engineering design challenges for military and aerospace products
DESCRIPTION
Talk for Society of Women Engineers 2013 national conference for the session on careers in government and military. The goal is to have an interactive session to engage college students in thinking about very large scale engineering projects typical of government and military.TRANSCRIPT
Engineering Design Challenges for Military and Aerospace Products
Debbie PostSandia National Laboratories
Society of Women Engineers National ConferenceOctober 24, 2013, Baltimore, MD
Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy's National Nuclear Security Administration
under contract DE-AC04-94AL85000. SAND NO. 2011-XXXXP, Doc ID: 53285371
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Engineering Design Challenges . . .
• Mission constraints– High reliability– High consequence of failure– Security and safety– Weight and volume
• Environmental constraints– Shock and vibration– Temperature– Radiation– Rain, mud, dust, sand, saltwater
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… for Military and Aerospace Products
Submarines
Missiles
Satellites
R&D
My Career with Military Systems
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Can You See Yourself in This Picture?
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Submarines
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Submarines
• What features or capabilities does theNavy need?
• What do you think?
• Write down at least ten things that you think are important
Silent Service Video
Customer Needs for Submarines
• Reliable software• Rugged equipment• Long operational life• Long cruising range• Weapon systems• Crew Safety• Stealth• Etc.
Customer Needs for Submarines
• Reliable software• Rugged equipment• Long operational life• Long cruising range• Weapon systems• Crew Safety• Stealth• Etc.
Challenges for Rugged Design:Fleet Ballistic Missile
Submarines
• Continuous vibration
• Shock• Radiation• Salt water• Confined
environment
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Human Factors for Submarines
• Launch control console
• What is important for the operator?
• What are the worst case conditions under which this equipment would be used?
USS Minnesota Video
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Human Factors for Submarines
• Status-at-a-glance• Tactile / visual feedback• Rugged hardware• Reliable software• Redundancy
• Other considerations: – The operator is very
sophisticated– Hardware & software must
be upgraded periodically
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Trade Offs for SubmarinesStealth vs. Weapon Systems Performance
Depth:Stealth,Protect
Boat
Surface / Shallow:Easier to Launch
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Solution: Launch
Underwater
Trade Offs for SubmarinesStealth vs. Weapon Systems Performance
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Tomahawk Cruise Missile(torpedo rocket aircraft)
YouTubeTomahawk
Missile Flight Testing
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What do you think are the biggest design challenges?
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• Weight & volume• Shock & vibration• Long shelf life• Storage temperatures• Etc.
• Navigation• System
integration• Materials
compatibility• Etc.
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Missiles
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Missiles & Driving Requirements
• “Driving requirements” for a product are those which present the greatest design challenge
• What do you think?
• Talk to your neighbor for 2 minutes and identify several driving requirements for the missile systems shown here
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Missiles & Driving Requirements
• Physical environment• Performance• Weight, volume• Reliability• Cost• Man-Machine Interface• Maintenance• Operational life• Etc.
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Anti-Armor Missiles
YouTube French ERYX
Anti Tank Missile Training
Exercise
Driving requirements: Think about the
UU (Ultimate User)
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Anti-Armor Missiles
• Man-machine interface– Basic user– Arm as late as possible
• Physical environment– Cold & hot
temperatures– Water, dirt, mud, snow– Rough handling
• Weight• Cost
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Intercontinental Ballistic Missiles (ICBM)
What do you think are the most stressing physical environments for design?
Minuteman III Launch Animation
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Intercontinental Ballistic Missiles (ICBM)
• Shock and vibration– launch– missile staging– reentry
• Exoatmospheric flight– radiation– temperature
extremes– temperature shock
• Etc.
Design Example: Flight Test Instrumentation for an ICBM
• Shock• Weight
• Volume• Bandwidth• Power and power and power
• Budget and schedule• Reliability
Submarine Launched
Ballistic Missiles
Design Challenge• limited volume in
submarine (height, width)
• non-aerodynamic shape of nose
Solution: Aerospike• mitigates shock-
wave• functions as
aerodynamic nose cone, without the cone
Submarine Launched Ballistic Missile: 1st Sea Trial of Trident II
• The problem– Water slams into nozzle– Missile out of control
• Lessons to be learned– Unknown unknowns– Test, test, test (the
Hubble Space Telescope syndrome)
YouTubeFirst Submarine Test
D5 Missile
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Satellites
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Defense / Aerospace Product Life Cycle
• Long life (decades)• Maintenance• Upgrades• End of life
• High complexity• High cost• High reliability• High consequence of failure
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Satellites• Long life• Hardware: No upgrade,
maintenance or repair• Software: upgradable?• End of life: de-orbit
• Radiation• Temperature extremes• Power consumption• Few, one-of-a-kind
production
GPS Video
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• Radiation– Rad-hard
electronics– Shielding
• Power– Solar– Radioisotope
thermal generator (Cassini Spacecraft)
• Manufacturing– Few or one-of-a-
kind production
Design & Manufacturing Challenges for Satellites
Radiation Hardened Integrated Circuits
• Sandia National Laboratories’ CMOS7 technology– strategically radiation-
hardened– 3.3 volt, 0.35 micrometer, SOI
(Silicon-on-Insulator) CMOS process
– 24 mask level process with 5 metal layers
– Custom, high reliability ASICs
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Research & Development
R&D for Arms Control
• Monitor high value items
• Report back to IAEA• Self-protect against
tampering• “Trust but verify”
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Storage Monitoring for Treaty Verification
Remote Monitoring
Item Monitoring
Facility Monitoring
Local Monitoring
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Remote Monitoring
Item Monitoring
Facility Monitoring
Local Monitoring
What do you think are the driving requirements for this system of systems?
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Remote Monitoring
Item Monitoring
Facility Monitoring
Local Monitoring
Low false alarm rateSecure communicationsTamper detectionDust, cold, rodents, vibrationCost vs. low volume production
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Remote Monitoring
Item Monitoring
Facility Monitoring
Local Monitoringwireless messaging
encryption
date/time stamp
unique identifier
tamper sensors
fiber optic seal
motion sensors
case tamper switches
tamper resistant housing
gloss coating
compound joints
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R&D for WMD Response
First responders need fast and accurate information
MicroChemLab: Portable Chemistry Lab
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In Conclusion
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Do You See Yourself in This
Picture?
Engineering Design Challenges for Military and Aerospace Products
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Photo & Video Credits• Ball Aerospace & Technologies Corp. (http://www.ballaerospace.com)• Boeing (http://www.boeing.com)• Cadence (http://www.cadence.com/)• Cogswell Polytechnical College, Online Fire Science Program
(http://www.cogswell.edu/firescience)• Defense Acquisition University (https://dap.dau.mil)• GPS Website of Air Force Space Command (http://www.gps.gov/multimedia/images/)• Lockheed Martin (http://www.lockheedmartin.com)• NASA (http://saturn.jpl.nasa.gov/multimedia)• Raytheon (http://www.youtube.com/watch?v=ym_KlL1qAUw)• Sandia National Laboratories (http://www.sandia.gov)• Transformers Movie Website (http://www.transformersmovie.com/Dark_Of_The_Moon)• United States Air Force (http://www.af.mil)• United States Army (http://www.army.mil)• United States Navy (http://www.navy.mil)• US Army War College (http://www.strategicstudiesinstitute.army.mil)