13 décembre 2019 | International, Terrestre

Army Revs Up High-Tech Tank Engine

By SYDNEY J. FREEDBERG JR.

WASHINGTON: Just outside Detroit, home of the muscle car, the Army's put together a powertrain as potent as three Trans Ams strapped together — with an electric stealth mode that sounds more like a lawnmower than a tank. The 1,000-horsepower Advanced Powertrain Demonstrator packs more diesel horsepower in less space than current engines, along with a 160-kilowatt generator that can power advanced electronics – like a drone-killing laser or anti-missile defenses – and even move an entire 50-ton vehicle for brief periods.

Now installed in an M2 Bradley hull for testing, the current version of the APD can move war machines up to 50 tons, but it's meant to be easily modified for larger or smaller vehicles.

“Each of the pieces can be scaled” up or down, said John Tasdemir, chief of the power & mobility branch of the Army's Ground Vehicle Systems Center (formerly TARDEC) in Warren, Mich. “It could not just fit a Bradley, it could fit a future vehicle, [or] it could fit a legacy vehicle as well.”

Compact enough to fit into the notoriously cramped Bradley, the 1,000-horsepower Advanced Powertrain Demonstrator produces 48 percent more horsepower than the most-upgraded Bradley variant and 67 percent more than the standard 600-hp model. The engine could also fit the turretless utility variant of the Bradley, the Armored Multi-Purpose Vehicle, or, with some rearrangement of the components, the M109A7 Paladin howitzer. And since the design is modular, the APD could be scaled down to 500 hp – potentially powering the more tank-like of the Robotic Combat Vehicles the Army's now developing – or up to 1,500 hp – enough to drive the 70-ton M1 Abrams main battle tank.

Another logical candidate for APD technology is the Optionally Manned Fighting Vehicle now in development to replace the Bradley. Fitting the new vehicle would require some redesign, said one of Tasdemir's engineers, Mike Claus, but if they could optimize the APD components for an all-new hull without the awkward compromises of the Bradley, the resulting design could be “way more compact.”

How It Works
Why is it important to be compact? Well, the heaviest part of a combat vehicle is its armor. The weight of the armor, in turn, is the product of its thickness and the surface area it has to protect. The bulkier you make your vehicle – the greater the “volume under armor,” in Army terms – the more tons of armor you need to get the same level of protection.

To make the APD more compact, it needs to be more efficient. To do that, the Army and its contractors went to work on every piece of the powertrain – for example:

  • In the diesel engine itself, built by Cummins, the pistons go through a two-stroke cycle instead of the usual four, allowing them to generate more horsepower with less waste heat from the same amount of gas. Historically, two-stroke engines are also highly polluting, which is why they've not been widely adopted, but the APD uses cutting-edge emissions controls.
  • The SAPA drive-by-wire transmission replaces traditional, inefficient mechanisms like pumps with precisely engineered electromagnetic controls called solenoids. The transmission is in fact so attractive to other Army programs that they're considering installing it even without the rest of the APD powertrain.
  • The cooling system replaces traditional filters – which wear out in 20 hours in dusty areas like deserts – with a Donaldson pulse-jet air cleaner that lasts 500 hours and provides much more airflow. Cooling armored vehicles is always challenging, even when they're not fighting in the desert, because they're basically metal boxes in which you want to punch as few holes as possible.
  • The L3-Harris Integrated Starter-Generator produces 160 kW – many times the current alternator on the Bradley – but doesn't require its own dedicated cooling system, unlike traditional electronics. That's because it uses heat-resistant silicon carbide components that can function at 105 centigrade (hot enough to boil water), the same as the engine block.

That electrical power is as important for modern combat vehicles as diesel horsepower. During the Iraq War, the Cold War-vintage Bradleys got upgraded with so many advanced sensors, communications networks, display screens, and radio jammers to deactivate roadside bombs that they couldn't power everything at once.

Now, worried about Russia's vast arsenal of RPGs and anti-tank missiles, the Army is pushing to install so-called Active Protection Systems on its armored vehicles, which use compact radars to track incoming projectiles – a big power drain – so miniature missile launchers can shoot them down. And for the near future, the Army is highly interested in high-powered laser and microwave weapons, albeit primarily against fast-moving, fragile targets like drones and rockets rather than heavily armored vehicles like tanks.

The Ground Vehicle Systems Center plans to test the APD powertrain on a stationary Bradley hull through this coming March, by which point they expect to have demonstrated what's called Technological Readiness Level (TRL) 6. Then they'll fully integrate the APD into a drivable Bradley, the Advanced Mobility Experimental Prototype (AMEP), which will be tested to TRL 7 or 8 – the highest level possible for a prototype – in 2022.

The next year, 2023, the Army will hold the final competition to build the Bradley replacement, the OMFV.

https://breakingdefense.com/2019/12/army-revs-high-tech-tank-engine

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  • Artillery Seeks Robot Ammo Haulers

    29 janvier 2020 | International, Terrestre

    Artillery Seeks Robot Ammo Haulers

    Six companies got $150,000 Field Artillery Autonomous Resupply contracts to study everything from exoskeletons that strengthen human ammo handlers to robots that might replace them. UPDATED to clarify contract details WASHINGTON: After 100 years of hauling 100-pound howitzer shells by hand, Army gunners are about to get some high-tech help. Last week, representatives from six small and mid-size tech companies trudged through the mud with soldiers at Fort Bliss, Tex., so they could watch close-up as troops moved 155 mm shells from pallets to their M109 Paladins. The six firms are under 12-week, $150,000 contracts to refine their ideas to augment or replace human muscle at every stage of the loading process, part of the Field Artillery Autonomous Resupply (FAAR) initiative run by Austin-based Army Futures Command. “For every projectile that goes down range, that projectile is picked up no less than five different times by a soldier and moved manually – and each one of those projectiles is 100 pounds,” Maj. Chris Isch told the Army's in-house news service. “We are looking for ways to automate that as much as possible.” Robotic logistics, from self-driving supply trucks to AI predicting engine breakdowns, lacks the ominous glamour of so-called killer robots. But the sheer complexity of identifying friend or foe amidst the chaos of combat, and deep-rooted Pentagon policy on human control of lethal force, mean that autonomous weapons will take much longer to develop than autonomous supply and support systems, some of which are already in field-tests. That said, Field Artillery Autonomous Resupply would definitely mark the Army more deadly. Artillery historically kills more troops than any other branch, and after years of letting Russia pull ahead in range and volume of fire, the Army is urgently upgrading its guns. The service's No. 1 modernization priority is what it calls Long-Range Precision Fires, and while hypersonics and post-INF Treaty missiles have dominated the headlines, the LRPF portfolio also includes conventional howitzers. The Army had already begun upgrading the hull and automotive systems of its venerable M109 armored howitzer vehicle under its Paladin Integrated Management (PIM) program. Now it's looking to upgrade the gun and turret under what's called Extended Range Cannon Artillery. A New Beast To Feed Between a longer barrel, precision guidance and new rocket-boosted shells, ERCA has already doubled the Paladin's range, from 30 km (19 miles) to 62 km (39 miles) in test-shots at Yuma Proving Ground. The goal is to double it again, to over 120 km (75 miles). ERCA also plans to add an autoloader mechanism to feed the gun, instead of humans manhandling shells into the breech. That should increase the rate of fire from four shells a minute to 10. Assuming standard high-explosive rounds, that means the ERCA gun can go through 950 pounds of ammo in 60 seconds and a ton in just over two minutes. How do you feed such a beast? Currently, ammo is shipped in crates and pallets to (relatively) safe supply dumps in the rear, where troops load the individual shells into a purpose-built armored vehicle for transport to the front. That M992 ammo hauler has an extendable conveyer belt to transfer shells directly into the howitzer vehicle, but the belt doesn't always work that well in the field. Besides, the ammo hauler holds 95 rounds of high explosive and propellant, which would blow up horrifically if hit, so a standard tactic is to park the ammo transport under cover, well away from the guns, and have soldiers schlep the shells. The Army's multidisciplinary Cross Functional Team for Long-Range Precision Fires, already working on multiple missiles at once, couldn't develop the ERCA gun and a new loading system at the same time, an officer explained at an AUSA robotics conference last fall. So the team turned to a sister organization within Army Futures Command, the Army Applications Lab, whose in-house Army Capabilities Accelerator reaches out beyond traditional defense contractors to universities, startups, and smaller firms, especially ones which have little experience working with the military. Five Functions, Six Firms, 12 Weeks The Applications Lab came up with the Field Artillery Autonomous Resupply concept and sought proposals to revolutionize every step of the process. An online solicitation lists five key functions: Robotic ammo handling and transport for the supply depot to move shells from crates & pallets to the ammo vehicle, or even carry it directly to the gun; Small unmanned ground vehicles or even drones to drive or fly a few shells at a time – at least 150 pounds payload, i.e. one shell plus packaging — from the ammo vehicle to a gun at least a kilometer away; Automated ammo handling for inside the M109 howitzer itself, not only auto-loading the shell into the breech, but also setting charges, adjusting propellant loads for range, and more; Exoskeletons, both powered and passive, to help soldiers handle 100-plus-pound objects without fatigue – the main limiting factor on sustained fire – or injury; and Command & Control systems to coordinate munitions delivery when GPS and radio are being jammed, including self-directing robot swarms. The response was vigorous: 83 submissions from 43 states and multiple foreign countries, which the Army weeded down to the six firms that went out to Fort Bliss last week. Each got a $150,000 contract to spend 12 weeks gathering feedback and refining their designs, with a final brief to the Army in Austin on April 1st. (UPDATE: Technically, the six firms are all subcontractors to Alion Science and Technology, which is administering the program for the Army). The Army will then decide which, if any, should advance further towards actual production. The six companies in the current phase? Actuate (formerly Aegis) develops computer vision software that analyzes surveillance feeds in real time to detect intruders and firearms. They're based in New York City, hardly the usual breeding ground for defense contractors. Apptronik builds exoskeletons and “human-centered robotics” designed to work with people. It's a four-year-old spin-off of the University of Texas at Austin. The Army picked Austin to be Futures Command's home town precisely because it's a hub of high-tech innovation with few existing ties to the military. Carnegie Robotics in Pittsburg is a decade-old spin-off of Carnegie Mellon University's National Robotics Engineering Center. CMU has a strong relationship with the Army and is now host to the Army AI Task Force. Neya Systems, also in the Pittsburgh area, develops aerial drones and off-road robots. It's a division of employee-owned defense contractor Applied Research Associates. Hivemapper is a Silicon Valley firm that turns surveillance video – including from drones – into digital maps, automatically updated by change-detection algorithms, for both the private sector and the Pentagon. Pratt & Miller Engineering, based in Detroit and South Carolina, and most famous for its work on race cars, whose seven-ton EMAV robot just won a field-testing contract for the Army's experimental Robotic Combat Vehicle – Light. Now, the RCV is still experimental, and Pratt & Miller's win hardly guarantees a production contract, it makes sense for them to offer a variant of the same robot for the artillery resupply program. It would definitely be simpler and cheaper for Army logisticians to use the same robotic chassis for both armed vehicles and ammo haulers. UPDATE “It's about creating direct, candid engagement between commercial solvers and Army problem owners to open the aperture on the realm of the possible,” said Porter Orr, production innovation lead at the Army Applications Lab, in a statement to Breaking Defense. “The capability presentations ...on April 1st...will be used to help shape thinking and inform future requirements, at a minimum.” “While it's possible that a single, ‘perfect' piece of hardware could come from the FAAR cohort, that's not the marker of success,” Orr continued. “Rather, it's about giving Army stakeholders better access and insight into commercial solutions with a low, upfront investment, while also creating channels that make it easier for non-traditionals to work with the Army. The FAAR cohort is the first to launch as part of this new model, but the intention is that it will not be the last.” Corrected 10pm to remove references to the Small Business Innovation Research (SBIR) process: While the Field Artillery Autonomous Resupply (FAAR) initiative is also exploring the use of the SBIR process, the contracts discussed in this article were awarded under a different vehicle. https://breakingdefense.com/2020/01/artillery-seeks-robot-ammo-haulers

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