Wheeled Vehicle Experience 0510

3600 Rider Trail South A Top 50 Company phone:314.785.0900

St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044

Wheeled Vehicle Experience

http://www.innoventor.net/



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:

-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

Tunner

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




• 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

DRS TechnologiesFlatrack 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 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 TechnologiesVehicle 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




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

SEI TOW Missile Launcher for Bradley Infantry Fighting Vehicle




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





• 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

SEI ASG-21 Gun Laying Mount (GLM)





• 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

Unidynamics Armored Box Launcher for Cruise Missile




Advanced Technology




• 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!

Emissions Buster




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

Air Knife which uses highly-

focused pneumatic power

• The Air Knife utilizes standard

components to the customer’s

current design

Dust build up on the customer’s

radiators created performance issues

Innoventor designed

an Air Knife that

sweeps across the

face of the radiator

using high-focused

pneumatic power to

clear the radiator




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




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

Software models can be changed much more quickly – saving time and money!

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.

Soil Lab R&D Systems





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

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.




PROBLEM:

Mobility Bin Dyno Cart

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





SOLUTION:

Mobility Bin Dyno Cart

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

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.

Compaction Monitor

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

SOLUTION:

Compaction Monitor

Innoventor created custom LabVIEW software for

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 ToolsSOLUTION: Innoventor created a software package that Caterpillar

now ships on its dealer hydraulic test systems.

• It includes real-time plotting of signals vs. time and time-saving

automated calibration procedures

• This versatile operator interface enables the creation of a custom

“virtual operator panel”, data collection, real-time limit evaluation,

test reporting, and data archiving.




Facility Vehicles




Space Shuttle Hydrogen Tank Transporter

Tank Transporter

US Army Cold Regions Test Support Transporter

Later Version of Hydrogen




MX Missile (Peacekeeper) Transporter

• 80 Tires

• 256k lbs empty weight

• 560k lbs loaded

• 5 mph top speed

• 5 modes of steering

• 2-450 hp engines

• Innoventor engineers, while at

McDonnell Douglas, designed and built

2 units for Vandenberg USAF




AGV’S




AGVAutonomous Ground Vehicle




F-35 JSF – Moving Assembly LineFour Stage Jack

Autonomous Ground Vehicle

Hydraulic motor

for Jack locking

Wire Encoder




CLOVerS




• 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

AGV for DARPA

AGV for DARPA Demonstrator

to X-Ray Fully Loaded Tractor

Trailers

Developed by an Innoventor

Engineer




Vehicle Testing




Dynamometer CartTrack Tester & Mobility Tester

• Data generated develops and validates virtual analytic

models

– Provides insight on how products interact with

different soils

• Tests tractive and mobility devices on a variety of soil

types in a laboratory

• 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

• 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

High Speed Test Equipment

• Performs life-cycle testing on check valves to be

used in the fuel injection system of diesel engines




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

• Off Road Design Experience

• Chemical/Biological Design Experience

• Hardened Electronics Experience

• Control Design Experience

• Obsolete Equipment Replacement Experience

• System Design/Subsystem Design Experience

• System Upgrade Experience

• Component/Subsystem/System Testing Capability

Rapid Prototyping Aided by: Experience Working With:

• USAF

• Army

• Marine Corps

• Navy

• NASA


Wheeled Vehicle Experience 0510

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