Transcript CH-53K Heavy Lift Helicopter: A Survivability Focused Design
CH-53K Heavy Lift Helicopter A Survivability Focused Design
Kathy Russell
Vulnerability Analyst NAVAIR China Lake, California
Martin Krammer
Vulnerability Test Engineer NAVAIR China Lake, California
Richard Gardner
Survivability Lead NAVAIR Patuxent River, Maryland
Nicholas Gerstner
Survivability Analyst SURVICE Engineering Dayton, Ohio
Presented at the American Helicopter Society 67 th Annual Forum Virginia Beach, VA May 3-5, 2011
This is a work of the U.S. Government and is not subject to copyright protection in the U.S.
Introduction
Next Generation Heavy Lift Helicopter for the US Marine Corps
• Operational Requirements • Survivability Key Performance Parameters • Air Vehicle Specification More Survivable Design CH-53E CH-53K
Background
Balanced Survivability Approach
•
Susceptibility
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the inability of an aircraft to avoid being hit Susceptibility Reduction - missile warning and missile jamming or decoying further enhance the survivability capabilities of the platform •
Vulnerability
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the inability of an aircraft to sustain damage once hit Vulnerability Reduction – threat tolerant design
Susceptibility and Vulnerability Reduction Verification • Analysis • Flight Test • Live Fire Test
Susceptibility Reduction
Threat Avoidance
Susceptibility reduction for the CH-53K consists of an integrated Aircraft Survivability Equipment (ASE) suite
Radar Warning Receiver AN/APR-39B(V)2 (RWR)/Electronic Warfare Management System Directional Infrared Countermeasures System (DIRCM) AN/AAQ-24(V) Missile Warning System (MWS) *update – Laser Detection incorporated with MWS Countermeasure Dispenser System (CMDS) AN/ALE-47
Susceptibility Verification
Susceptibility Analysis
• Incorporates threat systems • Aircraft performance data • Various models and simulations – Moderate Transmittance (MODTRAN) – Modeling System for Advanced Investigation of Countermeasures (MOSAIC) – Future Operational Combat Unified Simulation (FOCUS) – Multi-Service Electro-Optics Signature (MuSES)
Analysis and Flight Test will assess the ASE system effectiveness against AVS threats
Survivability Requirements
CH-53K Key Performance Parameters Two of the seven system KPP’s are Survivability Requirements
• •
Fly Away Capability Force Protection – Ballistic Tolerant Design – Cockpit and Cabin Armor Meeting the KPP requirements
• • • •
Challenging yet achievable Air Vehicle Specification (AVS) Continuous Survivability Analyses Early Ballistic Tests Early involvement and a coordinated survivability team
Vulnerability Reduction
Vulnerability Verification
Analysis and Test MODEL TEST
Vulnerability Verification
Vulnerability Analysis – Critical Data Sets
Geometry Conversion Techniques
• SAC CATIA to BRL-CAD format • Streamlines the modeling effort • Ensures precise and accurate component representation
Traditional Data Sets
• DMEA • Pd/h and Pk/d • FALT
Vulnerability Verification
Vulnerability Analysis – Critical Data Sets
Traditional Flight Regimes Discrete Mission Points
• Define specific flight conditions • Correlate to susceptibility analyses
Mission Points
Vulnerability Verification
Design Impact
Initial Assessment – Not compliant
• •
Assessment Updates
Updated preliminary designs Integrated CH-53E JLF results • • • •
Design Enhancements
MGB redundant lube system Supplemental fuel feed system Main rotor actuator redesign Tail rotor drive shaft growth • • •
Risk Reduction Testing
Identified components for testing to refine design and analysis Tail rotor drive shaft and Flexbeam successfully tested Additional items identified for testing
Vulnerability Verification
Assessment Progression
Milestone Assessments – Compliant Risks From CDR Design Challenges
Force Protection Verification
Design Impact
Initial and Milestone Assessments – Compliant
• • •
Assessment Progression
KPP requirements addressed cockpit and cabin occupant protection Weight optimization studies conducted to minimize ineffective armor and maximize protection Design changes assessed for impact on protection levels
CDR Cabin Armor CDR Cockpit Armor
CH-53K Survivability
•
Risk Reduction Tests
─ Tail Rotor Flex Beam ─ Tail Rotor Drive Shaft ─ Sponson Material - Fuel Cell Interaction ─ Fuel Line Leak Containment
•
Live Fire Tests
Risk Reduction Test
Tail Rotor Flex Beam Test Ballistic Impact Test Conclusion
Test articles were able to maintain the loads after damage
Test Damage
Risk Reduction Test
Tail Rotor Drive Shaft Test
Test Set-up
Test Conclusion
Tail Rotor Drive Shaft is tolerant to the AVS ballistic threat Ballistic Impact Test Damage
Risk Reduction Test
Sponson Material – Fuel Cell Interaction Fuel Line Leak Containment
Demonstrates structural capability to respond to hydrodynamic ram • Sponson composite wall construction • Self sealing performance of candidate fuel bladder Proposed solutions tested for leak mitigation / fire suppression initiated by ballistic impacts on fuel feed lines
LFT&E
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CH-53K is designated as a covered LFT&E system
– U.S. Code Title 10, Section 2366 (10USC2366) •
Alternative LFT&E (ALFT&E) strategy uses analysis to aid in identification of critical components and viable test shots
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Key Focus Areas
– Collateral and cascading effects – Assess potential crew and passenger casualty – Assess CH-53K Battle Damage Assessment and Repair procedures – Provide survivability comparison of CH-53K with legacy CH-53E – What modifications can be made to reduce the vulnerability of the CH-53K?
Component Level Ballistic Tests
Stationary and Rotating Scissors TR Pitch Beam Pitch Control Link Main and Tail Rotor Servos
• MRGB • IGB & TGB • TR Drive Shaft • TR Flex Couplings • TR Disconnect Couplings • TR Hangar Bearings & Mounts • Stationary Scissors • Swash Plate • MR & TR Servos • Sponson structure & cell • TR Blade, Flex Beam • TR Pitch Link • TR Pitch Change Shaft • TR Shaft • TR Pitch Beam • Armor – Crew, Cabin • Propulsion – GE 38
GTV System Level Tests
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Drive System Tests
– MRGB Rear Module – TR Gearbox – Intermediate Gearbox – TR Drive Shaft – TR Flex Coupling – TR Disconnect Coupling – TR Hanger Bearing and Bracket – NGB-MRGB Shaft, Coupling Hanger Bearing – Rotor Brake – NGB & Mounts •
Armor Tests
– Cabin floor / wall – Cockpit seat & wing •
Structure Tests
– Transition and Tail •
Fire Tests
– Engine Nacelle • Fire detection / ext. system – Fuel System • Sponson / SEFS • Feed (Engine) • Dump & Refuel • Fuel line Sleeves – Hydraulic System •
Flight Control Tests
– Control boxes & wiring – MR Servo Actuator – TR Servo Actuator – TR Blade – TR Hub – TR Pitch Beam – TR Control Link – TR Pitch Change Shaft – Swashplate CH-53E (mounted on a hover stand at WSL during JLF Tests)
Model - Test - Model
Trade Studies MODEL TEST ENSURES SURVIVABLE DESIGN