The Undertaking Director Sensors-Aerial Intelligence Frequent Sensor Payload (CSP) group, in collaboration with the Aviation and Missile Middle Software program, Simulation, Techniques Engineering and Integration Directorate Joint System Integration Lab, developed a brand new cooling shroud designed to slide over the CSP turret unit, which homes the electro-optical/infrared cameras and laser vary designator, and supplies cool air to the system to stop overheating whereas the plane continues to be on the tarmac. The finalized design supplies a troublesome outside efficiency cloth with a non-porous monolithic membrane adhered to the underside of the material, which varieties a barrier to environmental parts.
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The Frequent Sensor Payload is the electro-optical/infrared/laser vary designator sensor for battlefield commanders onboard the MQ-1C Grey Eagle uncrewed plane system. It supplies real-time imagery for detection and classification of targets and threats for battlefield commanders with day and evening imaging sensors, laser designation, pointing, goal marking, and spot monitoring for aerial intelligence.
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Two years in the past, Undertaking Director Sensors-Aerial Intelligence engineers developed and shipped out Frequent Sensor Payload cooling shrouds in six days after studying the sensors have been being uncovered to excessive warmth. The warmth brought about the sensors to overheat and shut off, or in some circumstances, brought about extra vital digital tools failure, requiring the Troopers to return the turret to the depot for restore.
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Each combatant command has its personal set of challenges that Troopers want to beat and adapt to. Within the Operation Inherent Resolve (OIR) theater in U.S. Central Command one in all these challenges is excessive warmth.
Two years in the past, Troopers recognized a necessity to supply cooling to the unit’s Frequent Sensor Payloads (CSP) that have been being uncovered to extraordinarily excessive temperatures whereas sitting on the tarmac earlier than missions. This may trigger the sensor to overheat and shut off, or in some circumstances, trigger extra vital digital tools failure, requiring the unit to return the turret to the depot for restore.
The CSP is the electro-optical/infrared/laser vary designator (EO/IR/LRD) sensor for battlefield commanders onboard the MQ-1C Grey Eagle uncrewed plane system. It supplies real-time imagery for detection and classification of targets and threats for battlefield commanders with day and evening imaging sensors, laser designation, pointing, goal marking, and spot monitoring for aerial intelligence.
“In simply six days from initially being notified of the difficulty, Undertaking Director Sensors – Aerial Intelligence [PD SAI] engineers have been capable of develop a prototype turret cooling shroud and get three shipped out to the unit,” mentioned Doug Haskin, Product Supervisor Aerial Enhanced Radars, Optics, and Sensors (PdM AEROS), underneath PD SAI.
The prototype efficiently carried out as anticipated out within the subject and Troopers started asking for extra, making a excessive demand. Leveraging joint experience from the Naval Floor Warfare Middle – Crane Division, the AEROS group rapidly started work on a brand new design. This culminated final month when the PdM AEROS CSP group efficiently carried out a technical and system evaluation of the newly designed cooling shroud at Redstone Arsenal in Huntsville, Alabama.
A collaborative effort between PdM AEROS and the Aviation and Missile Middle Software program, Simulation, Techniques Engineering and Integration Directorate Joint System Integration Lab, the evaluation consisted of a technical evaluation of the cooling shroud’s set up work packages, evaluation of user-caution particulars, and evaluation of the ultimate engineering design implementations.
“I’m undoubtedly impressed by our group’s environment friendly and fast technique of turning an thought right into a completed product in assist of the warfighter,” mentioned Wilson White, the CSP coaching subject material professional for PdM AEROS.
The brand new cooling shroud is designed to slide over the CSP turret unit, which homes the EO/IR cameras and LRD, and supplies cool air to the system to stop overheating whereas the plane continues to be on the tarmac. The finalized design supplies a troublesome outside efficiency cloth with a non-porous monolithic membrane adhered to the underside of the material, which varieties a barrier to environmental parts. The shroud additionally supplies safety from moisture, corrosion, ultraviolet gentle, sand, mud, overseas object particles, pests, and different environmental degradation.
There can be an preliminary supply of shrouds and corresponding technical handbook updates to make sure all Grey Eagle firms are geared up with the newest environmental hazard resolution. The brand new shrouds are anticipated to reach in theater on the finish of Fiscal Yr 2025 (FY25). The PdM AEROS CSP group will proceed to coordinate with Military items to make sure mission necessities are met.
The price of every shroud can be about $2,100.
“The price is properly definitely worth the funding,” Haskin mentioned. “The price of a turret is over $1 million and prices about $350,000 to restore every system. Whole restore turnaround time on the depot together with transit is over six months. The shroud has confirmed very profitable at stopping these avoidable repairs, saving money and time.”
Appropriate with future CSP model 3 (v3)
Together with being appropriate with all CSPs at the moment deployed, the brand new cooling shroud may also present longevity to the longer term CSP v3.
PD SAI accomplished the event of the brand new CSP v3 system in 2023 with the supply of six prototype methods for integration and testing. Preliminary flight testing in Could 2024 achieved excellent outcomes and preliminary manufacturing is underway with the primary CSP v3 deliveries to happen later this yr.
“The CSP v3 is the newest iteration of the CSP, which resolves a number of important subcomponent obsolescence points current on the at the moment fielded CSP v2 and incorporates up to date sensor {hardware} to supply enhanced imaging capabilities,” Haskin mentioned.
The CSP v3 will add a Goal Location Accuracy (TLA) functionality that can allow precision, near-real time engagements with coordinate looking for weapons by decreasing the sensor-to-shooter course of from minutes to seconds.
The CSP v3 is step one in offering a totally modernized sensor bundle that can assist Multi-Area Operations for the brand new -25M Grey Eagle. The CSP v3 manufacturing methods are anticipated to start delivering to the Military in June 2025.
Extra flight testing and demonstrations can be carried out because the CSP v3 prepares for fielding in FY27 to develop ways, strategies, and procedures for this new functionality.
