevant tests, protocols and techniques to better duplicate our failure modes and make better intuitive decisions on direction for research,” explained Bill Bradford, an R&D scientist with TARDEC’s Mobility R&D Center. “In the past, we conducted screening and quali-fi cation testing based on materials R&D methodology developed in the 1960s. Advances in mate-rial, testing equipment, sensors, computers and electronics have improved test equipment sensitiv-ity and reliability. Laboratory tests with components will always be at risk with respect to duplicating actual fi eld performance. How-ever, understanding the predomi-nant failure modes, optimizing state-of-the-art test equipment and methodology to closely

Soldiers change the tracks on their Bradley Fighting Vehicle. Testing done at TARDEC provides an understanding of how a vehicle’s components interact when in use, a capability that stand-alone component testing cannot provide. (U.S. Army photo by SGT Dan Purcell.)

A construction mechanic greases the tracks of a land excavator. Before integrating tracks and other components into a vehicle, TARDEC offi cials test the components on the Center Guide Wear Simu-lation Machine to reduce maintenance costs, improve life-cycle performance and keep warfi ghters out of harm’s way. (U.S. Army photo by PFC Eric Liesse.)

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mimic fi eld failures, brings us one step closer to screening improved components in the laboratory,” Bradford continued.

The result was the procurement of an R&D bushing test stand and development of test methodology that would leverage production bushings and identify radial and torsional loads that would result in duplicating the failure mode to the T-158LL track bushings. Over the last 18 months, this capability has provided two new improved bushing designs that are expected to improve the durability of the T-158LL bushing by more than 50 percent.

In conjunction with the test stand development, the EIP lab has estab-lished baseline hyperelastic data that was used to successfully develop,

optimize and deliver a Finite Element Analysis (FEA) model for the Abrams T-158LL bushing. This capability is a major break-through, providing a functional FEA model for design optimiza-tion with respect to maximum stress, energy input per loading step and the impact of insertion, radial and torsional loads. This capability, in concert with the elastomer test screening process, has provided the roadmap for-ward for improving the compo-nent’s durability by 50 percent, resulting in signifi cant savings.

The EIP uses a new testing methodology to extract rubber bushings from track components through specialized shiving tech-niques that produce consistent sample geometry for dynamic mechanical thermal analysis (DMTA). This testing provides a true assessment of the compo-nent’s properties during its life cycle and insight into required material improvements.

Bushing testing is also conducted off-site on another type of bush-ing tester. Although offi cials at the off-site research center and TARDEC are enhancing bushing testing capabilities through the EIP, the off-site bushing tester is still a useful tool in understanding whether new bushing materials meet rigorous Army standards.

“If a contractor comes in and says they have a new material that they want to use for military track, they go through a series of material property tests, and then we have them produce production-grade T-130 bushings,” Blash stated. “We insert them into simulated bores and run radial and torsional load profi les until the bushing meets a certain failure criteria. At that point, we tell them whether or not that is an acceptable mate-rial to use to build military track. The failure criterion is based on a certain defl ection — once the pin moves a certain amount, we say that bushing has failed. We take the cycle count at that point and look at whether it meets the mini-mum acceptance criteria.”

Bradford believes the R&D ac-tivities conducted by TARDEC will continue to expand the Army’s understanding and knowledge base to continuously improve track du-rability, performance and translate into more reliable track systems and reduce life cycle costs. “Our goal is to develop better laboratory R&D tests that mimic actual fi eld failures, increasing the probability of success and reducing the burden and costs associated with full vehicle tests. These laboratories provide us with the capability to evaluate new mate-rials and designs for improved track components, bushings, road wheels, ground pads and road wheel backer pads to support our warfi ghters,” Bradford concluded.

Chris Williams is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Communications team. He has a B.A. in communication from Wayne State University in Detroit, MI, and has previously written for The Source newspaper in Shelby Township, MI, and The Macomb Daily and C & G Newspapers in Macomb County, MI.

R&D Scientist William Bradford uses a DMTA testing tool to examine bushing properties. DMTA testing provides a true assessment of bushing properties during the component’s life cycle and insight into required material improvements. (U.S. Army TARDEC photo by Chris Williams.)

EIP testing determined that bushings undergo 55-percent deterioration after assembly, which can lead to track and component failure. TAR-DEC researchers are trying to create bushings made of a more durable, consistent material that will improve track durability and perfor-mance in harsh terrain. (U.S. Army TARDEC photo by Chris Williams.)

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TARTARDEDEC Turns Up Heat C Turns Up Heat on Vehicle Testingon Vehicle Testing Chris Williams

Mobility is a necessary capability of every U.S. Army ground vehicle. Soldiers may have access to the best equipment and weaponry, but it is all rendered useless without reliable transportation to get them to the fi ght. Whether or not warfi ghters have the ability to move from one location to another can mean the difference between

success and failure on an increasingly challenging battlefi eld.

A Mine Resistant Ambush Protected vehicle undergoes testing in Cell 9. Computer-activated heat lamps in the test cell can bring temperatures up to 160 degrees. Likewise, winds of up to 20 mph can be generated from eight different directions, allowing engineers to understand how environment affects a system and its components. (U.S. Army TARDEC photo by Ted Beaupre.)

Providing Soldiers with reliable and effi cient ground vehicles is a key mission for the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC). A collection of laboratories run by TARDEC’s Ground Vehicle Power and Mobility (GVPM) team exists to ensure that engines and vehicle components operate properly, both before integration into a larger system and under harsh desert or mountain conditions.

Full LoadFull Load Cooling Cooling Test ChamberTest Chamber Located in Test Cell 9 at the Detroit Arsenal, TARDEC’s Full Load Cooling Test Cham-ber provides engineers with an understanding of how vehicles operate in harsh environments. The facility is the Army’s largest indoor test lab. Two 1,000-horse-power (hp) fans bring in outdoor air at up to 1,200,000 cubic feet per minute, and the chamber can be heated to 160 degrees

Fahrenheit, while simulating the sun’s solar radiation with the use of computer-controlled solar lights. Winds of up to 20 mph can be generated and directed across the vehicle in up to eight different directions with the use of movable panels. “It was designed and set up for full load cooling tests, which is where you bring in a vehicle, connect it to a dynamometer and simulate torque,” explained Michael Reid, Team Leader for GVPM’s Testing,

65


Evaluation and Assessment Team. “We simulate that maximum load while the vehicle is at desert oper-ating conditions because we want to ensure that the vehicle isn’t going to fail while the Soldiers are fi ghting in desert-like conditions. We’re able to evaluate the vehicle’s performance and provide solu-tions to any cooling system issues that may exist.”

The chamber features two large gear boxes, which can be connect-ed to tracked vehicles’ sprockets. Two 2,500-hp dynamometers are located below and can absorb a tracked vehicle’s load and provide engineers with an understand-ing of the power generated by the engine in hot climates. Ad-ditional portable dynamometers

allow for tactical vehicle test-ing. Researchers then power the system and study how the various components and systems oper-ate in desert conditions, which is important because the harsh climates of Iraq and Afghanistan can affect vehicles in ways that cooler weather does not. “The temperatures are severe in those areas, and it’s easy to overheat

engine coolant, transmission oil and engine oil, which can cause those components to fail,” Reid remarked. “The advantage of do-ing it in a test chamber is that we can replicate those conditions 365 days a year. We don’t have to go to Yuma Proving Ground for a week when the temperature might be that hot.”

Currently, the GVPM Test Team is doing engineering and thermal insulation testing in the cham-ber for TARDEC’s Engineering Business Group, bringing in different technologies such as thermal blankets and insulating components that can be adhered to the vehicle to help reduce in-terior temperatures. The cell also has been used to test the impact of added vehicle armor on the temperature of the Army’s Family of Medium Tactical Vehicles and for understanding the impact of air-conditioning on vehicle systems. “We’ve been doing a lot of air-conditioning tests in there because, generally, the military never had air-conditioning in a lot of the vehicles,” Reid noted. “What they’re seeing in desert operating conditions is that the interior of the vehicle is getting over 160 degrees Fahrenheit, so they’re seeing a lot of failures of interior components, such as touch screens, on certain vehicles and power electronics.”

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A vehicle is prepared for testing in TARDEC’s Full Load Cooling Test Chamber. Located in Cell 9, the test chamber replicates climate conditions in high-temperature environments and allows engineers to test the entire vehicle at high-temperature extremes. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

“We simulate that maximum load while the vehicle is at

desert operating conditions because we want to ensure

that the vehicle isn’t going to fail while the Soldiers are

fighting in desert-like conditions.”

Air Filtration and Calorimeter Labs Desert conditions historically present problems for vehicle air cleaning systems. Dirt and sand can clog engine air fi lter systems, and high temperatures can wreak havoc on engine and transmis-sions if the radiators, oil coolers and charge air coolers are not correct. TARDEC’s Air Flow and Coolant System Component Eval-uation Laboratory was developed specifi cally to help researchers understand what must be done to avoid failures with those compo-nents. “All of our vehicles have air cleaners for the engines and some for the crew compartments,” explained TARDEC Mechanical Engineer Michael Richard. “What basically happens is that you end up shutting down the vehicle if the air fi lter gets plugged. If that happens when you’re on a mis-sion, obviously, you’re in trouble.”

The lab includes a radiator calorimeter and two fi ltration test benches that can simulate a variety of real-world condi-tions for evaluating radiators and

air-fi ltration systems that assess component-level performance, measuring heat rejection, restric-tion, fi ltration effi ciency and ca-pacity parameters. “We’re making signifi cant advancements in the testing and development of air cleaners,” Richard stated. “When I fi rst started here, tactical ve-hicles had a 4-hour dust capacity requirement on a test bench and armored ones were tested for 20 hours. Now we’re going for 200 hours across the board.”

The lab has the capability to test radiators on a calorimeter, although the range is limited. Testing can be done on compo-nents for vehicles as large as an

M1 Abrams Main Battle Tank. The lab, which was constructed in the early 1950s, is currently be-ing refurbished and an advanced laboratory will be part of the Ground Systems Power and En-ergy Laboratory, which is expect-ed to be completed by September 2011. “Our systems have gotten so much larger over time, so we’re really pushing the envelope, espe-cially as the power requirements increase on the vehicles,” Richard remarked. “In the new lab, we’re adding the capabilities of being able to test charge air coolers and oil coolers, whether they’re air-to-air or air-to-coolant. Right now we can’t test that here — we have to go to an outside partner. And for the fi ltration lab, we’ll have the capability to test M1 air clean-ers or larger.”

The new lab will provide re-searchers with the capability to test larger, more powerful vehicle systems as they are developed. “Right now we can’t test Palletized Load Systems and larger vehicle air cleaners. We don’t have the capability to test them, so we end up having to go to outside partners. The new lab is going to be able to test any air cleaner within the Army system,” Richard revealed. “It’s going to increase our capabilities so that we can do this work in-house. On the calorimeter, we’ll be able to stack our heat exchangers and test them simultaneously as they’re confi gured in the ve-hicle. That’s something we can’t do now — I don’t know if it’s something anybody can do at this time.”

Dynamometer LabsAlthough Test Cell 9 is the Army’s largest indoor test laboratory, several other TARDEC labs are able to replicate conditions in the fi eld and their effects on engines

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“Our systems have

gotten so much larger

over time, so we’re really

pushing the envelope,

especially as the power

requirements increase

on the vehicles.”

Bradley Fighting Vehicles (BFVs) are capable of transporting Soldiers into battle on a variety of terrains. TARDEC’s testing facilities allows researchers to further analyze ground platforms, and the facilities will better prepare vehicles for the air quality present in desert and mountain conditions. (U.S. Army photo by PFC Rebekah Lampman.)

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and vehicle systems. The Vehicle Transmission and Drive Axle Evaluation Test Cell and Labo-ratory, for instance, is capable of conducting critical engine, transmission, driveline or total propulsion system performance and evaluation testing at the vehicle or component level. The facility’s dynamometers have the capability to absorb output torque up to 44,000 foot pounds (ft-lb) per side and 68,000 ft-lb at stall and accom-modate a broad range of ve-hicle platforms from light-duty High Mobility Multi Purposed Wheeled Vehicles (HMMWVs) to Main Battle Tank applica-tions and the Bradley Fighting Vehicle System.

The cell also provides the capability to replicate desert temperatures and winds. Tandem dynamometers allow for testing tank transmissions and rear axles, and the cell’s size makes it possible to test engines for various systems and can ac-commodate other vehicle systems for full-system testing should the need arise, although the cell ac-commodates smaller vehicles than the Full Load Cooling Test Cell.

The nearby Power and Inertia Simulator Test Cell and Labora-tory houses a $20 million direct current (DC) dynamometer arrangement. The DC dyna-mometer is capable of simulat-ing steering maneuvers, steady-state operation and transient operation at the vehicle level for up to a 40-ton platform or 800 brake horsepower (bhp) under standard and elevated tempera-ture conditions. “This dyna-mometer allows us to do tran-sient testing, so we can simulate

a vehicle’s mission profile,” Reid stated. “In most of our test cells, the type of dynamometers we have are used to do steady-state or slow transience. The DC motor allows us to do that transient testing. It’s a benefit to our program managers because we’re able to evaluate different mission profiles to evaluate dif-ferent hardware.”

The GVPM team’s six dyna-mometer labs allow researchers to conduct performance, endur-ance, qualification and accep-tance testing on a variety of engine and transmission config-urations. Each cell features por-table dynamometers capable of testing engines from 100–3,000

bhp, and researchers can con-trol the labs’ temperatures and the flow rates of fuels, coolants and engine oils. The cells are used to evaluate engine technol-ogy and conduct research and design programs. The GVPM Test Team also conducts 400-hour NATO durability tests, considered to be the minimum qualifier of any engine that goes into a NATO country’s vehicles.

Preparing for the Field Rigorous testing is essential to ensuring that vehicles will oper-ate optimally in the fi eld. Many Army ground vehicles use com-mercially available engines, which are developed to operate at North American conditions on diesel fuel. However, military vehicles must be able to operate at condi-tions that are often considered far from optimal. “The military’s environment is more severe, and our primary fuel is jet propellant 8 (JP-8), which is harsher and has some detrimental effects to en-gines,” Reid revealed. “One of our benefi ts is that we’re testing these engines on the 400-hour NATO cycle, which we make more severe by running at desert operating conditions on JP-8 fuel. We’ve

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“This dynamometer allows us to do transient testing,

so we can simulate a vehicle’s mission profile.”

A Soldier training as a gunner enters an up-armored M1114-HMMWV during lane training for duty in Iraq. TARDEC’s mobility laboratories ensure vehicles operate properly in harsh environments. (U.S. Army photo by 1LT Ryan Pace.)

A Soldier in a BFV identifi es potential threats during a training session. The GVPM team’s six dynamometer labs al-low researchers to conduct performance, endurance, qualifi cation and acceptance testing on a variety of engine and trans-mission confi gurations. (U.S. Army photo by PFC Rebekah Lampman.)

uncovered several fuel-related issues, such as fuel pumps and in-jectors that aren’t really compat-ible with JP-8 fuel. We’re uncover-ing those issues and working with the manufacturers and suppliers to help resolve them.”

The GVPM Test Team coordinates with other teams throughout TARDEC to assist with compo-nent- and system-level testing. The cells’ large dimensions make them easy to modify and adjust to various testing, including evaluat-ing alternative fuels, batteries and fuel cells. The GVPM test team also works with several indus-try partners to optimize engine systems and components. “We work as a team,” Reid emphasized.

“We work together running these tests, and then we provide them with real-time data that they can feed into their programs to help develop and mature technology before it gets to the Soldier.”

The various cells allow for components and systems to be thoroughly evaluated and improved before they are inte-grated into vehicle platforms. This capability allows TARDEC researchers the opportunity to understand how the environ-ment impacts the vehicle’s oper-ating capability and also provides cost savings. “The laboratory is a controlled and easily replicated environment,” Reid explained. “If you’re testing it as a full vehicle on a proving ground, there are a lot of other factors that play into what the test results might be, but we’re able to isolate on a particular component or tech-nology and evaluate it. By having the full vehicle test cell, we can also replicate it in a full vehicle system. If you’re testing a tank system engine improvement, it’s a lot easier to run that in a test cell as opposed to buying a tank,

integrating the component into it and then running that whole system, where other subsystems could fail while you’re doing that,” Reid concluded.

TARDEC engineers, technicians and scientists continue to develop breakthrough technologies that, ultimately, give Soldiers unmatched capabilities on the battlefi eld. Thanks to the operation and test environments replicated in TARDEC’s test chambers and labs, TARDEC associates continue to evaluate and analyze vehicle systems and subsystem compo-nents to ensure vehicles reach their breakpoints in a laboratory setting and not on the battlefi eld.

Chris Williams is a Writer/Editor



Communications team. He has a

B.A. in communication from Wayne

State University in Detroit and has

previously written for The Source

newspaper in Shelby Township, MI,

and The Macomb Daily and C & G

Newspapers in Macomb County, MI.69


Other than the dirt, grit and dust generated in operational fi eld environments, TARDEC labs can simulate desert operating conditions for testing at maximum loads and accommodate vehicles up to and including the M1 Abrams Main Battle Tank. Here, an M1A2 Abrams fi res its main gun during a live-fi re exercise. (U.S. Army photo by SPC John Crosby.)

“We work together running

these tests, and then we

provide them with real-time

data that they can feed into

their programs to help develop

and mature technology before

it gets to the Soldier.”

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Advancing Ground Vehicle Research and

Development Michael D. Kaplun

Supporting current and future ground vehicle research and development (R&D) initiatives is the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC) Prototype Integration Facility’s (PIF’s) mission. The PIF, comprising more than 100 engineers, technicians and support staff, develops system and subsystem designs and fabricates and integrates advanced technologies on current and future ground vehicle prototype systems, while

also providing vehicle life cycle support. Since 2003, the PIF’s major focus has been to react and support rapid and urgent in-theater requirements. However, the PIF’s design and manufacturing engineers also undertake complex technology demon-stration and integration projects that support advanced technology objectives and program manager vehicle system enhancements.

TARDEC Engineer Jonathan Aboona walks guests through TARDEC’s PIF during a visit on Sept. 14, 2009. TARDEC PIF facilities, such as the Design and Rapid Prototyping Center, are revolutionizing ground vehicles in a time of constant adaptation and change. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

The PIF provides an experienced staff of engineers and technicians who leverage years of expertise spread throughout diverse tactical and combat vehicle systems. Me-chanical, electrical/electronics and system design teams have more than 46 design engineers who pro-vide timely, cost-effective design, engineering and digital mock-up support, while also creating 3-dimensional interactive, realistic, real-time computer-generated environments and models. Hard-ware is manufactured daily by the PIF’s trained and certifi ed welders, machinists, material handlers, tes-ters, vehicle mechanics and other dedicated technicians. The PIF also contains extensive, specialized equipment that supports diverse components and assemblies devel-oped by design engineers, includ-ing laser and water jet cutters, computer numerical controlled machines, vertical mills and eight welding stations.

The PIF’s Electrical/Electronic Integration Team (EIT) includes 14 experienced design engineers and technicians with expertise in circuit board manufacturing and electronic fabrication. “The EIT’s expertise in design and integration has led to extensive and impressive repeated col-laboration with several Program

Executive Offi ce (PEO) Ground Combat Systems, PEO Combat Support and Combat Service Support, and Special Operations Command partners,” remarked TARDEC Acting Associate Di-rector Luis Hinojosa.

In 2008, the PIF had a central role in TARDEC, receiving a U.S. Army Top Ten Greatest Inventions

award for the Mine Resistant Ambush Protected (MRAP) ve-hicle Expedient Armor Program Add-on-Armor Kit. In 2009, the PIF was instrumental in TAR-DEC receiving the Department of the Army Research and Devel-opment Laboratory of the Year Award for Collaboration Team of the Year for the Lightweight Vehicle Underbody Protection System in partnering with the Army Research Laboratory. “Both awards highlight the facility’s capabilities — rapid response and innovative technology develop-ments that save Soldiers’ lives,” Hinojosa affi rmed.

The PIF revolutionizes ground vehicle systems in a modernizing world. The facility’s associates develop, fabricate and integrate operational requirements and specifi cations to keep the cur-rent and future vehicle fl eets well equipped for critical missions.


“The EIT’s expertise in design and integration has led to extensive

and impressive repeated collaboration with several PEO Ground

Combat Systems, PEO Combat Support and Combat Service Support,

and Special Operations Command partners.” 71


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Shown here is an MRAP with the TARDEC-developed Overhead Wire Mitigation (OWM) kit, which protects Soldiers and helps to preserve the local infrastructure. TARDEC developments like the OWM kit better equip and protect present and future Soldiers. (U.S. Army TARDEC photo.)

Pictured is an MRAP being serviced in TARDEC’s PIF. The PIF’s Design and Rapid Prototyping Center develops system and sub-system designs and fabricates and integrates advanced technology in current and future ground vehicle systems, such as the MRAP. The center houses a 50-foot high bay with 16-inch reinforced concrete fl ooring to handle even the largest Army vehicles and weapon systems. (U.S. Army TARDEC photo.)

“The PIF provides an

experienced staff of engineers

and technicians who leverage

years of expertise spread

throughout diverse tactical and

combat vehicle systems.

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Testing Facility Provides Clean Water Solutions for SoldiersTesting Facility Provides Clean Patrick Pinter

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Testing Facility Provides Clean Water Solutions for SoldiersWater Solutions for Soldiers

Having a clean water source is a necessity, and providing that necessity in a war zone is often diffi cult. Supplying Soldiers with usable water is a problem that is being tackled at the U.S. Army Tank Automotive Research, Development and Engineering Center’s (TARDEC’s) Water Treatment Test Facility at Selfridge Air National Guard Base (SANGB), MI.

TARDEC’s Water Treatment Test Facility at SANGB has the capability to operate small to full-sized water treatment systems and components. Treatment facility researchers develop the equipment and capabilities to provide deployed Soldiers with clean water solutions, regardless of where their missions take them. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

The Water Treatment Test Facility, located on Lake Saint Clair, has the capability to operate small to full-sized water treatment systems and components. “The facility, which is right on the water, is large enough for us to do all kinds of testing relating to research, development and engineering support. We provide engineering support to Project Manager Petroleum and Water Systems,” remarked Bob Shalewitz, Water Treatment and Handling Equipment Team. “The goal is to take Army requirements for the area of water treatment and storage handling systems and develop materiel solutions for those. We provide engineering support for that purpose.”

The building includes a boat well in a heated room, which allows for year-round testing. The boat well provides a freshwater testing source

even in the winter months while the rest of the lake is frozen over. “During the winter months, we can close the roll-up door that goes over the water and encloses the well. The room is heated, so this unique capability allows us to operate all year long,” explained TARDEC Project Engineer Andrea Oehus. “A major benefi t at this facility is our ability to address problems from the fi eld, test a solution and send a tested fi x to the fi eld, not

just send something on paper you think will work.”

The facility houses several water purifi cation systems, which include Lightweight Water Purifi ers (LWPs), Tactical Water Purifi cation Systems (TWPS) and Reverse Osmosis Water Purifi cation Units (ROWPUs). “At this facility, we perform research and development on water purifi cation equipment,” commented Oehus. “We currently have all of our production models that we support here in the facility. There is at least one of each model, but for most there are two or more here.”

The LWP utilizes ultrafi ltration and reverse osmosis technologies to provide 125 gallons per hour (GPH) of potable water from a freshwater source and 75

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A Water Treatment Test Facility engineer records data collected from one of several testing units that are currently housed at the SANGB facility. Current units include LWPs, TWPS and ROWPUs. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

“The goal is to take Army requirements for the area of water treatment and storage handling systems

and develop materiel solutions for those. We provide engineering support for that purpose.”

“A major benefit at this

facility is our ability to

address problems from the

field, test a solution and send

a tested fix to the field, not

just send something on paper

you think will work.”

GPH from a saltwater source. Its purpose is to provide a safe water supply to Soldiers on the battlefi eld. “The LWP is intended for special operation units that are away from the main major water source. Because of its light weight, the system’s intent is to go with the fi rst group of Soldiers in and most far forward on the battlefi eld,” commented Oehus. “It travels on the back of a High Mobility Multipurpose Wheeled Vehicle and is portable by four Soldiers.”

In addition to the LWP, associates at the Water Treatment Test Facility have worked signifi cantly on the TWPS, which is a 1,500 GPH drinking water system for division and brigade units in remote areas. The system also has been used for disaster relief operations, humanitarian efforts and peacekeeping missions.

The units housed at the facility can be used as test beds for evaluating the performance of commercially available and ex-perimental components for their

usefulness on military water treatment equipment, and also can be used to train water treatment system operators on military and commercial water

treatment systems. “A couple of things that we focus on here are preplanned product improve-ments. We look at new compo-nents, more effective ways of running the systems and new technologies. We can do anything from the component scale all the way to full-system testing here at the facility,” remarked Oehus. “We also share equipment with the U.S. Army TACOM Life Cycle Management Command New Equipment Training team. It is a win-win for everybody having everything located here at SANGB.”

Patrick Pinter is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Communica-tions team. He has a B.A. in journalism and political science from Western Michigan University.

77


“A couple of things that we focus on here are preplanned product

improvements. We look at new components, more effective ways of

running the systems and new technologies.”

A facility engineer conducts water testing. Most work being done at the Water Treatment Test Facility relates to developing several water purifi cation systems, including LWPs, TWPS and ROWPUs. Ongoing testing looks at everything from chemical processes and desalination to ultrafi ltration and reverse osmosis. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

TARDEC’s Water Treatment Test Facility runs off in-house power but also has several generators on-site, which are used for different types of testing. (U.S. Army TARDEC photo by Patrick Pinter.)

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Keeping Warfighters Well-Hydrated — Keeping Warfighters Well-Hydrated — SDTF Delivers Optimal SDTF Delivers Optimal

Water Purification SystemsWater Purification SystemsMatthew Sablan

The Port Hueneme, CA, Seawater Desalination Test Facility (SDTF) is located at the entrance to Naval Base Ventura County’s harbor. It houses state-of-the-art equipment for executing tests and research otherwise unavailable to the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC).

From left: U.S. Marine Corps (USMC) SGT Julian Munoz instructs PFC Alejandro Camargo and LCPL Jeremy A. Doty on using an Reverse Osmosis Water Purifi cation Unit (ROWPU). The ROWPU can fi lter every-thing from saltwater to nuclear, biological and chemical-infected water to produce con-sumable water for ground forces. (USMC photo by Leigh Campbell.)

Storage tanks are connected to a water-dispensing unit at the Joint Security Station Shawra Wa Um Jidir water distribution site in Iraq. The line that pumps the raw water runs from a well-water bag to a ROWPU that puri-fi es water for distribution. The ROWPU is one of the many pieces of equipment TARDEC and NAVFAC have partnered to test. (U.S. Army photo by SSG Matthew Meadows.)

Four freshwater pumps are used to draw water from the Euphrates River to supply ROWPUs operated by Marines at a Tactical Water Dis-tribution System (TWDS) during Operation Iraqi Freedom (OIF). TARDEC and NAVFAC also test water packaging and water distribu-tion systems for the Army and Marines. (USMC photo by MSG Edward D. Kniery.)

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A Marine operates a ROWPU for the TWDS, which contains three 50,000-gallon collapsible water tanks, during OIF. TARDEC and NAVFAC collaborate on main-tenance, training and technical support for all fi elded Army and USMC ROWPUs. (USMC photo by MSG Edward D. Kniery.)

Establishment and PartnershipThe SDTF was fi rst established in 1983 at the Naval Civil Engineer-ing Laboratory. In 2000, TARDEC entered into an agreement with the Naval Facilities Engineer-ing Command (NAVFAC) and Engineering Services Center (ESC) to station two engineers at Port Hueneme. These engineers sup-port the SDTF’s unique operations and bring the facility’s capabilities to TARDEC. “The SDTF conducts research, development, testing and evaluation of water purifi cation systems,” TARDEC Engineer Jere-my Walker explained. “The SDTF’s primary purpose is to conduct research, development, test and evaluation of water purifi cation systems and ancillary equipment with particular interest in opera-tions on seawater.”

Tests allow the Navy and TARDEC to address any problems with equipment before delivery to warfi ghters. This allows engineers to develop solutions before these problems are encountered in the fi eld. The facility also conducts

pilot and demonstration studies on water purifi cation technolo-gies for potential future military systems. The SDTF has supported various private sector companies, the Bureau of Reclamation and the U.S. Army, U.S. Navy and U.S. Marine Corps (USMC).

Water Purifi cation SystemsThe SDTF tested and developed Army and USMC fi eld water pu-rifi cation equipment, and NAV-FAC partnered with TARDEC to develop, test and evaluate water purifi cation technology. Some equipment this partner-ship has been involved in pro-ducing includes:

• Tactical Water Purifi cation System, used by the Army and USMC.

• Lightweight Water Purifi er, used by the Army and USMC.

• Water packaging, used by the Army and USMC.

• Maintenance, training and tech-nical support for the 600 gal-lons per hour (GPH) and 3,000 GPH Reverse Osmosis Water

Purifi cation Unit (ROWPU).• 45–90 day shipboard Reverse

Osmosis certifi cations for SSN-688- and LPD-17-class vessels.

Water is processed prior to testing, and the facility can process one million gallons of seawater a day. The equipment the SDTF offers includes water purifi cation sys-tems with incandescent and laser turbidimeters, particle size analyz-ers, silt density index meters and fl uorescence meters to measure the seawater’s fouling potential.

The SDTF is also available for certain commercial test and evaluation entities. If you have any questions or would like more information about the SDTF or NAVFAC ESC, please contact the NAVFAC ESC Public Affairs Of-fi ce at (805) 982-1069.

Matthew Sablan is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Com-munications team. He has a B.A. in English and history from Marymount University in Arlington, VA.

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TARDEC Leads Fuel and Lubricant Technology

Development and Design Patrick Pinter

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When we think about protecting Soldiers and their vehicles on the battlefi eld, often the fi rst thing we think about is integrating armor or adding weapons. Sometimes it is not about adding power or protection to the vehicle, but making sure the engine runs properly or at an optimal level to handle the current operational environment and terrain.

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The Grease and Fluid Lab’s mission is to make sure that the proper fl uids make ground vehicles run smoothly in diverse operating environments and weather conditions. (U.S. Army TARDEC photos by Elizabeth Carnegie.)

Without research and develop-ment (R&D) in the areas of fuels and lubricants, air and ground equipment would not be able to operate reliably at the level Soldiers demand and require on the battlefi eld. One of the U.S. Army Tank Automotive Research, Development and Engineering Center’s (TARDEC’s) goals is to be the Department of Defense’s (DOD’s) leader for fuel and lubricant technologies for ground equipment systems. That goal is ambitious, but the work being done at TARDEC-managed labs is helping to achieve new levels of product excellence and effi ciency. “In a true systems-of-systems engineering approach, we have to consider everything, including fuels and lubricants,” remarked Luis Villahermosa, Fuels and Lu-bricants Technology Team (FLTT) Leader. “We have unique require-ments we are working with. It’s important to remember that fuels and lubricants are an integral part of the equipment.”

When it comes to fuel and lubri-cant technologies, TARDEC is responsible for R&D; specifi cation development; product qualifi ca-tion; general petroleum, oil and lubricants (POL) standardiza-tion; testing support for other TARDEC organizations; and fl uid fi ltration assessment. This is in support of the mission responsi-bility assigned to TARDEC under Army Regulation 70-12, Fuels and Lubricants Standardization Policy for Equipment Design, Operation and Logistic Support. TARDEC accomplishes this with its state-of-the-art POL testing equipment and facilities.

Fuels and Lubricants Vehicle Filter Test EquipmentThis test equipment is capable of evaluating vehicles’ fuel and lubri-cant fi lters using the latest Interna-tional Organization for Standard-ization (ISO) test procedures. The equipment allows evaluation of expected life, effi ciency and other parameters needed to establish fi l-ter performance for vehicles. “The fi lter test rig is intended to assess the fi lter’s performance. A fuel or lubricant fi lter is hooked up to the test rig to fi nd its capacity to re-move particles, the size of particles removed, how long it will last and how many particles it can retain,” commented Villahermosa. “The test tool was used in the evaluation of the cleanable fi lter system that the Stryker vehicle started with and was found to be inadequate.”

Fuels and Powertrain Lubricants LaboratoryIn this laboratory, tests are per-formed for developing, evaluating, qualifying and researching fuels, alternative fuels and powertrain

lubricants (e.g., engine oils, gear lubricants and transmission fl uids) to enable introduction of new technologies and development of new performance standards. In ad-dition, FLTT team members also conduct assessment of environ-mental compliance and develop environmentally friendly products.

Grease and Fluid LaboratoryHere, tasks are performed in developing, evaluating and re-searching hydraulic fl uids, semi-solid lubricants, solid lubricants, greases, antifreeze and solvents to enable introduction of new tech-nologies and development of new performance standards. FLTT team members also use this lab to assess environmental compliance and develop environmentally friendly products. “In the labora-

tory, we have a wide variety of chemical and physical property testers,” stated Villahermosa. “One example is the environ-mental chamber. We can put samples of products and materials

“It’s important to remember that

fuels and lubricants are an integral

part of the equipment.”

“We have a long history working with alternative fuels,

specifically with analysis, testing and evaluation, which

continues today with the laboratory and technical expertise

provided to TARDEC’s NAC Alternative Fuels Team.”

A TARDEC scientist performs testing analysis in the Grease and Fluid Lab.

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in it and test them at different temperatures or humidity.”

Developing Solutions that Improve Effi ciencyWith these labs and test tools, TARDEC is able to develop fuel and lubricant solutions for DOD. These developments help maxi-mize equipment effi ciency and reliability, promote fuel source diversity and reduce costs and maintenance over a vehicle’s life cycle. In the end, these solutions help minimize maintenance and logistics burdens. “With the experience here in the lab, techni-cians and scientists are able to make sure the equipment does what it is supposed to do,” Vil-lahermosa explained. “Through testing here, we are able to pro-vide equipment validation.”

The work TARDEC does in its labs is on the following types of fuels and lubricants:

• Traditional fuels (e.g., diesel, jet propellant 8, etc.)

• Multipurpose engine oils• Gear lubricants and greases• Hydraulic fl uids• Preservative engine oils• General purpose preservatives

and lubricants

Part of TARDEC’s mission in fuels and lubricants is to mini-mize the number of products needed to support a vehicle or equipment system and standard-ize those that remain. For this reason, lubricant products are designed and developed so they can be utilized in as many com-ponents as possible. Take military engine oils as an example. They have additional requirements to

operate in military transmissions and also are capable of being used in hydraulic systems. Using one product in three components reduces the number of products needed for maintenance, reduces misapplications and waste, and simplifi es training.

At the TARDEC laboratories, extensive work also is being done with alternative fuels. “There is always something going on in the lab. We have test-ing going on regu-larly,” remarked Villahermosa. “We provide a lot of support in engine testing and fuel testing. In addi-tion, we are deeply involved with alternative fuels. We have a long history working with alternative fuels, specifi cally with analysis, testing and evaluation, which continues today with the laboratory and technical expertise provided to TARDEC's National Automotive Center (NAC) Alter-native Fuels Team and the overall Army Alternative Fuels Certifi ca-tion effort. The NAC and FLTT have a truly symbiotic relationship on the alternative fuels effort.”TARDEC also does signifi cant testing and research in other

areas, such as biodegradable greases and hydraulic fl uids, fl uid fi ltration, brake fl uids, coolants and antifreeze. “Here in the labs, we have the capabilities to test products’ biodegradation,” com-mented Villahermosa. “We try to do environmental programs as much as we can, while keeping in mind that the mission comes fi rst. Durability and performance is the prime focus, and we do our best from there.”

Without the work being done in the areas of fuels and lubricants, engines and vehicles would not be able to run properly. Research, development and design in these areas are critical parts of the vehicle design process. “The one thing people don’t realize is that fuels and lubricants are a fairly neglected technology area,” remarked Villahermosa. “They are not always acknowledged during

the primary design of equipment, even though it is an integral part of the process.” And that is where the FLTT makes its greatest contributions to ground vehicle systems fl eet management.


Scientists collect information in TARDEC’s Grease and Fluid Lab. Various types of testing takes place in these labs, including research, analysis and testing of biodegradable fuels and lubricants, fl uid fi ltration, brake fl uids, coolants and antifreeze.

“The NAC and FLTT have a truly

symbiotic relationship on the

alternative fuels effort.” TARDEC scientists discuss test results in the Grease and Fluid Lab. The equipment housed within the lab is capable of evaluating vehicles’ fuel and lubricant fi lters using the latest ISO test procedures and standards.

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GROUND SYSTEMS SURVIVABILITY

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Lab Puts Armor Under the Gun to Save Soldiers’ Lives Chris Williams

PVT Alfred Dorsey cleans the window of a Mine Resistant Ambush Protected (MRAP) vehicle door at Camp Taji, Iraq, prior to a route clearance mission, while SGT Ryan Bednarski loads a .50-caliber machine gun. Ballistics testing done in the SABL is conducted at temperatures similar to those experienced in Iraq to ensure armor safety in hot climates. (U.S. Army photo by SGT Doug Roles.)

Sometimes a sheet of glass is all that separates a Soldier from harm. Transparent armor (TA) is a crucial component in many of the U.S. Army’s ground

vehicles, allowing Soldiers to keep a watchful eye on their sur-roundings while protecting them from attack. Should Soldiers fi nd themselves caught in an ambush, bullet-resistant windows can withstand several hits, provid-ing Soldiers with critical time to escape or respond.

The U.S. Army Tank Automo-tive Research, Development and Engineering Center’s (TARDEC’s) Ground Systems Survivability (GSS) Survivability Armor Bal-listics Laboratory (SABL) plays a key systems engineering, integra-tion and collaborative role in the process of equipping ground vehicles with effective TA protec-tion. The SABL’s primary mission is to conduct ballistic testing on transparent and opaque armor materials, which is required before they are integrated onto vehicle platforms. “The Army Research Laboratory’s [ARL’s] primary mission is materiel development; the Army Test and Evaluation Command [ATEC] conducts testing on the entire vehicle during system testing,” explained SABL Range Man-ager Steve Hoffman. “We fi t in between such that when a spe-cifi c material or particular armor recipe is proposed for system integration, the SABL conducts the testing that qualifi es whether the proposed TA solution satisfi es the threat levels defi ned for the specifi c vehicle platform.”

Custom TestingSABL engineers and technicians constantly strive to better under-stand what parameters must be tweaked to repeatedly replicate

a projectile strike on armor that consistently simulates a specifi c threat in a lab environment. To accomplish this, each round is tailor-made by selecting the pro-jectile and hand measuring the propellant to achieve the required test goals for threat, caliber and velocity. “We can simulate a 100-yard standoff or a 200-yard standoff just by changing the ve-locity at which the projectile hits the target,” stated Hoffman. “To do that, each round is disassem-bled, and the propellant charge is adjusted and reassembled to obtain the velocities we’re look-ing for at impact.”

“Some of the projectiles are non-standard — they’re not what you would see elsewhere,” commented Hoffman. “We can simulate pretty much any stan-dard, military-type, small-arms threat. There are different ways of shooting it. It’s all just a means to get the projectile down range, which is our primary function — to get the projectile into a target at a controlled velocity.” Another projectile used by the SABL is the Fragment Simulator Projectile (FSP), which replicates materials present in improvised explosive devices (IEDs). The impact that an actual IED fragment may have on a vehicle varies based on speed and orientation of impact, so FSPs were designed to corre-spond with a chart showing what percentage of IED fragments each FSP corresponds to. The FSP is a U.S. and NATO standard test projectile used by other Army

laboratories, providing a consis-tent means of data comparison.

The Big Bang Once the projectiles are ready for fi ring, they are taken to the launcher. Projectiles are shot from a customized launcher that allows engineers to fi re rounds electroni-cally from a secure control room, reducing risk to the test team and providing them with a location to study impact effects. Firing posi-tions are precisely aligned by laser, allowing accurate aim for each test. “We’ll take a few shots to make sure we have our velocities and everything where we need it. We’ll adjust the laser, move the target and use the laser as an aim point designator,” explained David Sass, a Senior Electrical Engineer. “It’s the best thing we’ve found. Otherwise, you basically just look down the barrel and try to line it up. It’s a lot faster with the laser.”

The SABL initiated the develop-ment and controls the distribu-tion of the Armor Tech Product Description (ATPD 2352), which has gained widespread Army use on TA testing since its fi rst release on Jan. 3, 2008. ATPD 2352 defi nes a standardized 4-shot pattern, which was characterized by work done in conjunction with the NATO STANAG 4569 “Protec-tion Levels for Armored Vehicles” group. This pattern is now used

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“The SABL's primary

mission is to conduct

ballistic testing on

transparent and opaque

armor materials...“

The impact that an actual IED

fragment may have on a vehicle

varies based on speed and

orientation of impact, so FSPs

were designed to correspond

with a chart showing what

percentage of IED fragments

each FSP corresponds to.

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throughout the Army to provide consistent criteria in the evalua-tion of multiple impacts on TA armor. “Glass isn’t bulletproof, it’s resistant,” commented Hoffman. “What it does is buy the people inside the vehicle time to react or leave the area. That’s the reason for a multi-hit pattern — how many seconds of time under at-tack can we buy those people?”

Projectiles are fi red at the armor samples, called coupons, which are placed in the impact cham-ber. Each coupon is tested at high, low and ambient tempera-tures to gain an understanding of the material’s performance in various environments. Test teams have 25 minutes to fi re four rounds into the target before the temperature begins to change.

“The armor responds very differ-ently to different temperatures,” Sass explained. “Right now we are deployed in regions that are subject to both hot and cold weather extremes. That is why we have a hot and cold test require-ment — because we don’t have a single vehicle that operates in only one climate.”

EvaluationA number of different tools are available to the SABL team to understand what occurs during impact. High-speed video equip-ment provides a detailed look at the event, and computers record the velocity, temperature, humidity and other environmental factors that may skew the test results. A test engineer is always on hand to provide a visual assessment of the test results, i.e., studying the armor for fracture patterns, character-izing bumps, holes and collecting debris for further analysis. “What

they’re looking for might be separation in the plies. They may be looking for patterns that are different, a bulge in the back,” re-marked Sass. “They’re looking for anomalies. When we worked with ceramic opaque armor, some of the visuals were different than we’re used to seeing. We make it a point to always coordinate

with the TA developers when we see results that are different than what we are used to seeing. We do this mostly when we’re doing research. When we’re doing qualifi cation testing, it’s a simple pass or fail.”

The qualifi cation testing for transparent armor looks for one important piece of information: will the impact cause harm to Soldiers? Each coupon has a wit-ness plate placed behind it. If the projectile or any debris perforates tghe witness material, the armor coupon has failed the qualifi ca-tion testing.

The qualification testing

for transparent armor looks

for one important piece of

information: will the impact

cause harm to Soldiers?

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“Glass isn’t bulletproof,

it’s resistant.”

U.S. Air Force Special Agent Nate Notargiacomo, Offi ce of Special Investigations, Kandahar Airfi eld, Afghanistan, conducts rear security from an MRAP. Testing done in TARDEC’s SABL ensures that the ballistic glass windows provide adequate protection from ambush and attacks. (U.S. Army photo by SSG James L. Harper Jr.)

The SABL team has worked and is working with program managers for nearly every Army ground vehicle system fielded today in the qualification and acceptance of TA armor. The SABL is also working closely with research teams throughout TARDEC in developing and integrating new and improved opaque and TA into vehicle platforms. As a part of the Army test community, the SABL lab has an open communication and collaboration policy with ARL, ATEC and other Army laboratories to share data in an effort to improve the material that shields Soldiers from harm in the field. It’s this mission — saving warfi ghters’ lives — that is the most fulfi lling part of the SABL’s work. “One of the things I’m most proud of is that one customer we did testing for came back a few months later and said the work that we did saved some lives,” remarked Sass. “I like direct feedback like that.”

Chris Williams is a Writer/Editor



Communications team. He has a

B.A. in communication from Wayne

State University in Detroit, MI, and

has previously written for The Source

newspaper in Shelby Township, MI,

and The Macomb Daily and C & G

Newspapers in Macomb County, MI. TARDEC Engineer Terry Avery customizes a launch package for fi ring prior to testing. The SABL customizes each package fi red to adjust for desired velocity, allowing for customized and consistent results. (U.S. Army TARDEC photo by Ted Beaupre.) 89


TARDEC SABL Engineer Scott Wiseman examines an armor coupon after testing in the SABL. (U.S. Army TARDEC photo by Ted Beaupre.)

It’s this mission —

saving warfighters’

lives — that is the most

fulfilling part of the

SABL’s work.

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Innovative Materials Bridge Partnership Between TARDEC

and Lawrence TechMatthew Sablan

The Army’s vehicles endure harsh environments in the fi eld every day. In Afghanistan, for instance, extreme heat and cold are both possible, and the country has some of the driest regions in the world, not to mention some of the most rugged mountainous terrain in the region. Continued operations in this environment stress material and systems components, and the

U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC) continues to fi nd ways to ensure that the Army’s vehicles withstand these diverse elements. As part of TARDEC’s ongoing research and development (R&D) initiatives, it entered into a partnership with Lawrence Technological University in October 2008 to develop, install and operate an environmental/loading chamber. This chamber is part of Lawrence Tech’s Center for Innovative Materials Research (CIMR), and its scientists and engineers assist TARDEC with environmental testing of advanced materials for vehicle armor and structural components.

A gunner checks his weapon while working through a sandstorm near Camp Victory, Iraq. The harsh conditions in Iraq and Afghanistan can be recreated at CIMR to allow TARDEC to test vehicles and components to ensure they will withstand the elements in the theater of operations. (Multi-National Corps Iraq Public Affairs photo.)

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Establishing the CIMRWith dedication of the CIMR building in early 2008, the Army has been able to capitalize on Lawrence Tech’s groundbreaking research and testing in the areas of infrastructure, military fabrics and other sustainable materials.

“Lawrence Tech has built expertise for a number of years,” declared Dr. Nabil Grace, Lawrence Tech Professor of Civil Engineering and CIMR Director. “We have a good

track record with simulation and new materials.”

For TARDEC, the CIMR is helping to create vehicle armor that weighs less than 100 pounds per square foot. “We plan to use the CIMR to look at new materials that can be incorporated into Army vehicles’ armor and structures,” TARDEC Engineer Scott Hodges commented.

Research CapabilitiesThe CIMR has a broad range

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of capabilities, so its research covers a wide range of topics. Built to military standards, the CIMR’s fi re/loading chamber can test objects up to 22 feet long, including military vehicles such as the High Mobility Multipurpose Wheeled Vehicle. The facility also is able to test impacts up to one million pounds of force in static, repeating or impact measurements.

The facility is equipped with hydraulic pressure pumps capable of 160 gallons a minute and can produce fl ames and other effects. The fi re/loading chamber can become hot enough to simulate the effects of Sept. 11, 2001, with temperatures up to 2,300 degrees Fahrenheit. The weather simulations can mimic up to 40 mile per hour winds, rains

and 100-percent humidity. The environmental loading chamber is built to Military 310 Global Climatic Data for Developing Military Product standards. No other facility in the United States can provide full-scale environmental testing such as the CIMR.

The CIMR’s environmental chamber measures 3,600 cubic feet — approximately 12’ wide x 21’ 6” deep x 14’ high — and is built from insulated blocks. The fl oor can withstand 150 pounds per square inch in a cyclic load condition while undergoing temperature transitions from -85 degrees to 185 degrees Fahrenheit. The chamber has a liquid temperature conditioning system that allows the chamber to prepare for American Society for

Testing and Materials freeze/thaw testing and rain preconditioning. After explaining these capabilities, Grace noted, “The CIMR is a comprehensive test facility.”

TARDEC Engineer Donald Ostberg explained that the CIMR also would assist TARDEC in researching armor components. TARDEC has Lawrence Tech test for specifi c properties and materials. “The work done at Lawrence Tech will let us model the materials more appropriately,” Ostberg remarked. “TARDEC lets them know, for example, what temperature range to test at. We help them make sure they’re not going in the wrong direction.”

The facility’s tests will allow engineers to design vehicles that are safer and capable of saving more lives. These capabilities also will allow TARDEC to reduce life cycle costs, since more tests can be performed in the same area, reducing travel and scheduling challenges.

Ongoing Technology Development“Lawrence Tech has conducted signifi cant work,” Grace stated. “Several graduate and undergraduate students are working around the clock.” On top of student work, professors and other engineers have access to the facility. The Federal Highway Commission, National Science Foundation and Michigan Department of Transportation have successfully engaged in research with Lawrence Tech.

Lawrence Tech’s Dr. Nabil Grace stands in front of the environmental chamber at Lawrence Tech's CIMR. The environmental chamber became operational in December 2009 and will be able to test vehicle components in various conditions, furthering TARDEC’s, ARL's and Lawrence Tech’s R&D initiatives. (Photo courtesy of Lawrence Tech.)

“We plan to use the CIMR to look at new materials. These materials

can be incorporated into Army vehicles’ armor and structures.”

“Lawrence Tech has built

expertise for a number of years.

We have a good track record

with simulation and

new materials.”

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Additionally, some of the research conducted at the CIMR is being looked at internationally. Ostberg also cited the work Lawrence Tech fi nished with ductile hybrid fabrics, a hybrid between glass and graphite fi bers. Furthermore, Lawrence Tech created a grid system for use with the Army’s ceramic armor tiles.

A new environmental chamber became fully operational in December 2009, and provided the CIMR even more capabilities. “This is a unique facility — we can provide any test and evaluation required,” Grace continued. “Our students benefi t from this as well, as Lawrence Tech produces well-rounded engineers with exposure

to real-world engineering problems and solutions.”

The new environmental chamber will allow vehicle armor to undergo full- and partial-scale vehicle and composite armor testing. The facility’s capabilities will allow the armor to be tested under salt spray, humidity, solar and ultraviolet light along with freezing and thawing environments. Vehicles can be put through their paces, ensuring their ability to deal with the harsh climates the Army typically operates in worldwide. Lawrence Tech’s CIMR also is investigating advanced carbon fi ber materials to improve military vehicle and body armor performance while also reducing total vehicle and equipment weight.

Matthew Sablan is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Com-munications team. He has a B.A. in English and history from Marymount

University in Arlington, VA.

Lawrence Tech’s CIMR is capable of various military scale tests. Here, a line of burners are active. These burners can reach temperatures up to 2,300 degrees Fahrenheit and will be used to test a vehicle’s heat thresholds and tolerances. (Photo courtesy of Lawrence Tech.)

The interior of the CIMR after a demonstration. The central surface combustion chamber can determine if component parts or vehicle systems can withstand the heat up to more than 2,000 degrees Fahrenheit and various amounts of force. The beams in the foreground are about to undergo testing in the CIMR, with the environmental chamber in the background. (Photo courtesy of Lawrence Tech.)

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Testing Capabilities Help

On the battlefi eld, Soldiers are faced with many explosive threats. Weapons such as mines or improvised explosive devices (IEDs) can cause great damage and harm to Soldiers and their vehicles. Finding a way to mitigate this is a high priority for the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC) in Warren, MI. Through extensive research and devel-

opment, engineers and scientists are working on methodologies that will help prevent extensive damage from these heinous explosive weapons.

A High Mobility Multipurpose Wheeled Vehicle (HMMWV) mounted with countermine equipment plows through a testing course at Yuma Proving Ground (YPG) in Yuma, AZ. Results from these tests are used by TARDEC researchers to design optimal countermine equipment to help provide Soldiers with better vehicle protection when driving on potentially mine-strewn battlefi elds. (U.S. Army photo courtesy of YPG Public Affairs Offi ce (PAO).)

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Surrogate Instrumented Mine (SIM) CapabilityTo develop tools that defeat explosive devices, TARDEC has the SIM, an engineering tool used to optimize, verify and character-ize countermine and IED neu-tralization equipment. The SIM system is comprised of specialized instrumentation devices and soft-ware. It was developed to evaluate countermine roller performance

as it relates to mine neutralization capability. This specialized tool can be used to conduct anti-tank mine vehicular overpass analysis in a dynamic environment.

The SIM, which provides real-world data not previously available, has proven to be cost-effective and has the ability to provide valuable in-sight into countermine and coun-ter-IED equipment performance.

“We have a couple of different versions of the same sensor, and by sensor I mean look-alike for a land mine. The imitation mine has mul-tiple sensors inside that allow us to tell what is going on with the pres-sure plate at any particular moment in time,” explained Chris Newell, Countermine Science and Technol-ogy Lead on TARDEC’s Mechanical Countermine Team. “We can take that capability and make it work

Mitigate Explosive Damage Patrick Pinter

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with a laptop, a wireless repeater and the mine. We literally have just three pieces of equipment we need to send.”

TARDEC developed the SIM as an effectiveness evaluation tool to assist in developing countermine and counter-IED neutralization equipment. The SIM’s mission is to provide consistent and accurate informa-tion regarding a targeted threat’s neutralization. Another objective for the SIM is to reduce equip-ment development time and testing costs.

The SIM contains no explosive charge so testing can be per-formed anywhere without explo-sive ordnance disposal support. Its purpose is to provide data regarding how an explosive

hazard would react to the me-chanical countermine equipment that it encountered. This data then provides engineers with the information they need to make any necessary changes to the countermine or IED defeat equipment so that the desired result is achieved.

Additionally, the Mechanical Countermine Team has support equipment that is often used with the SIM. The Mobile Data Acqui-sition trailer is used to support an isolated test site. “The capability we have in the trailer is not just a SIM support trailer. It supports the entire team function, which can be strain gauging, instrumen-tation and acquiring global posi-tioning data,” commented Newell. “We have the ability to monitor testing and some tools in there,

“We don’t have a facility, per

se. We have the sensors, and

wherever we need to take

them, we go with them.”A SIM is an engineering tool to optimize, verify and characterize countermine equipment performance. The SIM system is comprised of specialized instrumentation devices and software to evaluate countermine roller performance as it relates to mine neutralization capability. (U.S. Army photo courtesy of YPG PAO.)

An up-armored HMMWV mounted with SPARK rollers fore and aft runs through a testing course littered with TARDEC-developed SIMs. Information and data gathered from these tests allows engineers and researchers to develop better blast mitigation tools. (U.S. Army photo courtesy of YPG PAO.)

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like a drill press, that allow us to do on-the-fl y repairs or modifi ca-tions during testing.”

Countermine Testing FacilityThe Countermine Testing Com-plex is a dedicated area at Aber-deen Proving Ground (APG) in Aberdeen, MD. This testing facil-ity allows engineers to establish a countermine system’s capability to reliably clear a minefi eld seeded with pressure-fused, tilt-rod actu-ated, seismic, magnetic infl uence and acoustic mines. The facility includes mine lanes, a magnetic countermine test area, static blast test area, shop and equipment storage facilities, and fully func-tional offi ce space to support testing. “We frequently have the SIM at APG and YPG. Our sensor is getting pretty advanced at this point. We don’t have a facility, per se. We have the sensors, and wher-ever we need to take them, we go with them. This is a wonderful capability to have,” Newell voiced. “We have many different

organizations we have worked with in regards to the SIM. They have used our devices extensively to characterize per-formance of equipment that is going into theater.”

Continuing to Find SolutionsAs a result of TARDEC’s SIM ca-pability, signifi cant advancements

have been made in researching and developing countermine and counter-IED neutraliza-tion equipment, such as the Self Protection Adaptive Roller Kit (SPARK). Despite the devel-opments in countermine and counter-IED defeat tools, TARDEC and Product Manager IED Defeat/Protect Force must continually evolve because of the enemy’s ever-changing tactics. “It is challenging to design equip-ment to negate a threat like this, but we are learning more and more about mines, collectively as the Mechanical Countermine Team and TARDEC,” remarked Newell. “There are a lot of com-plicated devices out there. We continue to try to fi nd solutions. Overall, having these SIMs and having the ability to take them to the facility and countermine equipment manufacturers for testing has been a major benefi t.”


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“It is challenging to design equipment to negate a threat like this,

but we are learning more and more about mines, collectively as the

Mechanical Countermine Team and TARDEC.”

A Mine Resistant Ambush Protected vehicle equipped with SPARK rollers is run through countermine testing at YPG. Mines continue to be the most prevalent battlefi eld threat in Iraq and Afghanistan. TARDEC engineers are developing solutions to counter this threat and save Soldiers’ lives. (U.S. Army TARDEC photo by Scott Merritts.)

The SIM, buried during testing, serves as an effective evaluation tool to assist in developing countermine equipment. The tool also provides consistent and accurate information regarding a targeted threat’s neutralization. (U.S. Army photo courtesy of YPG PAO.)

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Laser Protection Research Laser Protection Research and Integration Laboratory and Integration Laboratory — Protecting Soldiers’ Eyes — Protecting Soldiers’ Eyes

and Optical Sensors and Optical Sensors Michael D. Kaplun

New cutting-edge tools and instruments are improving Soldier vision. Through the U.S. Army Tank Automotive Research, Development and Engineering Center’s (TARDEC’s) Laser Protection Research and Integration Laboratory, these tech-nological enhancements protect Soldiers’ eyes and day-vision cameras used for fi re control or antisensor laser weapons. The

laboratory provides Soldiers with equipment to combat laser threats and other battlefi eld or environmental hazards.

TARDEC Associate John Vala performs a sensor vulnerability test with a laser at the Laser Protection Research and Integra-tion Laboratory. Through enhancements in laser technology, Soldiers will have better protection against laser threats and hazards. (U.S. Army TARDEC photo.)

At right, the Omni-Directional Inspection System (ODIS) was originally developed by TARDEC to help Soldiers screen vehicle undercarriages for explosive devices, contraband and other suspicious materials at security checkpoints in Iraq and Afghanistan. ODIS is teleoperated by Soldiers who remain at safe standoff distances. Laser Protection Research and Integration Laboratory scientists and engineers continue to overcome daunting operational challenges to harden and enhance optical vison and surveillance devices being used by Soldiers in Iraq and Afghanistan. (U.S. Army TARDEC photo by John Vala.)

Soldiers from the 101st Airborne Division (Air Assault) train with advanced combat training gear, including the Digital Infrared Timing Simulator (DITS). DITS adds realism and authenticity in this newest form of nonlethal, force-on-force training equipment that employs lasers and blank cartridges to simulate actual battle. (U.S. Army photo by SPC Joe Padula.)

Located in a Class 100,000 clean room, the TARDEC facility seeks to preserve Soldiers’ sight, which increases survivability and mis-sion completion probability, while creating and developing materials that limit the amount of light that can fi lter through to a sensor or human eye. Ad-ditionally, the facility develops techniques that harden and enhance combat vehicle surveil-lance vision devices. Laboratory equipment includes laser sources, detection devices, spectromet-ric instrumentation, optical test benches, laser beam profi ling systems, optical microscopes and computer support facilities. New

devices are fabricated, integrat-ing the materials and designs. “The laboratory will be used to investigate sensor vulnerability to lasers and possible protection solutions,” explained TARDEC Associate Robert Goedert. “Lasers are becoming ubiquitous in the Army and will only increase their presence on the future battlefi eld.”

Various tests are conducted at the TARDEC laboratory on optical performance. By using vision devices with the laser protec-tion fi lters, engineers are able to determine the amount of damage a given laser attack may have on the human eye. These tests on

nonlinear optical materials and novel optical designs are increas-ing the laboratory’s capabilities and creating indispensible new tools for the Future Force. “The TARDEC lab has evolved into a great asset for assessing poten-tial problems relating to future laser devices and investigating potential protection techniques,” Goedert concluded.


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Paratroopers with the 82nd Airborne Division (Advise and Assist Paratroopers with the 82nd Airborne Division (Advise and Assist Brigade) train using infrared lasers and night vision optics at Camp Brigade) train using infrared lasers and night vision optics at Camp Ramadi, Iraq, Oct. 26. The paratroopers train constantly to maintain Ramadi, Iraq, Oct. 26. The paratroopers train constantly to maintain their fi ghting edge while standing ready to provide assistance to Iraqi their fi ghting edge while standing ready to provide assistance to Iraqi security forces. (U.S. Army photo by SPC Mike MacLeod.) security forces. (U.S. Army photo by SPC Mike MacLeod.)

MODELING AND SIMULATION (M&S)

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When Soldiers need an immediate vehicle solution on the battlefi eld, there is no time to waste in the design process. Design and development phases cannot take months or even weeks — engineers must fi nd viable solutions that can materialize in a matter of days. When this type of request comes in from the fi eld, engineers at the U.S. Army

Tank Automotive Research, Development and Engineering Center (TARDEC) use every tool possible to deliver vehicle solutions quickly to Soldiers on the front lines.

A Stryker mechanized unit from the 2nd Stryker Cavalry Regiment performs tactical maneuvers in a training exercise during Joint Task Force – East in the Novo Selo Training Area in Bulgaria. The CAVE has been used for Stryker vehicles and components to simplify and expedite vehicle design, development and platform enhancement. (U.S. Army photo by MSG Cecilio Ricardo.)

Total Immersion in Leads to Engineering Patrick Pinter

One such tool is the Cave Automatic Virtual Environment (CAVE). The CAVE is an immersive, virtual reality environment where projectors are directed toward a number of walls in a room-sized cube. Users stand inside the CAVE wearing special glasses to view the 3-dimensional (3-D) graphics that are generated. With these glasses, objects appear to be suspended in space, and viewers can walk

around them for a fully immersive view showing the object’s various sides and components. The CAVE gives designers and engineers the ability to see how components fi t and operate on a vehicle before any manufacturing is completed, providing enhanced design reviews that lead to more rapid development of vehicles and vehicle components. “We use the CAVE for many things, such as simulation,

design reviews and development of new vehicles,” explained TARDEC Engineer Jon Petrosky.

The ability to walk around a 3-D model is made possible by electromagnetic sensors. When a person moves around in the CAVE with a pair of special glasses on, his or her movements are tracked with these sensors, and the video adjusts accordingly.

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Virtual Environments Innovation

Depending on the vehicle model’s complexity, or fi delity, designs can be ready for viewing in the CAVE in a matter of days. If the model and the engineers’ plans are fairly simple, the design can be loaded into the CAVE quickly. “The process typically starts when we get contacted by someone who asks to see their vehicle in the CAVE,” commented Petrosky. “They give me their computer-aided design (CAD) data. We have a converter that converts almost any CAD format to the CAVE’s format. The length of time to import a vehicle into the CAVE really depends on the model. If the model is very detailed with every last nut and bolt, it takes longer. But if it is simple, it can be ready to go in only a few days.”

The CAVE also has a connecting desktop version so that the projected images can be viewed as needed on any computer. With

the desktop version, “when you leave here, the process is not over,” TARDEC Engineer Brian Brumm stated. “The data you see here in this immersive 3-D environment, you can bring back to your desk in a miniature version that will help you remember what you saw.”

Soldier Feedback Helps Design Engineers Deliver SolutionsFeedback from Soldiers who have used the CAVE has been extremely helpful for a product’s development phase by providing designers with a perfect opportunity to get comments from the people who have been and will be out in the fi eld using these vehicles. “Most of the people who have been in the CAVE say they really like it. Most have never been in anything like this. With something like the CAVE, where the design is right

there in front of them, people feel like they can reach out and almost touch it,” noted Petrosky. “Most Soldiers who come in here think this tool is very helpful. It gives them the ability to tell us what will work and what won’t work.”

The CAVE’s primary benefi t is that it is easy to use for everyone involved. Users do not have to be CAD or engineering experts to use the CAVE. Any customer, engineer or Soldier who walks in and picks up a pair of glasses can see the design. “When we get Soldiers or other people in here without CAD or engineering knowledge, they have the ability to easily understand and comment on designs or modifi cations without any formal training,” Petrosky remarked. Brumm also added, “What the CAVE is really good for is a nontechnical person. It helps them in understanding what is going on rather than looking at a normal CAD design. This tool can be used to explain ideas to other people rather than just engineers or designers. During your standard design reviews, PowerPoint slides with design specifi cations are usually only presented. In most cases, that is hard for a person to visualize. The CAVE takes the design review to the next level.”

“The TARDEC CAVE was one of the design review locations for the Stryker model,” Brumm remarked. “That was a project that was given an aggressive timeline for comple-tion, and the CAVE played a big

Eleven Soldiers from the 82nd Airborne Division visited the Detroit Arsenal in July 2009 to view the work done by TARDEC researchers and engineers. TARDEC Mechanical Engineer Allen Rubel explains a Stryker vehicle virtual environment to Soldiers during a visit to the CAVE. The special glasses make images inside the CAVE appear to fl oat in space with users able to virtually walk around them. (U.S. Army TARDEC photo by Ted Beaupre.)

“Most Soldiers who come

in here think this tool is very

helpful. It gives them the

ability to tell us what will

work and what won’t work.”

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role in meeting that timeline. The vehicle was quickly and complete-ly understood by all participants because they were able to see the vehicle without having to visualize it in their heads. Here you are able to visualize a vehicle in complete detail. There are not many places within the Army where you can do this type of thing.”

TARDEC also has the capability to bring the CAVE to customers out-side the TARDEC facility through the Reconfi gurable Automatic Virtual Environment (RAVE). Similar to the CAVE, the RAVE is a transportable, multiperson, high-resolution, 3-D video/audio environment. The system has three rear-projected screens and a front-projected fl oor, and it can be set up in various confi gurations.

Overall, the CAVE has simplifi ed vehicle design and development so that it is not just engineers making all the tough decisions — Soldiers and other customers can be involved in the process and provide suggestions. This type of feedback is particularly valuable from Soldiers so that when vehicles like the Stryker hit the road, the vehicle/Soldier

system is better prepared to meet battlefi eld demands.







“Here you are able to visualize

a vehicle in complete detail.

There are not many places

within the Army where you

can do this type of thing.”

CW3 Jason Greegor looks at a Family of Medium Tactical Vehicles in the CAVE virtual reality environment. His fi rst time in the setting, Greegor tries to reach out and “touch” the image. (U.S. Army TARDEC photo by Bill Dowell.)

Visitors to the CAVE are amazed by the virtual reality’s authenticity and capabilities. (U.S. Army TARDEC photo by Bill Dowell.)

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Computing systems and their abilities to recreate battlefi eld scenarios play an important role in training Soldiers and testing vehicle equip-ment operation. The virtual experience allows for signifi cant train-ing and testing time, as well as a safe training environment. At the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC), this capability is used extensively to ensure Soldiers

and equipment are ready for real-world battlefi eld experiences.

TARDEC Engineer Jonathan Joyce works with the Embedded Simulation crew station. Through tools like this, TARDEC has the ability to create a virtual battlefi eld environment that replicates real-world battlefi eld conditions for Soldiers getting ready to deploy to the theater of operations. (U.S. Army TARDEC photos by Bill Dowell.)

A Virtual Environment A Virtual Environment Gets Soldiers Ready Gets Soldiers Ready

for Actionfor Action Patrick PinterPatrick Pinter

The crew station screen gives the operator a simulated The crew station screen gives the operator a simulated view of what he or she would see on the battlefi eld. view of what he or she would see on the battlefi eld. The platform provides a number of stimuli to give test The platform provides a number of stimuli to give test subjects the feeling that they are really on the battlefi eld. subjects the feeling that they are really on the battlefi eld.

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With its Embedded Simulation (ES) Laboratory, TARDEC can develop component or system models. The lab’s ES system sup-ports local and long-haul distrib-uted simulation in both classifi ed and unclassifi ed environments. “The lab is more like a set of tools,” explained Scott Lohrer, Embedded/Distributed Simula-tion Team. “With the ES system, we can provide a simulation environment to promote the development of crew station technology. We provide the stimulus to the Soldier and, by creating the virtual battlefi eld, we tie in other tools, like a com-puter-generated force, and that tool basically will augment and fi ll out the battlefi eld.”

The ability to create a virtual battlefi eld environment that replicates real-world battlefi eld conditions for Soldiers, or any

other test subject, is one of the ES system’s primary benefi ts. “We provide a lot of the stimuli to give the test subjects a feel that they are in some kind of battlefi eld envi-ronment,” remarked Lohrer. “One example that we have worked with is to measure workload for a com-mander. We would simulate the tasks a commander would experi-ence in a real-world mission.”

Another system benefi t is the ability to replicate a weapon’s fi r-ing without actually fi ring a live round. “The crew stations that Intelligent Ground Systems build can be set up in a lab environment or moved inside a vehicle so our software can go with the crew in-side,” explained Lohrer. “Without the ability of live fi ring indoors, we can provide a live virtual envi-ronment where you can replicate a live fi ring.”

The lab houses primarily off-the-shelf computing systems capable of running either Linux or Windows operating systems that are used to evaluate component or system models. The lab supports both high-level architecture and distributed interactive simulation

protocols. “With the ES system, we can also work in a distributive environment,” commented Lohrer. “If there are other labs that are focusing on sensor modeling, we can run their high-fi delity models, for example, and create a coopera-tive modeling environment.”

The high-tech simulation work being done with the ES system is helping provide valuable infor-mation and feedback, which is promoting the development of crew station technology. This development is a key component in delivering to Soldiers the user interface and vehicle solutions they need to meet current battle-fi eld threats.







“We provide a lot of

the stimuli to give the

test subjects a feel that

they are in some kind of

battlefield environment.”

Joyce operates the ES crew station. Tools like this give Soldiers an opportunity to test equipment that could possibly be used on the battlefi eld.

The foot pedals on the crew station represent the gas and brake pedals that are located in combat vehicles, contributing to the simula-tor’s realism. The ES team tries to replicate the same environment and conditions that Soldiers will face on the battlefi eld.

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Ground Vehicle Simulation Laboratories Simulate Real-World Testing and Analytics

Patrick Pinter and Matthew Sablan

An MRAP and Interim High Mobility Engineering Excavator are shown on the RNPS where the posts, or fi xtures, are easy to set up and can accommodate vehicles with gross vehicle weight (GVW) up to 80,000 pounds. Computer- and servo-controlled hydraulic actuators provide the forcing function into the test specimen. The actuator duty cycle can originate from proving ground, computer-based or swept sine sources. (U.S. Army TARDEC photo.)

Experimentation has been the heart of scientifi c methodology for centuries and is often time-consum-ing and expensive, but it is necessary to advance

relevant technology and scientifi c research. The U.S. Army Tank Automotive Research, Develop-ment and Engineering Center’s (TARDEC’s) Ground Vehicle Simulation Laboratories (GVSL) have been leveraged by various program managers (PMs) and internal TARDEC engineers and scientists since 1985 to assist with reducing costs and time by simulating natural phenomena and environments. These actions have led to expanding experimen-tation capabilities and a wealth of usable data.

The U.S. Army develops some of the most highly technical ground vehicles in the world. Before these vehicles reach the battlefi eld, hundreds, sometimes thousands, of hours of testing and research go into develop-ing them and making sure they meet Soldier requirements. TARDEC has tools that facilitate this research and development to ensure these vehicles are ready when they hit the battlefi eld.

The GVSL uses modern technol-ogy to simulate the effects of real-world testing in a controlled environment. These facilities allow TARDEC to complete more tests on its premises, which, in turn, reduces travel and centralizes assets and test data accessibility.

The lab’s simulators include the Load Handling System Simulator (LHSS), Reconfi gurable N-Post Simulator (RNPS), Pintle Motion Base Simulator (PMBS), Vehicle Inertial Properties Evaluation Rig (VIPER), component test fi x-tures and tire test machines.

The LHSS is a motion platform designed to test the payload of Heavy Expanded Mobility Tactical Truck (HEMTT) and Palletized Load System vehicles. The RNPS features vertical tire and track-coupled fi xtures generally used for chassis and body/payload fatigue studies capable of characterizing or testing wheeled vehicles with two to fi ve axles. The PMBS uses servo-hydraulic actuators

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to reproduce real-world and proving ground terrain.

Vehicles can undergo preliminary testing at TARDEC, allowing engineers to fi nd and solve design problems before embark-ing on expensive real-world tests at the Army’s various test centers. The simulators can provide durability evaluations and characterizations of systems, subsystems and components. “The GVSL’s various simulators provide engineering support services to the Army ground vehicle platform managers,” re-marked TARDEC Acting Associ-ate Director for the Hardware and Man-in-the-Loop Simula-tion Group Dr. Mark Brudnak. “We can support laboratory testing, vehicle characterization, system and component durabil-ity, and hardware/man-in-the-loop simulation. Along with the other tools available, the GVSL provides test and analysis sup-port to a variety of customers.”

TARDEC also has two simula-tors that help researchers solve vehicle problems and familiarize Soldiers with new and upcoming vehicles. Those tools are the Ride Motion Simulator (RMS) and the Crew Station/Turret Motion Base Simulator (CS/TMBS).

Soldiers Inside SimulatorsThe RMS is a 6-degrees-of-free-dom motion simulator designed for crew station and Soldier-in-the-loop experimentation. It is capable of reproducing the ride of automotive, combat, tactical and nearly any other type of ground vehicle with high precision. It has integrated motion, audio and visual systems for high-fi delity simulations. “The RMS consists of hydraulic actuators, which move the simulator. It houses one occupant and has a recon-fi gurable cab, which you can bolt different components to, such as seats, displays and controls to simulate a vehicle cab,” explained Motion Base Technologies Team Leader Harry Zywiol. “It can be confi gured as a wheeled vehicle, a combat vehicle or any land ve-hicle. This permits us to simulate the mobility or ground motion of the vehicle on cross-country, secondary road or, really, any ter-rain surface.”

The ability to create various sce-narios in many environments is a unique RMS benefi t. The simula-tor can replicate environments that Soldiers will face on the battlefi eld in Iraq or Afghanistan or at any proving ground. “Many of the real Army proving grounds — we can simulate those and

more,” commented Zywiol. “Environments in Afghanistan or Iraq can be simulated using this motion base. The drive in Iraq is more of a fl at ride and less rough. In Afghanistan, the terrain is really rough and hilly. We can also simulate the visual sense, what you would see as you are driving. We can simulate hills, valleys, buildings, lakes, streams and the movement and actions of friendly, enemy and civilian forces using computer-generated imagery and models.”

With the RMS, TARDEC engi-neers address two challenges — quick solutions to vehicle prob-lems and understanding Soldiers’ cognitive processes. “What we do with this simulator are two kinds of work. The fi rst is helping to solve the problems currently in vehicles in Afghanistan and Iraq. Those problems could be seat-ing and restraint issues or con-trol positions that affect Soldier performance, fatigue and com-fort — basically, rapid solution

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“We can support laboratory

testing, vehicle characterization,

system and component

durability, and hardware/man-

in-the-loop simulation.”

An MRAP is being tested on the VIPER, which is used to accurately measure a vehicle’s center of gravity and inertial characteristics. (U.S. Army TARDEC photo.)

TARDEC’s Dr. Mark Brudnak keeps a close eye on data recorded during RMS testing. Brudnak and his team use the RMS test data to help engineers and designers better understand the decision-making process Soldiers use on the battlefi eld. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

testing,” explained Zywiol. “The second thing we do with this is heavily research focused. We are beginning to look at the Soldiers’ cognitive abilities, in particular the way Soldiers think and their thought processes to, ultimately, design signifi cantly better vehicle crew stations. The whole idea is that we have a good handle on how people respond to motion when they are in vehicles, but we don’t have a good handle on their cognitive processes, what causes them to make the decisions they are making and what are the in-fl uences on those decisions. That is what we are trying to research.”

The CS/TMBS also is capable of reproducing dynamic condi-tions encountered by combat or tactical vehicle. However, this simulator can be confi gured as either a full crew station simula-tor or as a gun turret system. There are six hydraulic actuators below that support a table capable of having vehicle subsystems mounted on top of it. “The idea here is that everything is recon-fi gurable to fi t any customer. For example, we can make this crew station cab into a High Mobility Multipurpose Wheeled Vehicle (HMMWV) or a Mine Resistant

Ambush Protected (MRAP) vehicle for whatever we have to do,” explained Zywiol. “This is a Soldier-based simulator that can fi t multiple people in it.”

The CS/TMBS is a popular testing tool with Soldiers. The experience Soldiers have in the simulator enables them to provide good feedback, which leads to mak-ing vehicles better. The simulator also allows Soldiers to test new vehicles that have not yet reached the fi eld. “There is a lot of feed-back from users. Soldiers really like it because they are deeply engaged in the scenarios, and they think it is realistic. However, they also point out that it is not per-fect. They let us know what key pieces we are missing so we can make it better,” Zywiol noted. “We often use this simulator to come up with what we call a duty cycle, which is synonymous with vehicle use history of new or upcoming vehicle designs. Vehicles on the drawing board don’t have a lot of use history, but we can get a good

idea of how Soldiers would drive and fi ght in these vehicles with the simulator. We can now have measurements on how the driver is using all the power and energy

on board. This information helps TARDEC engineers learn how the Soldiers are going to use the vehicle,” Zywiol continued.

VIPERThe VIPER is used to accurately measure a system's center of grav-ity and the inertial characteristics of trucks, trailers and turrets. Most vehicles can be evaluated without modifi cation or disas-sembly. “On this equipment, we test for the center of gravity and the moments of inertia. When the vehicle comes to an abrupt stop, there is a tendency for an object to resist changes. The VIPER is able to calculate it,” said Physi-cal Simulation Lab Operations Team Leader Terry Hoist. “There is interest to use it for Army or Joint Vehicle Programs, as well as private businesses.” The data

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“We can simulate hills, valleys,

buildings, lakes, streams and

the movement and actions of

friendly, enemy and civilian

forces using computer-generated

imagery and models.”

“Using simulation is

advantageous because you

can identify potential problems

and then quickly apply

engineering solutions.”

A close-up shot of what the simulator looks like while being tested. Personnel, seated in the RMS, train in similar conditions that Soldiers face on the battlefi eld. The feedback that TARDEC researchers and scientists receive helps in developing solutions for vehicle-related challenges Soldiers are facing in the theater of operations. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

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The CS/TMBS simulator allows Soldiers to test new vehicles that have not yet reached the fi eld. The experience that Soldiers have in the CS/TMBS enables them to provide good feedback, which leads to better engineered vehicles. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

generated by the VIPER are used by the Concepts, Analysis, Sys-tem Simulation and Integration (CASSI) group to model vehicle dynamics to help mitigate vehicle rollover hazards as well as im-prove handling performance and ride quality.

The VIPER consists of four in-ground scales, a confi gurable platform and the software necessary to post-process the results. “We have also done work with the Department of Transportation,” remarked Hoist. “Overall, we characterize vehicles approximately 40-50 times per year. The VIPER has become especially useful for the characterization of MRAPs.”

RNPSThe reconfi gurable motion base simulators feature vertical tire

and track-coupled fi xtures that are generally used for chassis and body/payload fatigue studies. These posts, or fi xtures, are easy to set up and can accommodate GVWs up to 80,000 pounds. “With the RNPS, we test the vehicle’s suspension, chassis and integrated subsystems to verify whether or not it can endure proving ground and real-world terrains. The ability to do the suspension testing here in the lab is a big advantage,” commented Hoist. “Using

simulation is advantageous because you can identify potential problems and then quickly apply engineering solutions.”

Computer- and servo-controlled hydraulic actuators provide the forcing function into the test specimen. The actuator duty cycle can originate from proving ground, computer-based or swept sine (analysis used for measure-ments involving high dynamic range or wide frequency inter-vals) sources. “We have ways to record information and moni-tor the vehicle while it is on the N-Post. We have strain gauges on the axles to make sure we are not bending them. We also mount ac-celerometers at various locations,” remarked Hoist. “We not only test the vehicles to see if they are durable, we also provide the data to our modelers and analytical

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“The value here is that we have

Soldiers right in the simulation

with the same ride they get in

the theater, and we are using the

same equipment they would be

using in the field.”

people so they can modify and improve their designs.”

Having testing equipment like the N-Post Simulator onsite at TARDEC gives engineers the abil-ity to test a vehicle’s durability before it is sent to a proving ground. “When you take the vehicle to the fi eld, you are going to have much higher confi dence since it has been through signifi -cant testing,” said Hoist. “That is the big selling point: to start here in our laboratory rather than at a proving ground. We perform simulations here to improve the vehicle’s chance of success before it is sent to a proving ground.”

The RNPS has proven itself to be a very useful tool in developing, studying and designing ground vehicles. It is constantly being used to develop vehicle solutions for to-day’s Soldiers. “This piece of equip-ment is very busy,” commented Hoist. “We have performed many HMMWV tests here. Now, with the focus shift to MRAPs, we test a lot more of those.”

PMBSThe PMBS is a hydraulically powered physical motion-base simulator designed to test light- to medium-weight lunette, or hitch, trailers with GVWs of up to 20,000 pounds. “Right now it is mostly used for testing with light tactical trailers,” said Hoist.

This simulator can impart mo-tion to a trailer’s lunette in three directions — vertical, lateral and longitudinal — to emulate the forces imparted by the prime mover. In addition, the PMBS can move each trailer wheel ver-tically, like the RNPS.

Continuing to Provide Soldiers with RidesTARDEC’s simulations allow a repeatable, controllable environ-ment and process to compare different technologies and solu-tions on the same vehicle while reducing or eliminating ques-tionable variables. Simulations ensure that when enhancements are made to a vehicle, its struc-tural integrity is not compro-mised, reducing the total number of tests. “In short, the physical simulation labs assist PM deci-sion making and provide pro-gram risk reduction, saving time and money,” Brudnak noted.

“The value here is that we have Soldiers right in the simulation with the same ride they get in the theater, and we are using the

same equipment they would be using in the fi eld,” remarked Zywiol. “Having this capability here highlights TARDEC’s labs.”TARDEC’s simulation tools are helping to deliver rapid solutions on new and future vehicle platform designs. These simulators are providing invaluable information and feedback that are being used to help today’s Soldiers remain lethal, mobile, survivable and sustainable on a very complex and evolving battlefi eld.







Matthew Sablan is a Writer/Editor



munications team. He has a B.A. in

English and history from Marymount

University in Arlington, VA.113


TARDEC’s simulations allow

a repeatable, controllable

environment and process

to compare different

technologies and solutions

on the same vehicle while

reducing or eliminating

questionable variables.

The HEMTT is a transport truck with a payload capacity of more than 10 tons. To ensure this vehicle fl eet remains at maximum operational capability, TARDEC’s LHSS tests HEMTT payload capabilities to fi nd any engineering problems that need addressing. (U.S. Army TARDEC photo.)

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Assessing Material and Assessing Material and Microstructural Failures — Microstructural Failures — Metallurgical and Failure Metallurgical and Failure

Analysis Laboratory Provides Analysis Laboratory Provides Critical AnalysisCritical Analysis

Michael D. Kaplun

TARDEC’s Demetrios Tzelepis displays samples of tested objects in TARDEC’s Metallurgical and Failure Analysis Laboratory. An EBG Materials and Environmental Team member, he orchestrates the laboratory’s analysis capabilities and metallurgical manufacturing processes. (U.S. Army TARDEC photos by Bill Dowell.)

Seeking to ensure Soldiers have safe, high-quality equipment to execute their operations, the U.S. Army Tank Automotive Research, Development and

Engineering Center’s (TARDEC’s) Metallurgical and Failure Analysis Laboratory specializes in providing objective, cost-effective analyses of component failures. The lab, located in the Prototype Integration Facility, utilizes the experience of highly skilled and trained technicians and engineers to provide material evaluation and identifi cation, microstructural evaluation, hardness testing and fracture analysis to assess component failures on all vehicle and weapons systems.

Analyses performed in the laboratory range from nuts and bolts, track components, wheel rims, weldments and steering arms, to High Mobility Multipurpose Wheeled Vehicle (HMMWV) doors and Mine Resistant Ambush Protected (MRAP) vehicle hulls. Nondestructive testing, including dye penetrant, magnetic particle inspection and radiography, are available to inspect suspect parts.

TARDEC’s Metallurgical and Failure Analysis Laboratory supports the Physical Prototyping Team, while also performing work for program managers, program executive offi ces, the Army Criminal Investigation Division, U.S. Navy, Naval Criminal Division and fi elded units. The lab is equipped with a scanning electron microscope (SEM) and electron dispersive spectrometer (EDS). The SEM can magnify a fracture face up to 10,000 times its size, and the EDS can do a qualitative chemical analysis

of minute inclusions in the material. The laboratory also has a spectrographic analyzer, which enables chemical analyses of most metals, including alloy steels, stainless (nickel-based) steels, titanium, copper and aluminum alloys.

Serving as the laboratory’s senior technician is TARDEC Associate Midge Krueger. “I have been asked to analyze parts that have caused fatal accidents to determine if the failure caused

the accident or if the accident caused the failure,” Krueger remarked. She also emphasized that TARDEC’s efforts are progressing to increase the laboratory’s use, which can be seen by the Engineering Business Group (EBG) Materials and Environmental Team’s recent addition of Demetrios Tzelepis, a materials engineer specializing in metallurgy. “His knowledge and understanding of the laboratory’s capability, as well as the metallurgical manufacturing processes, will enable us to better assess and fi x component problems,” affi rmed Krueger.






Hobart and William Smith Colleges. 115


Veteran Associate Midge Krueger studies test samples under a microscope in TARDEC’s Metallur-gical and Failure Analysis Laboratory. Analyses performed in the facility range from nuts and bolts to HMMWV doors and MRAP vehicle hulls.

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The lab utilizes the experience

of highly skilled and trained

technicians and engineers to

provide material evaluation and

identification, microstructural

evaluation, hardness testing

and fracture analysis to assess

component failures on all vehicle

and weapons systems.

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Conducting M1A2 Conducting M1A2 Software Maintenance and Software Maintenance and

Enhancement — M1A2 System Enhancement — M1A2 System Integration LaboratoryIntegration Laboratory

Michael D. Kaplun

Armor crew members from Company C, 1st Battalion, 66th Armor Regiment, 1st Brigade Combat Team, 4th Infantry Division, fi re the main gun of their M1A2 Abrams Main Battle Tank during a tank screening at Range 8b, Camp Buehring, Kuwait. The Soldiers’ training is in support of Multi-National Division – Baghdad and Operation Iraqi Freedom. (U.S. Army photo by SGT David Hodge.)

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Managed by TARDEC Engineer Keith Shockley with support from fellow TARDEC associ-ates Aaron Micyus, Matt Brief, Patrick Delehanty, Jim Gengler and Rhonda Paprocki, the SIL was developed in the mid-1990s and has continually added new capabilities. These new capabili-ties enable SEC engineers to fully develop and test their software before it is installed on a vehicle, while allowing software and test engineers to resolve a variety of fi eld problems and system trouble reports by implementing changes to the SEP display; diag-nostic; and Command, Control, Communications, Computers, Intelligence, Surveillance and Reconnaissance software. An

example of the SIL’s adaptable nature is the recently added simulation software that enabled SEC engineers to quickly develop and test software that integrated an experimental auxiliary power unit into the SEP system.

The laboratory shares its assets and supports other organiza-tions within TARDEC, includ-ing Mobility, Survivability and Project Manager Heavy Brigade Combat Team training devices. The SIL’s staff also validates trouble reports and software update testing on the M1A2 SEP v2, while supporting Mine Resistant Ambush Protected vehicle development and Stryker SIL acquisition.

TARDEC’s M1A2 SIL provides a multitude of systems integra-tion capabilities. The laboratory’s operations are integral in help-ing TARDEC achieve its chief mission — enhance warfi ghter readiness and protection.


The M1A2 System Integration Laboratory (SIL) provides the hardware, operating system, network and software infrastruc-ture that enables the Software Engineering Center (SEC) to conduct software maintenance and enhancement projects for the M1A2 Abrams Main Battle Tank System Enhancement Pack-age (SEP). The M1A2 SIL is an integral part of the U.S. Army

Tank Automotive Research, Development and Engineering Center’s (TARDEC’s) SEC under Associate Director Mark Slominski. The facility includes line-replaceable unit and system benches, develop-ment servers, emulators, tank software, Force XXI Battle Command Brigade and Below support, automated test software and various simulators. “The M1A2 SIL has proven to be an indispensible tool in sustaining the software for the Abrams tank to a high-quality level,” remarked Slominski.

These new capabilities enable

SEC engineers to fully develop

and test their software before it

is installed on a vehicle, while

allowing software and test

engineers to resolve a variety

of field problems and system

trouble reports.

Software Engineer John Konopik reads through auxiliary power unit emergency shutdown proce-dures for the driver’s integrated display station prior to simulation tests in the M1A2 SIL. (U.S. Army TARDEC photo by Bill Dowell.)

Software Engineer Scott Pletz tests the auxiliary power unit tank software interface in the M1A2 SIL, part of TARDEC’s SEC. The laboratory provides the hardware, operating system, network and software infrastructure that enables the SEC to conduct software maintenance and enhancement projects for the M1A2 Abrams Main Battle Tank SEP. (U.S. Army TARDEC photo by Bill Dowell.)

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TARDEC Associate Jonathan Bence manages the network from a console workstation, TARDEC’s heart to DREN connectivity. (U.S. Army TARDEC photos by Bill Dowell.)

DREN Provides DREN Provides TTARDEC’s ARDEC’s Computing PowerComputing Power

Michael D. Kaplun

The Defense Research Engineering Network (DREN) is a nationwide, robust, high-capacity, low-latency computer network created in the late 1980s to further crucial military research and development (R&D) projects. Operated by the Department of Defense (DOD) High Performance Computing Modernization Offi ce (HPCMO), DREN supports DOD- and

Army-wide R&D initiatives while providing digital, imaging, video and audio data transfer services between defi ned service delivery points.

DREN was originally used to connect Defense Supercomputing Research Centers (DSRCs) and 17 other smaller distributed computer centers. Today, there are four Defense Research Centers — two for the Army (Army Research Laboratory and Engineer Research and Development Center), one for the Air Force (Air Force Research Laboratory) and one for the Navy (Naval Oceanographic Offi ce). Several distributed centers have been removed from the DOD HPCMO, but many, such as TARDEC, have maintained their DREN connectivity to interact with DSRCs and other partners.

“DREN is a technology enabler,” remarked TARDEC Team Leader Ted Currier. “It provides a viable conduit to the Army for collaboration among the research, hardware and software development, engineering and testing communities.” As the backbone of TARDEC’s laboratory environment, DREN enables high-performance computing (HPC), embedded simulation labs, ground vehicle simulation

labs, advanced collaborative environments and systems integration labs to establish and connect simulation and test environments. This connection allows for real-time modeling and simulation experiments, as well as high-end computational analyses supporting DOD- and Army-wide strategic initiatives. Through DREN, TARDEC is able to partner and collaborate with other U.S. Army Research, Development and Engineering Command laboratories linked together by the network. “Much of TARDEC’s broadband efforts would not be possible without the interconnection fabric of DREN,” Currier affi rmed. “This is why the network was created and has fl ourished.”

Today, there are many other laboratories, agencies and testing facilities with DREN connectivity to perform research, development and testing (RDT). TARDEC’s DREN operation hosts approximately 150–200 workstations throughout the center and several larger systems,

such as supercomputers and HPC systems. These supercomputing systems and other DREN systems are accessible to anyone working within Army RDT and evaluation programs, in accordance with standard DOD computer use policies.

Through DREN’s active technological engagement, TARDEC is on the forefront of leading-edge connectivity and technology transfers across DOD. The center’s position ensures enhanced technological capabilities exist in and out of the network.

TARDEC Associate Jonathon Smereka checks network server connections. DREN connectivity is TARDEC’s conduit for high-speed DOD technology transfer.

TARDEC Associates Jonathan Bence (stand-ing) and Dan Kedziorek verify proper con-nections in a station network rack. Proper connections are vital to DREN operability.

Here, Kedziorek traces Ethernet wire connec-tions in a network rack. Ethernet wires are plugged in for each line to connect computers to the network server.

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“DREN is a technology enabler. It provides a viable conduit to the

Army for collaboration among the research, hardware and software

development, engineering and testing communities.”

Michael D. Kaplun is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Com-munications team. He holds a B.A. in English and media and society fromHobart and William Smith Colleges.

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What’s Going on at the HPC?TARDEC’s HPC houses more than 1,000 processors spread across two systems. These systems are used for analyzing various physics problems re-lated to ground vehicle systems. “TARDEC, being the ground vehicle integrator, has the ca-pability to evaluate the vehicle performance manufacturers are claiming against all of the design parameters,” remarked HPC Team Leader Ted Currier. “TARDEC transforms vehicle characteristics from the vendors into electronic models, and the scientists and engineers run an array of analytical simulations. Without this capability, it would be impossible to evaluate the complex vehicle systems that are being developed and fi elded.”

Researchers and developers from TARDEC and enterprise partners from the U.S. Army TACOM Life Cycle Management Command use the HPC to run numerous simulations in the areas of vehicle dynamic analy-sis, computational fluid dynam-ics (CFD) and computational structural mechanics (CSM). These complex physics-based analyses help solve potential ve-hicle problems before they ever reach Soldiers.

“Vehicle dynamic analysis is where the mathematical model of a specifi c vehicle is run over a real-terrain database that is represented mathematically in a supercomputer. This type of simulation helps us assess vehi-cle performance and the effects

of modifi cations to current ve-hicles,” commented Currier. “An-other focus area is CFD, which mainly focuses on analyzing fl uid fl ow. Here at TARDEC, our primary CFD focus is on inter-nal engine combustion and ther-mal and signature modeling. We also do a lot of analytical simu-lations in CSM to evaluate kit designs and material strength. This is one of TARDEC’s core analysis capabilities. Basically, CSM is determining the stresses and strains on the vehicle and how the vehicle is going to react in certain environments. In this case, environments are defi ned as force-loading scenarios based on vehicle operational events.”The HPC systems include sub-stantial online and offl ine storage and high-speed, high-bandwidth fi beroptic networking for HPC-based computation and visualiza-tion throughout TARDEC. The

High-Performance Computing High-Performance Computing Center Delivers Proven Center Delivers Proven

Vehicle SolutionsVehicle Solutions Patrick Pinter

“CSM is determining the stresses and strains on the vehicle and

how the vehicle is going to react in certain environments.”

When Soldiers enter the crew compartment of a tactical vehicle, they’re putting a lot of trust in the vehicle’s ability to meet the highest standards of mechanical performance, survivability and rigorous battlefi eld demands. One reason Army vehicles are able to meet and surpass these high demands results from the work being done by the highly skilled scientists and engineers using the U.S. Army Tank Automotive Research, Development and Engineering Center’s (TARDEC’s) High-Performance Computing (HPC) Center.

Two TARDEC engineers monitor the work being done in the HPC. The HPC runs simulations in a variety of areas but mostly focuses on vehicle dynamic analysis, CFD and CSM. (U.S. Army TARDEC photos by Todd Solgat.)

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TARDEC HPC Center was estab-lished in 1988 and designated as a Department of Defense (DOD) HPC Distributed Center from 1996–2002 and is still prominent today in the Army and DOD HPC communities.

“Back in the 1980s, the govern-ment and the Army were looking into scientifi c computation as a means to deal with the ever-increasing complexities in vehicle design and performance. Super-computing was becoming a new fi eld, and the Army decided it needed some sort of supercom-puting capability,” remarked Cur-rier. “Around that time is when TARDEC received this capability. Today we have a world-class com-puting center, supporting a large

user base of vehicle engineers, consisting of a team of 16 people.”

In addition to specifi c modeling and simulation in the focus areas of vehicle dynamics, CSM and CFD for developmental vehicle platforms and systems, the HPC is used to develop solutions for fi elded vehicle systems. “We do other less complex tasks, too, which are not so glamorous — something is in the fi eld and isn’t working, a component or structure is failing but is within design specifi cations, things like that where we have to fi nd a solution. It is smaller stuff but very valuable,” explained Currier. “TARDEC and TACOM receive requests from fi elded units, and TARDEC scientists and engineers using HPC can model and per-form physics-based analyses to solve the issue fairly quickly.”

Pushing to Develop Quicker Solutions in the FutureDespite the great work being done in the HPC, Currier knows that vehicle solutions need to be provided more quickly to better serve today’s Soldiers. The HPC Center is working with TARDEC

researchers and developers to provide a more rapid response for full-vehicle platform analyses and decision making. “TARDEC scientists and engineers have the ability to look at fatigue, corro-sion, stress fracture and thermal breakdown, crew survivability and a variety of other failure modes. The HPC Center super-computers here are being used to expand simultaneous, multi-discipline analysis capabilities,” Currier concluded.

With the work being done using the HPC, proven ground vehicle solutions are being delivered to American Soldiers. HPC research and analysis validates ground vehicle designs and models. This validation is imperative in deliv-ering strong, proven designs to Soldiers who require vehicles that meet rugged battlefi eld conditions.







“TARDEC scientists and

engineers have the ability

to look at fatigue, corrosion,

stress fracture and

thermal breakdown, crew

survivability and a variety of

other failure modes.”

Pictured are some of the computing equipment in the HPC. The HPC can resolve potential physics problems that appear in ground vehicle designs provided by the manufacturer.

An engineer tests HPC equipment to ensure it is running optimally. The HPC computers perform complex analyses on vehicle models. These analyses attempt to determine whether models measure up to the manufactures’ promised specifi cations.

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Established with the Bridge Engineering Team in the 1960s, the DSLSL began at Fort Belvoir, VA, former home of the U.S. Army En-gineer School. It continued

operating there until 1993, when the mission and equipment were transferred to the U.S. Army Tank Automotive Research, Develop-ment and Engineering Center (TARDEC) in Warren, MI. By the late 1990s, the DSLSL was operat-ing at Michigan’s Selfridge Air National Guard Base.

Securing the Army’s BridgesHoused inside an airplane hangar leased from the Air Force, the DSLSL tests and certifi es the safe load capacity of mobile military bridges, including verifying their working loads, overloads and

ultimate loads in accordance with the Trilateral Design and Test Code for Military Bridging and Gap-Crossing Equipment agree-ment among the U.S., United Kingdom and Germany. The facil-ity is equipped to accomplish this mission with an overhead gantry, 10 computer-controlled hydraulic load actuators on fi ve moveable transoms, tool crib, parts crib and fabrication area. “We test and certify a wide range of mobile bridges. Some are mounted on tank or truck chassis,” noted Suzanne Culkin, TARDEC Bridge Engineering Team Leader.

The DSLSL addresses the bridges’ structural capacity. These bridges are often modular, with vary-ing requirements, depending on the environments where they

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Dynamic Structural Load Dynamic Structural Load Simulator Laboratory (DSLSL) Simulator Laboratory (DSLSL)

Bridges Capability GapsBridges Capability GapsMatthew Sablan

Hydraulic cylinders hanging from the transoms above push through load cells onto the load feet, or whiffl es, to test this segment of bridging. Various loads can be applied to the Armored Vehicle Launch Bridge (AVLB). By testing bridging technology under various conditions, TARDEC engineers can certify the military’s bridges for operational deployment. (U.S. Army TARDEC photos by James Stankewitz.)

will be deployed. To fulfi ll this mission, the facility is equipped with a reconfi gurable load gantry with a one-million-pound load capacity. The gantry can apply a load that adheres to the North Atlantic Treaty Organization’s Standardization Agreements for Military Load Class vehicles. The gantry applies the load to a bridge with a width of up to 30 feet and a length of up to 165 feet. The DSLSL also has 100,000-pound load cells with National Institute of Standards and Technology-traceable and calibrated recording systems, which allow for high-precision load measurement and recording. While testing bridges

and materials, researchers use a 120-channel data acquisition system and custom load-feedback control system to help gather infor-mation for review. “We certify the military’s bridges will safely sup-port their crossing vehicles before the bridges are released to Soldiers in the fi eld,” Culkin summarized.

External ApplicationsIn addition to the Bridging Team, other organizations use the facil-ity to conduct analysis, evaluate equipment and otherwise support the Current and Future Forces. The DSLSL’s drop tower simulates the impact of a mine blast, and TARDEC has used the tower in testing. “TARDEC recently used the DSLSL to conduct engine tests in a joint effort with a contractor,” Culkin explained.

TARDEC Bridging Systems Proj-ect Engineer James Stankewitz explained another organization’s use of the facility, stating, “The National Aeronautics and Space

Administration (NASA) used the facility to test a system that is part of a prelaunch check for ice formation.”

Stankewitz added that the DSLSL “is also reclassifying bridges for the growing up-armored ve-hicles.” As the vehicles grow in weight to meet emerging threats, the Bridging Team must evaluate improvements to bridging tech-nology to accommodate the extra weight the up-armored vehicles place on the bridge.

The Bridging Facility provides invaluable support to Soldiers in the fi eld by ensuring their bridges are capable of transporting sup-plies and vehicles across numer-ous obstacles and waterways. Logistics issues are increasingly important in the current confl icts in Afghanistan and Iraq, and the Bridging Team’s tests are pivotal in ensuring that the Army’s vehicles are able to meet the mobility demands and challenges they are currently facing in Southwest Asia and around the world.

Matthew Sablan is a Writer/Editor



munications team. He has a B.A. in

English and history from Marymount

University in Arlington, VA.

“We certify the military’s

bridges will safely support

their crossing vehicles before

the bridges are released to

Soldiers in the field.”

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An AVLB is tested at the DSLSL. In addition to testing bridges, TARDEC’s DSLSL has been used by other organizations, such as NASA, for testing. The laboratory uses test equipment to ensure the launch bridge meets various usage requirements.

The DSLSL uses spare bridge modules to support the bridge ramps during a test. This represents the abutments’ or bank slope’s condition the laboratory wants to examine.

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TARDEC Chief Scientist Helps TARDEC Chief Scientist Helps Develop Army Ground Systems Develop Army Ground Systems

Technology FocusTechnology FocusMichael I. Roddin and Chris Williams

As U.S. Soldiers face evolving challenges on the battlefi eld, Dr. David Gorsich, Chief Scientist for the U.S. Army Research, Development and Engineering Command (RDECOM) Tank Automotive Research, Development and Engineering Center (TARDEC), must evaluate and make recommendations re-garding TARDEC’s science and technology (S&T) portfolio to

properly equip warfi ghters for today’s challenges, while strengthening technology for tomorrow’s battles.

Dr. David Gorsich began his position as TARDEC’s Chief Scientist in January 2009. A project under development in the laboratory he previously oversaw is the crew station/turret motion-based simulator, which is shown here testing a prototype turret. (U.S. Army TARDEC photo by Bill Dowell.)

With the number of challenges facing TARDEC’s S&T community, collaboration is crucial. Gorsich, who has nearly two decades’ experi-ence as an Army researcher and earned a Ph.D. from the Massa-chusetts Institute of Technology, depends on TARDEC’s senior technical experts (STEs) to dive deep into their areas. “I have a huge challenge on my shoulders in that I have a lot of ground to cover,” stated Gorsich, who began his new posi-tion in January 2009. “I can’t do this on my own.”

As TARDEC’s top scientist, Gor-sich must ensure that TARDEC associates conduct the neces-sary research and development (R&D) to meet emerging and future ground system battlefi eld requirements. To keep the orga-nization focused on the Army’s S&T strategy and in sync with the U.S. Army TACOM Life Cycle Management Command (LCMC) Annual Operating Cycle, Gorsich collaborates closely with TARDEC and RDECOM executives. “I focus on the STEs and the technology directorates,” Gorsich explained. “Because I reach out across the ground systems enterprise, I look to them for help because they are an entry point into their organi-zations and help me understand the S&T challenges in those groups. They also help me reach out to and develop the junior technical staff and our universi-ties and other research partners.”

Portfolio Management ProcessPortfolio Management ProcessGorsich believes proper portfolio management is essential to ensur-ing that TARDEC’s work benefi ts the entire TACOM LCMC and all its enterprise partners. Properly managing the ground system’s S&T portfolio affects nearly every aspect of the organization, including long-term investments in human capital and facility planning. “My interest

is making sure that TARDEC has a well-defi ned, rigorous portfo-lio management process that we then use to balance our technol-ogy portfolio,” he stated. “The overall way in which we manage a portfolio is very important to me. It’s probably the most important thing I’ve been watching since becoming chief scientist. My role is to ensure that we get it estab-lished correctly and that the tech-nology reviews we do at TARDEC feed that portfolio management process. It’s a big task that several people are involved with, and it’s very important to us in terms of transitioning technology and coordinating all of our different efforts and business processes.”

Proper portfolio management is particularly important given the current economy and changes coming to weapon systems procurement. In May 2009, U.S. Secretary of Defense Robert Gates announced that cuts in the Department of Defense’s (DOD’s) budget would affect the Army’s Future Combat Systems (FCS) — now Program Executive Offi ce Integration — and ground vehicle programs. Gorsich said proper portfolio management will be required for TARDEC scientists and engineers to develop solu-tions that are able to protect Soldiers from current threats, while also ensuring that research-ers are anticipating and develop-ing solutions for potential future needs. “The former FCS program had been looking to spin out its technologies as much as possible earlier-on in current platforms,” Gorsich remarked. “We see this as a greater opportunity to develop technologies for the current fl eet of vehicles, because wherever you see us doing future systems-related work, you see applications of that work being integrated into current tactical vehicle systems.”

Predicting Future Needs Predicting Future Needs Predicting Soldiers’ future needs has always been a challenge. In addition to the complexities and unpredictability involved in anticipating what may arise, the majority of TARDEC’s S&T budget is focused on meeting current requirements. Only a small amount has been dedicated to predicting and preparing for future needs. “Most of what TARDEC does is driven by custom-er needs today,” Gorsich clarifi ed. “A small amount of funding is actually addressing tomorrow’s customer needs. We cannot have half our budget dedicated to tasks that customers aren’t asking for — you just can’t do that in this current environment. It’s a challenge for us because we have a really small budget to work with to predict what’s coming down the path and invest in some key technology areas and initiatives to drive that discovery process.”

One future need that TARDEC is focusing on is developing, imple-menting and executing alternative fuel and energy programs. To im-prove the Nation’s energy security and decrease its dependence on foreign oil supplies, the Army must fi nd new ways of powering ve-hicles and bases through biofuels, hybrid-electric (HE) technology or alternative energy sources. As the Army’s and DOD’s lead for fuels and lubricants, TARDEC bears the responsibility for devel-oping these resources and ensur-ing that life cycle management is properly integrated into all new and existing ground vehicle pro-grams. Gorsich works regularly with offi cials in various power and energy groups to stay up-to-date on alternative power devel-opments. “We’ve been having a series of small strategy sessions to defi ne what we need to do in the area of fuels,” he explained.

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“We’ve looked at fuels, and we know that there’s a requirement to eventually have a single fuel and lubricant on the battlefi eld. The question we are dealing with now is, ‘How do we address that given our current vehicle fl eet?’ We’re also looking at jet propel-lant 8 and biofuels and how they behave in internal combustion engines — how do they affect the performance and reliability of those platforms?”

Gorsich said there are a number of key areas that TARDEC researchers are focusing on — one such focus area is the use of new innovative materials. As the Army Research Laboratory (ARL) develops new materials and composites that are lightweight, strong, durable and survivable, TARDEC associates will be responsible for developing and integrating them into the Army’s ground vehicle fl eet to meet mobil-ity, payload and survivability needs. “There is the problem of technolo-gy integration area of new types of materials, ceramics and composites with multiple properties that we haven’t necessarily seen before,” he explained. “The challenge is integrating those materials into the vehicle’s structure without de-grading current capabilities.”

Gorsich also plans to help TARDEC associates make strides in researching and developing other technologies throughout the coming years. “We’re looking at advancements in transmissions to get higher effi ciencies out of powertrains and higher densities out of batteries,” he stated. “We’re working hard to mature technol-ogy in intelligent ground systems (IGS) such that we can make autonomous ground systems that are practical, safe and effective on the battlefi eld. There’s still a lot of progress that needs to be made to create a fully autonomous system.” Additionally, there is a new

emphasis on neuroscience and cognitive systems. “We’re hoping that we can take into account a Soldier’s cognitive processes and link those into a platform to make the Soldier-machine interface more effective,” Gorsich remarked.

Additionally, Gorsich hopes that TARDEC’s Technology Integration and Assessment Process, which was used to develop the Mine Re-sistant Ambush Protected (MRAP) Vehicle Expedient Armor Program and deal with weight issues in the early days of operations in Iraq, will continue to mature. “This is a process by which we look at technologies, their readiness levels and their size, weight and power to assess whether there may be a good solution for a specifi c requirement,” he related. “Then we look at all the ‘-ilities’ of the system — survivability, transportability, mobility, etc. — and match those signatures. We’ve found we can as-sess the impacts of many technolo-gies on a system.”

Partnering with AcademiaGorsich leverages TARDEC’s partnerships with academia, serv-ing on a number of university review boards and assisting in developing curriculum that may

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This Utility Variant Vehicle is equipped with a remote weapons system, night-vision capability, ballistic glass, video cameras, touch-screen controls and a diesel-electric hybrid engine. Future tactical vehicles will have extremely large auxiliary power demands. Hybrid vehicles are an important P&E thrust area for TARDEC’s energy research program. (U.S. Army photo.)

TARDEC Chief Scientist Dr. David Gorsich (left) and a TARDEC associate speak with Michigan Technological University student Timothy Rossetto about his experience working in TARDEC’s Summer Hire Program. (U.S. Army TARDEC photo by Ted Beaupre.)

produce next-generation Army scientists. “What’s important to us is having students that have an interdisciplinary perspective on life,” he stated. “They’re not just trained in mechanical engineer-ing, mathematics or electrical engineering. We want them to have a broader perspective when they walk in the door. When they come to TARDEC, we want them to take a more systems engineer-ing approach and understand our overall acquisition process.”

As TARDEC continues its rela-tionships with those in academia through joint research projects, Gorsich believes it’s important to involve more students with TARDEC engineers and scientists. “We must be involved personally with the graduate students who are on the university projects we’re funding,” he expressed. “As we do that, we have a better opportunity of bringing them onboard to TARDEC and also getting more from them in terms of transitioning the research and technology they do at the university for TARDEC.”

Each summer, several students and faculty members from various universities work at the TARDEC campus in Warren, MI. Gorsich said it is imperative that TARDEC engineers work closely with the faculty to facilitate mutually ben-efi cial relationships. “We need to work with faculty to understand what the fundamental gaps in knowledge are and provide them with an understanding of various programmatic needs and tech-nology issues that our engineers and scientists face in emerging technology programs,” he stated. “The faculty should understand what types of research to propose to us and what types of students to recruit who would be interested in TARDEC’s research requirements. That type of collaboration is very

important, and it has to happen face-to-face for it to work.”

Rewarding InnovationIn a time when the enemy is highly agile and adaptable, capable of exploiting available technologies, the Army remains steadfast in staying ahead of emerging threats to our Soldiers and their vehicle systems. TARDEC continually works toward this goal by fostering innovation and “out-of-the-box” thinking. Gorsich and other TARDEC senior scientists and technical staff have established the TARDEC Innovation Grant to cre-ate a fl ood of new technology ideas.By enabling associates to translate novel ideas into new in-house capabilities, along with technolo-gies and processes, the TARDEC Innovation Grant gives the orga-nization an essential leading edge in technology R&D. The goal for the grant is to acquire and manage knowledge so all technology proj-ects, whether successful or unsuc-cessful, always benefi t TARDEC. The grant’s output will be reviewed by a board for patentability and business development potential.

Typical grant amounts will range from $25,000 to $200,000. In ad-dition, according to Army Regula-tion 27-60 – Intellectual Property, intellectual property owners can receive up to 10 percent of its

profi ts, as well as additional funds for the laboratory. All innovation funds are good for one year. The fi rst TARDEC Innovation Grants were awarded to: Dr. Matt Castanier and Dr. David Lamb to develop an analytical tool to im-prove predictions of durability and reliability of vehicle fl eets; Dustin Gascho, Michael Baker and Daniel Rowell to develop a restraint system for military vehicles; Jason Hefter, Bernard Sia and Randy Cassner to design a high-strength, low-weight footbridge; Jeremy Gray to develop a prototype for a door opening mechanism for the Small Robotic Toolkit; William Norton and Steve Caito to design a new type of rocket propelled grenade defeat mechanism; and Dr. Thomas Meitzler and Dr. Elena Bankowski to develop an experi-mental prototype of nanometer-sized spintronic devices that can be attached to armor to detect microwave radiation for anti-radar and communications applications.

Energizing the Technical Workforce As chief scientist, Gorsich serves as TARDEC Director Dr. Grace M. Bochenek’s principal scientifi c advisor and is respon-sible for developing TARDEC’s technical staff and its reputation as a nationally recognized center of technical excellence. During a

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A platform Hybrid-Electric Reconfi gurable Moveable Integration Test Bed (HERMIT), developed by TARDEC, is designed to evaluate ground combat vehicle components. Platforms such as the HERMIT will allow TARDEC to address HE needs and assist in future ground vehicle systems development. (U.S. Army TARDEC photo.)

meeting with TARDEC associates

on Oct. 7, 2009, Gorsich highlight-ed the organization’s renewed com-mitment to research and the role of newly created positions within the Army’s S&T community. “It is very important that even though we get caught up in all the current activities we do in war, and all of the things we do for our custom-ers, we must spend the time to keep updated and active in technologies related to automotive research,” explained Gorsich.

To further support Gorsich and TARDEC’s scientifi c community, STE positions have been created across TARDEC’s six technical fo-cus areas. The STEs work alongside TARDEC’s associate directors and are responsible for technical devel-opment in their selected areas. STEs will play a crucial role in develop-ing and evaluating TARDEC’s S&T portfolios. “As I’m concerned about the development of the technical staff in the entire organization, the

STEs are concerned about the tech-nical staff in their specifi c organiza-tions. We have very similar objec-tives, and they mirror each other,” Gorsich explained. “If we only have one transmission expert in all of TARDEC out of 1,500 people and yet we manage approximately 2,000 systems across the command, that’s a problem. I rely on those STEs and meet with them on a regular basis, and we come up with strategies on how to address and build up the right skills in the organization.”

Dr. Peter Schihl has been named STE for TARDEC’s Power and Energy Team, and Dr. Jim Over-holt has been named STE for TARDEC’s IGS. As of press time, STE positions were still being fi lled in the areas of Surviv-ability, Force Projection, Vehicle Electronics and Architecture, and Concepts, Analysis, System Simulation and Integration.

Another program, TARDEC’s Factor IV Program, helps defi ne TARDEC’s technical career track. Factor IV provides opportunities for researchers to eventually move into higher positions, such as those of STEs. Gorsich emphasiz-es the importance of publications, patents, society memberships and other factors in moving TARDEC

associates forward in their careers and having the correct skill sets needed by customers.

Looking Forward Despite the economic challenges ahead, Gorsich maintains that TARDEC will continue to play an essential role in developing new technologies that will benefi t Soldiers. “We know that transporta-tion and the need to have protected mobility will always be crucial,” he offered. “We know that there will be a focus on having robust, mobile, safe systems that are reli-able — that is a given. Ultimately, we have to continue to focus part of the Army’s S&T portfolio on improving ground systems viability and performance, even with the unpredictable economy. Because of this and because the Nation cannot afford to lose its automotive indus-try and manufacturing base, we are strengthening our partnerships with industry. We cannot lose this organic capability — it’s too tied in to national defense and embedded with so many different businesses and jobs in the United States, so we will address this issue over time.”

Michael I. Roddin is the TARDEC Strategic Communications Director and accelerate Editor-in-Chief. He holds B.S. degrees in English and journalism from the University of Maine and an M.S. in marketing from the University of Southern California. Roddin is a former Army Advertising Program Manager and 3-time Army Keith L. Ware Journal-ism Award recipient. In 2005, he was selected by the Secretary of the Army for Editor-of-the-Year honors.

Chris Williams is a Writer/Editor with BRTRC and provides contract support to TARDEC’s Strategic Communica-tions team. He has a B.A. in communi-cation from Wayne State University in Detroit, MI, and has previously written for The Source newspaper in Shelby Township, MI, and The Macomb Daily and C & G Newspapers in Macomb County, MI.

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“Ultimately, we have to continue to

focus part of the Army’s

S&T portfolio on improving

ground systems viability and

performance, even with the

unpredictable economy.”

During the recently completed Convoy Active Safety Technologies testing, Soldiers wore a neuroergonomic cap to record brain waves related to their reactions to driving autonomously. Gorsich hopes to use neuroscience research to take Soldiers’ cognitive functions into account when developing this and other IGS technology. (U.S. Army TARDEC photo by Paul Tremblay.)

Energy Storage Team Leader Sonya Zanardelli (right) explains to Chiarelli TARDEC’s Power and Energy (P&E) initiatives in developing advanced Lithium-ion (Li-ion) batteries that improve energy storage capabilities. TARDEC is shouldering numerous alternative energy/energy storage challenges through its advanced P&E initiatives, including developing advanced Li-ion batteries that improve energy storage capabilities and researching electric, hybrid and fuel cell technologies. The strategies TARDEC is developing have the potential to change how the military uses fuel and energy over time.

TARDEC Engineer Harry Zywiol discusses the Ride Motion Simulator’s capabilities for total Soldier training immersion in this laboratory’s unique simulated environment. From left: Fletcher; Special Assistant to the VCSA in Science and Technology Dr. Kathleen Quinkert; Bochenek; Chiarelli; and Zywiol.

Vice Chief of Staff of the Army (VCSA) GEN Peter W. Chiarelli toured the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC) in Warren, MI, on Nov. 24, 2009. During the visit, TARDEC Engineer Dr. Mark Brudnak (right) showcased several test lab capabilities in TARDEC’s Ground Vehicle Simulation Laboratory. From left: Chiarelli; TARDEC Director Dr. Grace M. Bochenek; TARDEC Executive Director of Development Thom Mathes; and TARDEC Military Deputy COL Eric Fletcher. (U.S. Army TARDEC photos by Elizabeth Carnegie.)

TARDEC Ground Vehicle Integration Center Director Dr. Bruce Brendle highlights Prototype Integration Facility (PIF) projects currently in production at TARDEC facilities. Pictured from left: Brendle; Acting PIF Associate Director Luis Hinojosa; Chiarelli; Mathes; Bochenek; and Executive Director of Engineering Magid Athnasios.

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