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L-3 FUZING & ORDNANCE SYSTEMS PUBLIC DOMAIN. Th is document cons is ts o f genera l capab i l i t i es in format ion that i s not def ined as cont ro l led techn ica l data under ITAR Par t 120.10 or EAR Par t 772.

A Real-time RF/Bluetooth Application for Low Cost Fuze Test Telemetry Collection Gregory Bixler Abstract # 18558 May 2016

TPL-313352

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Problem Statements • Data recovery is difficult from a damaged device

– Sensor wires are easily broken in environmental/high-g impact – Imbedded Data Recorder may not survive the test

• Centrifuge is typically required for acceleration testing – Slip rings, lead time for Test Fixtures, balancing, etc… – Troubleshooting an issue with an electromechanical device under

dynamic forces is problematic

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Projects & Goals

• 3 similar projects related to wireless data acquisition – Wireless data transmission during high-g event

• Basic prototype, Proof of concept testing – Non-centrifuge acceleration test bed development

• On board data record, and wireless transmission • Build a new test bed

– Wireless Centrifuge transmission options • Project currently in testing phase

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Wireless High-g Project Goals • Pick a wireless technology for testing

– Needed to stream an analog and digital signal – Desire to stream data as fast as possible

• Build a prototype for impact testing – A platform for on board devices, with wireless streaming of

test signals. • Subject the article to a high-g impact

– See if the device survives and continues to function

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High-g Project: Controller Selection • Needed to transmit as fast as possible • Transmit analog data (accelerometer), and digital

(impact switch closure) • Internal Memory not required/desired • Decided to convert the analog data to digital using a

microcontroller (Arduino Uno) before transmitting

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High-g Project: Method of Data Transmission • Transmitter Options:

• Bluetooth • Arduino compatible adaptors (“Shields”) available • Large packet sizes

• Wifi Shield (802.11, 2.4GHz WLAN) • Wireless network required • Transmission speed • Stability of connection

• XBee Transmitters (required Xbee Shield) • Nodal network platform for plant equipment continuous monitoring • Extensive features for cloud data collection, remote monitoring.

• RF Transceiver • Cheap ~$3 • Simple • Small packet sizes • Small board, < 1 in2

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High-g Project: Prototype Build • Electronics Packaging

– 3D printed housings – Microcontroller & Sensor in separate housings – Supporting material added

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High-g Project: Test Shot & Results • Known velocity and mass of Bird resulted in ~5,000g impact • Article measured the event, survived impact, and continued to

transmit throughout the event

Recorded Data from the wireless receiver

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High-g Project: Test Shot & Results • Limitations with the Initial Prototype

– Sampling Rate • Limitation with the microcontroller

– Range of transmission • Improved antenna • RF transceiver can handle a faster transmission rate

• Proof of Concept test provided confidence – Implemented into a dynamic acceleration test bed project – Potential for a wireless centrifuge

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Non-Centrifuge Acceleration Test Bed Project • L-3 FOS developed a Rocket on a Rope (ROR) test facility for

special test purposes – Test bed for wireless and on board instrumentation, no slip

rings/centrifuge needed – Allows for higher fidelity simulation of actual rocket motor

acceleration environment – Can support quick turn evaluation of concepts once a particular

acceleration setup has been established – The facility was based on similar methods used to test rocket

launched systems – Onboard data recording in parallel with wireless streaming.

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Rocket on a Rope: Test Stand

Arrestor Rocket

Wire support Wire support

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Rocket on a Rope: Hardware Overview

COTS available rocket motors

Wire guides Payload

Radio/ transmitter

Internal Memory

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Rocket on a Rope: Video

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Rocket on a Rope • Transmitted and on board data captured

Transmitted and on board data identical

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Rocket on a Rope Test • Transmitted data was captured successfully

– Test article on board data recorder destroyed as part of test and data was not recovered

Portion of impact acceleration transmitted

Wireless transmittal ensures data capture despite test article destruction

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Wireless Data Recorder Next Steps

• Secondary velocity measurement – Photo eyes, Radar, High speed camera?

• Data capture/programming – Optimization of transmission speed – Robustness of transmission – Develop interface that uses “standard” type high g accelerometers

for use in high g applications

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Future Projects • Centrifuge with wireless signal transmission

– No need for slip rings – Prototype can be accomplished at fraction of the cost of current test

methods – Troubleshooting issues simplified

• Plug in more wires to transmitter, receiver sees no changes

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L-3 Fuzing & Ordnance Systems Business Development Department

3975 McMann Road Cincinnati, Ohio 45245

513-943-2000

Contact Information

A Real-time RF/Bluetooth Application for Low Cost Fuze Test Telemetry CollectionProblem StatementsProjects & GoalsWireless High-g Project GoalsHigh-g Project: Controller SelectionHigh-g Project: Method of Data TransmissionHigh-g Project: Prototype BuildHigh-g Project: Test Shot & ResultsHigh-g Project: Test Shot & ResultsNon-Centrifuge Acceleration Test Bed ProjectRocket on a Rope: Test StandRocket on a Rope: Hardware OverviewRocket on a Rope: VideoRocket on a RopeRocket on a Rope TestWireless Data Recorder Next StepsFuture Projects Contact Information