Test and Evaluation of Electromagnetic Railguns

Transcription

1 Test and Evaluation of Electromagnetic Railguns NDIA Gun & Missile Systems April 23-26, 2007 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited

2 EM Railgun Game Changing Slide 2

3 How it Works Magnetic field generated around rails as current flows through circuit Magnetic field interacts with armature current generating a Lorentz force Lorentz Force accelerates armature and projectile down barrel Switch closes, current flows through rails & armature B J F Lorentz Force = Current (J) X Magnetic Field (B) or Lorentz Force =1/2 Inductance Gradient (L ) * Current (I)^2 Slide 3

4 Current Facility Key Statistics (2007) Operating Muzzle Energy: up to 7 MJ Terminal Area: 16-MJ Slug Gun lines: 1 32-MJ Green Farm PFN Temporary Control Vans 8-MJ SSG Gun Line #1 Terminal Catch: Up to 16-MJ Slugs 2007 Slide 4

5 Current Facility Slide 5

6 32-MJ PFN Fiber Optic Cable Controls Cabinets System Controller (Located in Control Van) Slide 6

7 Switching and Output Cables Spark Gap Switch 350-MCM Coaxial Cable Slide 7

8 SSG Construction Safety Shield (capable of stopping broken studs) Containment Studs Bore Insulators Breech Studs Upper Containment Plate (3 total) Side Containment Plate (8 total) Lower Containment Plate (3 total) Pre-Injector Tube Rail Backing Insulators Launch Package Slide 8 Rails

9 Launch Package Total Mass = kg Aluminum Slug and Armature Nylon Bore Riders Design based on earlier work at Kirkcudbright and Greenfarm 2.40 kg 2.89 kg 3.40 kg 3.20 kg Slide 9

10 Gun - Facility Interfaces Muzzle Chamber 1" Thick A36 Steel Plate Bolts Directly to Gun Foundation Bolts Directly to Bridge Section Adaptable to Variety of Launchers Bridge Section Muzzle Chamber Assembly Recoil Plates 3" Thick A36 Steel Plate Bolt Directly to the Gun Foundation Plates Bolt Directly to Underside of SSG Slide 10

11 Terminal Area Design 7 Each Bridge Sections (8 L x 16 W x 10 H x 10 Thick) Free Standing, Reinforced Concrete, Flash X-Ray Cutouts 7 Each Sand-Filled Steel Boxes (4 x 4 x 3 ) (21' of Sand Along Line of Fire) Shot Line ~75 Above the Ground ~66 to 1 st Sand Box 32 ft 20 Each NRL Shield Blocks Double Course (8 L x 2.5 W x 1.5 Thick) Interlocking, Reinforced Concrete ~37 ft Opening 24 ft Concrete Blocks Statically Support last 3 Sand-Filled Steel Boxes Steel Muzzle Chamber Terminal Pad (100 L x 32 W) Standard Gage Crane Rails, 3 Rows of Tie Downs every 8, 2 Instrumentation Troughs Slide 11 I-Beam Catch Cart (8 mini-rr wheels, 12 long) Move/Replace first 4 Sand- Filled Steel Boxes

12 Catch Component 7 Each Sand-Filled Steel Boxes, Total of 14 On Hand 4 ft x 4 ft x 3 ft Wt 5740 lbs when Filled 21 ft of Sand along Line of Fire Open Top, Stackable, 4-Way Forklift Entry I-Beam Catch Cart Support the First 4 Sand Boxes to Allow Quick Movement & Replacement Runs on Crane Rails Using Mini-Railroad Wheels Concrete Blocks Support the Last 3 Sand Boxes Slide 12

13 Shot 13 Breech Current and Muzzle Voltage Breech Current (MA) Actual Current Predicted Current Muzzle Voltage Muzzle Voltage (kv) Time (ms) Slide 13

14 Shot 13 Velocity Velocity vs Time Velocity (m/s) Voltage (V) Bdots vs Time Time (ms) Time (ms) Slide 14

15 Muzzle Launch View Shot 7 Muzzle Arc is 500K Amps at 2.3 KV 9 PSI Overpressure at 99 from muzzle Slide 15

16 Flash X-ray Images Static Xray Image Shot 2 Xray Image Shot 4 Xray Image Side View Top View All images are 3 feet from muzzle Slide 16

17 In-Flight Images Shot 8: Shot 9: Shot 10: Shot 21: Frame captures from Phantom 7 high speed video camera Slide 17

18 Target Impact Shot 1: Shot 2: Shot 10: Slide 18

19 S&T Technology Challenges Launcher Multi-shot barrel life Barrel construction to contain rail repulsive forces Scaling from 8MJ (state of the art) to 32MJ 64MJ Muzzle Energy Thermal management techniques Projectile Gun launch survivability (45 kgee acceleration, Electromagnetic Interference Potential) Hypersonic guided flight for accuracy Lethality mechanics Pulsed Power System Energy Density Rep rate operation & thermal management Switching Torque management and multi-machine synchronization (rotating machine) Slide 19

20 ONR INP Phase I Program FY05 FY06 FY07 FY08 FY09 FY10 FY11 Executive Steering Committee Conclusion and Recommendation Program Initiation Aug 05 Concept Design Multiple Awards A B C EMLF Test Facility NSWCDD Exercise Options Initial 8MJ Test Capability General Atomics BAE Projectile Trades & Develop 4 Year Plan 32MJ Lab Gun For Bore Life Development Technology Development & Preliminary Design 100MJ Capacitor Bank For Launcher Testing Boeing Draper BAE Initial 32MJ Test Capability Launcher Bore Life Development Advanced Containment Go No Go Decision Point Aug 09 Detail Design & Fabrication A B 32 MJ ADVANCED CONTAINMENT DEMO 33MJ 33MJ 33MJ Advanced Capacitor Development General Atomics Rotating Machine Component Development Integrated Launch Package (ILP) Development 32 MJ LAUNCHER 100 SHOT BORE LIFE DEMO Slide 20

21 Milcon Addition Key Statistics (2009) Muzzle Operating Energy: 32 MJ Terminal Area: 64-MJ Projectile Gun lines: 2 P306 FY09 MILCON ($9.9 M) Protected Control Room Gun Line #2 Gun Line # MJ Pulsed Power System Ballistic Tunnel Terminal Catch: Up to 16-MJ Slugs Terminal Area: 64-MJ Projectiles 2009 Slide 21

22 Test Results Video of Test Results Slide 22

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27 Railgun Contact Information ONR Dr. Elizabeth D Andrea (Program Manager) Office of Naval Research (Code 352) 875 N. Randolph Street Arlington, VA NSWC Mr. Charles Garnett (Program Manager) Naval Surface Warfare Center, Dahlgren (Code 308) 6096 Tisdale Road Dahlgren VA Mr. Tom Boucher, P.E. (EMLF Test Director) Naval Surface Warfare Center, Dahlgren (Code 606) Thompson Road Dahlgren VA Slide 27

28 Back-up

29 Velocity km/s Energy MJ Power Ramp Up Testing Plan (2.4kg) 10 KV KV Banks

30 Actual Power Ramp Up Testing Velocity km/s 10 KV 8.5 KV MA@T= Banks

31 Slide 31 Test Results Efficiency (%) Muzzle Energy (MJ) Muzzle Velocity (m/s) Peak Current (MA) Charge Voltage (KV) Mass (KG) Shot

32 Slide 32 Test Results (continued) Efficiency (%) Muzzle Energy (MJ) Muzzle Velocity (m/s) Peak Current (MA) Charge Voltage (KV) Mass (KG) Shot

33 Launch Package Results Recovered from Shot 1 Original Launch Package Recovered from Shot 2 Slide 33

34 Bore Life EMLF Testing Concept FY07 8MJ Testing 18 months Series A (SSG) Procure parts Test Analyze 20 Shots Series B (SSG) Procure parts Test Analyze 20 Shots Series C (SSG) Procure parts 20 Shots Series D (LL32) Procure parts 20 Shots Series E (LL32) Procure parts 20 Shots SSG - Army Single Shot Gun LL32-32MJ Lab Launcher Test Analyze Test Analyze FY08 2Q/3Q Test Analyze Contractor Tests on Gun-line #2 Go No-Go 16-32MJ Testing Series U (LL32) 18 months Procure parts Test Analyze 20 Shots Series V (LL32) Procure parts Test Analyze 20 Shots Series W(LL32) Procure parts Test Analyze 20 Shots MILCON Series X(LL32) Procure parts Test Analyze 20 Shots Series Y(LL32) Procure parts Test Analyze 20 Shots Series Z(LL32) Procure parts 20 Shots Series YY(LL32) Procure parts 40 Shots Series ZZ(LL32) Procure parts 40 Shots GA Adv Containment Procure parts Test Analyze BAE Stub Tube Procure parts Test Analyze Slide 34 FY09 Test Analyze Test Analyze FY10 Order Core 2Q/3Q Test Analyze Adv. Containment Launcher BAE & GA PDR CDR FAB Fab Core FY11 Potential 32 MJ 100 Shot INP Demo Option 32MJ Half mass-full velocity (10kg, 2.5km/sec) Full mass-full current-2/3 velocity (20kg, 5.5MA, 1.7 km/sec) INP DEMO - 32MJ Test Analyze 100 Shot GA DEMO - 32MJ 100 Shot Test Adv Containment Launcher BAE DEMO - 32MJ 100 Shot Test Adv Containment Launcher

35 Navy Electromagnetic Railgun What is it? Gun fired with electricity rather than gunpowder Revolutionary 250 mile range in 6 minutes Mach 7 launch / Mach 5 hit Highly accurate, lethal GPS guided projectile Minimum collateral damage Why is it important? Volume & Precision Fires Time Critical Strike All weather availability Variety of payload packages Scalable effects Deep Magazines Non explosive round/no gun propellant Greatly simplified logistics No IM (Insensitive Munitions) Issues Missile ranges at bullet prices Who needs it? Marines and Army troops on ground Special forces clandestine ops GWOT Suppress air defenses When? Feasibility Demo 2011 System Demo 2015 IOC Slide 35

36 Naval Railgun Key Elements Launcher Projectile Pulse Forming Network (PFN) Ship Integration Capacitors or Rotating Machines Slide 36

37 Key Parameters for Sizing a Naval EM Launcher Pulse Forming Network Size ½ * Launch Mass * Muzzle Velocity 2 Desired Muzzle Energy Current Profile - Rail Separation Forces - Transient Localized Heating Barrel Length - Max Projectile Acceleration - Bulk Rail Heating Bore Size & Shape Launcher Efficiency Slide 37

38 Risk Matrix Summary Probability of Failure, P F E D C B A L5 Muzzle Arc ER1 Energy Density ER4 Switch Recovery EC1 Rep-Rate EC2 Energy Density Parasitic Mass P4 ER2 Rotor Cooling S4 Auxiliary Cooling ER3 Bore Life Pulse Sync S5 Recoil L1 Tactical Containment Dispense Shot Life P3 EC3 L2 P2 S3 Power Generation S2 Cabling & Ring P1 Heat Mount Removal Integration L4 L3 Launch Survivability P5 S1 Electronics Hardening Endo/Exo Controls Dynamic Power Management L P ER EC S Risk Ranking & Key Impacts Launcher Projectile Rotating Machine PPS Capacitor PPS Ship Integration Failure Impacts Capability Failure Impacts Volume, Weight & Cost A B C D E Consequence of Failure, C F Slide 38

39 ONR INP Phase 1 Objectives Traceability to 64MJ, 6-10 round / min indirect fire weapon system Bore Life 32 Mega-Joule (Muzzle Energy) EM Lab Launcher 10kg launch package; full muzzle velocity of 2.5km/sec 20kg launch package with full current of ~5.5MA Demonstrate more than 100 shot bore life Containment 32 Mega-Joule Advanced Containment Launcher 10kg launch package; full muzzle velocity of 2.5km/sec 20kg launch package with full current of ~5.5MA round predicted containment structural barrel life Design for thermal management at a rate of 6 round / min Design launcher for minimal round dispersion Transportable on pallets and/or in sea containers, Consider marine environment Slide 39

40 Integrated System Demo Strategy INP I INP II EM Lab Gun for Bore Life Development INP Phase I EM Railgun Demonstration Launcher Launcher Trades & Concept Dev. Launcher Technology Dev. INP Phase II EM Railgun Demonstration Launcher INP Phase II Long Range Integrated System Demo Projectile Trades & Concept Dev. Electromagnetic Test Facility ILP Interface in bore dynamics Terminal Range Mid-Range Endo-Exo Testing Railgun ILP Tests Long-Range Terminal High Velocity Powder Gun Slide 40

41 Bore Life Consortium NAVY ARMY BASIC RESEARCH ($) 100 SHOT DEMO S ($$$$) SCALED TESTING ($$$) SUB-SCALE TESTING ($$) Spans Basic Research to Full-Scale Demo s Parallel development paths via multiple research sites Avoids Duplication Efficient use of test resources Supports both Navy and Army EM Efforts Government purpose data rights to permit competition during the acquisition phase. Coordinated Development! Slide 41

42 Bore Life and Containment Lab Launcher - EMTF Advanced Containment Launcher Phase Phase of Project Period Greenfarm 32MJ PPS Basic Conceptual Design Trade Studies 7 mos. Army Add Trade Studies for Army Application 3 mos. Option I Technology Development and Preliminary Design 30 mos. Option II Detailed Design, Fabrication and Demonstration 29 mos. 32MJ Lab Launcher for Bore Life Slide 42

43 Advanced Containment Launcher Phase Basic Army Add Option I Option II Phase of Project Conceptual Design Trade Studies Trade Studies for Army Application Technology Development and Preliminary Design Detailed Design, Fabrication and Demonstration Period 7 mos. 3 mos. 30 mos. 29 mos. General Atomics Team Northrop Grumman Team BAE Team Slide 43

44 Projectile Concept Trades Description of Effort Develop long range projectile concept Lethal Consistent with Navy CONOPS Compatible with any EML gun development Identify critical development GN&C Aerobody (drag and thermal protection) launched survivability Produce a development plan The Boeing AASP Team Draper Team Slide 44

45 Advanced Pulsed Power Rotating Machine Watch Army Effort (Demo in FY08) Navy Specific Critical Component Development Advanced Capacitor Increased Energy Density Thermal Management for Multi Shot Operation Slide 45

46 Steel Muzzle Chamber Component Steel Muzzle Chamber Mates to both SSG & Lab Launcher Bolts to 1 st Concrete Bridge Section Collar Plates Seal Gaps between Launcher & Chamber 1"-8 UNC Grade 8 Bolts Holes to Allow Bolting to Threaded Inserts Cast Into Bridge Section (7/8"-9 Thread) 1 st Precast Concrete Bridge Section 1" A36 Steel Plate Custom Made to Adapt to Each Launcher 1" A36 Steel Plate 8 x 6 x 1 Steel Angle Slide 46

47 Vans on Van Pad Overflow Van VIP Van Control Van Pole with PTZ camera for Range Control Storage Van Slide 47