Wheeled Vehicle Experience 0510

Wheeled Vehicle Experience

3600 Rider Trail South A Top 50 Company phone:314.785.0900
St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044

Overview
• Off-Road Military Vehicles
• On-Board Systems
• On-Board Weapon Systems
• Advanced Technology
• Simulation
• Facility Vehicles
• Over-the-Road Vehicles
• Vehicle Testing
• Summary


Off-Road Military Vehicles


SEI Engineering Projects
• Innoventor has provided design expertise to Systems &
Electronics, Inc., an Engineered Support Systems
Company
• In a five year span with this customer, Innoventor has
placed teams of engineers in multiple manufacturing
facilities
• Innoventor has assisted SEI in the following areas: Tunner
-Concept Development -Structural Design
-Hydraulic Design -Electrical Packaging
-Pro Engineering Modeling -Cost Reduction
-Program Management
• SEI considers Innoventor to be a trusted source for
engineering teams when their work load requires it

M1000


Boeing Munitions Handling Unit
• Innoventor was contracted by the Boeing Company to overhaul an out-of-service
munitions handling unit (MHU), which lifts and orients munitions on various
aircrafts.
• Innoventor evaluated the unit and developed solutions to get the unit back in
working order. Services included: he repair of hydraulic system components,
running gear components, and exterior re-paint. Future maintenance costs were
reduced by adding foam to the tires, eliminating the possibility for flat tires.
• Innoventor developed the requirements to
replace the existing diesel engine with a
propane-fueled engine, enabling the unit to
run inside an aircraft hangar.
• Following the retrofit of the engine and full
refurbishment of the unit, comprehensive
safety and functional tests were conducted
prior to final delivery to Boeing.

DRS Mobile Environmental Systems
Kingpin Converter Dolly

• GVWT of 8,500lbs
• Vertical kingpin load of 1,500lbs
• Adjustable Pintle Height
• Single wheels
• “NATO” lights with blackout lights
• Military specification transportability and lift able
• The ability to run at highway speeds of 65mph
and limited off road use at reduced speeds


On Board Systems


CRS3
COMMON REMOTE STABILIZED
SENSOR SYSTEM


Chemical, Biological Protective Shelter

• Chemical Biological Washdown Capable
• Emergency Medical Use in Battle Areas
• Rugged Light Weight Design
• Currently in Build Cycle


Predator Shelter
• Redesigned existing control shelter for
manufacturability w/o impacting quality
testing
• Developed improved raw material
process and flow
• Designed tooling to match production
projections


DRS Technologies
Flatrack Refueling Capability
• DRS Technologies sought Innoventor’s expertise to help design a portable, rugged “gas station” providing
a stand-alone storage tank and pumping system for fueling aircraft and ground vehicles for the Army and
Marines
• Innoventor designed a compressed module containing the system components, which could be assembled
outside the FRC and then dropped in as a single unit allowing for efficient packaging with all-around access
for assembly

• Maintenance and service of the module can be performed without having to remove it from the frame

• Innoventor creatively routed the piping, valves and controls to one side
of the unit, which enables the system to be controlled by a single
operator, even though Marine procedures allow for two operators

• The entire system can be hoisted onto Marine and Army transport
vehicles, shipped via standard rail protocol on any train throughout
the world, and even stacked eight high on transport ships
• DRS employees were located at Innoventor’s facilities, enabling the
customer and Innoventor to work as an integrated project team

DRS Technologies
Vehicle Mounted Combat Cooling System
• Innoventor was asked to prototype a DRS concept for a
rugged, insulated field cooler system that chills water to
support operations in hot and arid remote areas

• The requirement was to chill 100 liter bottles of water by 40
Degrees F in a 24- hour period
• The system had to be designed to plug
into the power outlet of a HumVee

• The rugged, impact tolerant design
dispenses water bottles in a first-in, first-
out basis.


On Board Weapon Systems


SEI TOW Missile Launcher for
Bradley Infantry Fighting Vehicle
Innoventor personnel:

• Did the proposal and design
effort for a 4-shot launcher as
opposed to the older two-shot
model
• Installed the launcher mock-
up on the vehicle for US Army
demonstration


Ground Support Equipment - Mechanical
• Weapon Systems and
Weapon Support
Equipment
• US Navy EMERLEC
30mm Cannon Turret
• US Navy ASROC Missile
Launcher
• US Navy ASROC
Weapon Handling
System (AWHS)


Ground Based Weapon Systems, Weapon
Support Equipment and GSE include:
• M901 Improved TOW Vehicle (ITV)
• FISTV Vehicle Laser Target Identification System for ITV
• M860 Patriot Missile Launcher


SEI ASG-21 Gun Laying Mount
(GLM)
• Served as the lead
mechanical engineer
• Upgraded the standards
and drawing packages
for the B-52H for
production of 2 units 30
years after the initial
order


Unidynamics
Armored Box Launcher for Cruise Missile
• Served as the lead hydraulic
engineer
• Performed stress analysis for
compliance with shipboard and
launch load environments
• Supported installation and
integration of Armored Box
Launcher on multiple US Navy
ship platforms

Advanced Technology


Emissions Buster
• Captures carbon dioxide emissions from vehicle
exhaust before it is expelled to the atmosphere
• Specially manufactured calcium oxide filter
captures the gas and stores it as a solid
• After full adsorption is reached, filter is replaced
with a fresh one
• Adsorbed filter is regenerated for re-use by turning
the carbon dioxide back into a gas and capturing it
for permanent storage
• Last major emissions technology breakthrough
was the catalytic converter - this
is the next vehicle emissions
breakthrough – capturing greenhouse gases!

Advanced Heat Exchangers
Challenges:
• Modeling heat transfer
characteristics
• Special material with very little
empirical data available
• Restriction of an existing design
Challenges Met:
• Computational Fluid Dynamics
(CFD)
• Modeling approaches to allow CFD
analysis


Radiator Debris Air Knife
• Innoventor was asked to create
a way to remove fine dust build-
up on radiators

• The Team designed and built the Dust build up on the customer’s
radiators created performance issues
Air Knife which uses highly-
focused pneumatic power Innoventor designed
an Air Knife that
sweeps across the
• The Air Knife utilizes standard face of the radiator
using high-focused
components to the customer’s pneumatic power to
clear the radiator
current design

Common Transport Erector System

• Zero-Torque Induced Cradles
• Off-Road and Highway Use
• 50,000lb Payload
• End User – Missile Defense Agency, Department
of Defense


Simulation


Soil Lab R&D Systems
PROBLEM:
The Soil Lab uses a scale model of a bucket
or other earth-moving tool

Some things, like soil, are too complicated
to model in a computer.

Building prototypes is very expensive – Creating virtual models is much cheaper!
Software models can be changed much more quickly – saving time and money!

SOLUTION: Innoventor wrote the software and
helped build the hardware for the system that does this.
To explore the interaction of the machine with the soil we
combine a software virtual model of a machine with a
robot containing a scale model of the part that interacts
with the soil. The robot is used to dig in the soil and
collect data for later analysis.

The Innoventor software has the
added benefit of a modular
design, resulting in a lot of code
reuse between the various
systems, and a similar method of
operation, reducing learning
curve and errors for operators.

Building prototypes is very expensive – Creating virtual models in software is much cheaper!

Mobility Bin Dyno Cart
PROBLEM: Design and build a new system that will test the
interaction between a wheel and the soil in a bin

This will require Innoventor to:
• Design and build an entirely new carriage
• Incorporate 5 axis of motion
• Integrate both electric and hydraulic drives


Mobility Bin Dyno Cart
SOLUTION: Innoventor has designed a system that will combine the desired
functionality of the mobility tester with another proposed
system for testing tracks in the bin.

Innoventor noticed the similarities of two systems that we
were proposing and designed a combined solution

The combined design:
• saves money
• increases functionality of each system
• saves precious space in the soil bin


Soil Lab Mobility/Track Test
• Wheel test and Track Test
functions in same cart with
limited reconfiguration
• Track with MTS cylinder
for 20 Hz cyclic excitation
• Wheel 18”-42” dia
• National Instruments
– LabVIEW for all
operation/control
– Embedded fast control

Machine Research
Compaction Monitor
PROBLEM: Caterpillar needs to be a leader in intelligent compaction
technology and products. One first step is to develop a
prototype compactor that monitors its own effectiveness.

The system must collect data to
determine its location on a job site,
and how much of the energy it is
expending that is delivered to the
compaction surface.

The less energy that goes into
compaction, the better compacted
the surface is.


Machine Research
Compaction Monitor
Innoventor created custom LabVIEW software for
SOLUTION: compaction monitoring.
The software runs on an onboard ruggedized computer
display. It collects and stores GPS and machine data for
each 1’ x 1’ square over an entire job site. The data for
each pass over a square is retained so that later
analysis can reveal the compaction history of any spot.
The software displays a real-time
data map for the immediate
vicinity of the compactor for the
operator to identify weak spots.
The user can also zoom out to
see the entire site.

Service Tools
PROBLEM: Create software to add data acquisition capability to the
hydraulic test systems that Cat sells to its dealers.

These systems are used to test
individual hydraulic parts (pumps,
valves, etc.) that are part of a
Caterpillar machine.

The dealer performs diagnostic
testing to determine the problem
with a trouble part, and verifies
repairs using the same system.


Service Tools
SOLUTION: Innoventor created a software package that Caterpillar
now ships on its dealer hydraulic test systems.

• This versatile operator interface enables the creation of a custom
“virtual operator panel”, data collection, real-time limit evaluation,
test reporting, and data archiving.
• It includes real-time plotting of signals vs. time and time-saving
automated calibration procedures


Facility Vehicles


Later Version of Hydrogen
Tank Transporter

Space Shuttle Hydrogen Tank Transporter

US Army Cold Regions
Test Support Transporter


MX Missile (Peacekeeper) Transporter

• 80 Tires • 5 modes of steering
• 256k lbs empty weight • 2-450 hp engines
• 560k lbs loaded • Innoventor engineers, while at
McDonnell Douglas, designed and built
• 5 mph top speed 2 units for Vandenberg USAF

AGV’S


AGV
Autonomous Ground Vehicle


F-35 JSF – Moving Assembly Line
Hydraulic motor Four Stage Jack
for Jack locking

Wire Encoder

Autonomous Ground Vehicle


CLOVerS


AGV for DARPA

AGV for DARPA Demonstrator
to X-Ray Fully Loaded Tractor
Trailers
Developed by an Innoventor
Engineer

• Central PC Programmed in Microsoft Visual Basic
• Graphical display AGV position, doors x-rays etc
• Mouse based click to dispatch
• Controls using Allen Bradley programmable controller
• Radio with custom designed serial protocol

Vehicle Testing


Dynamometer Cart
Track Tester & Mobility Tester
• Tests tractive and mobility devices on a variety of soil
types in a laboratory
• Data generated develops and validates virtual analytic
models
– Provides insight on how products interact with
different soils
• Investigates complex interaction between machine
and soil
• Exposes innovative solutions, improving tractive and
mobility performance
• Evaluates track, rubber tires or steel drums for traction,
mobility & compaction performance

Automated Wheel Audit Test Station
• Rack mounted PC based system
with DAQ and Motion
• Application written entirely with
LabVIEW development system
• Fully automated measurement and
analysis of wheels
– Four attributes of run out
– Selectable speed of operation
– Synchronized LVDT sampling with
angle
– Exact repositioning for marking
– Plots comparing to 1st harmonic and
calculation of 20 harmonic terms
• Precise to within 0.001 inches

Development of Genset for
Alternative Power
• Application written entirely with LabVIEW
development system and includes remote
monitoring with DataSocket.
• Broad range of interface hardware
– SCXI (TCs, Pressure, Flow, Power)
– SCXI relay for load bank control
– DAQ for fast cylinder pressure
– RS-232 for emissions gas analyzer
– CAN for generator control/monitor and
for engine control/monitor
– RS-485 for power meter
communications

Eaton Corporation Check Valve
High Speed Test Equipment

• Performs life-cycle testing on check valves to be
used in the fuel injection system of diesel engines

• Integrated a data acquisition system utilizing National
Instruments’ Labview software to monitor and record
the data at 4,000 reads per second
• Hydraulic drive system operates @ 3000 psi testing a
check @ 600 psid and oscillates @ 27hz
• This unit replaces a dynameter and engine stand @
¼ the cost


Thales ATM Interface Test Adaptors
• Provides interface between custom
designed circuit card assembly & computer
control automated test equipment for FAA
• Multi-axis adjustability of CCA/ITA interface
connector


Over the Road Vehicles


Cardiac Catheterization Lab


Summary

Rapid Prototyping Aided by: Experience Working With:
• Off Road Design Experience • USAF
• Chemical/Biological Design Experience • Army
• Hardened Electronics Experience • Marine Corps
• Control Design Experience • Navy
• Obsolete Equipment Replacement Experience • NASA
• System Design/Subsystem Design Experience
• System Upgrade Experience
• Component/Subsystem/System Testing Capability


Wheeled Vehicle Experience 0510

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