Multi-Spectral Scene Proj ection (MSSP) demonstration

Francisco A. Arredondo *a, Stockbridge Robert *a, Eric W. Glattke **b,

R. Walker *a
Robert W. Copeland
a Air Force Research Laboratory, Munitions Directorate, b MacAulay-Brown Inc., CMission
Research Corporation

J0

ABSTRACT
A new generation of advanced, highly capable, multi-spectral missile systems is being developed to address
advanced systems threats. These missile systems will require extensive and elaborate testing to validate their
effective operational envelopes. The increasing costs of live fire field testing balanced against lower testing
budgets, strict environmental impact limitations, and political consequences of test failures, are dictating an absolute
requirement to test the vast majority of the missile capabilities in the laboratory environment. Consequently, the
MSSP demonstration program was developed to address laboratory capabilities required to conduct robust dynamic

dual mode missile system guidance and control testing. The MSSP demonstration hardware was used to
simultaneously project dynamic, co-aligned, infrared (IR) and radio frequency (RF) targets to a common aperture
dual mode sensor. The demonstration of dynamic RF and JR scene generation presented many unique challenges.

Among the challenges were the development of a suitably representative dual mode sunogate sensor, spatial
alignment of the RF and JR targets within the sensor's field-of-regard/field-of-view, development of the RF and JR
beam combiner which minimized RF interference and maximized JR reflection and image quality, and development
of the optics and RF positioning systems. Significant modifications were made to the KHJLS RF Facility at
AFRL/MN Eglin AFB, FL in support of the unique requirements of testing a dual mode sensor. This paper presents
the system setup used for demonstrating the multi-spectral seeker testing capability and the results obtained.

The MSSP program is a tn-service development of a capability for test and evaluation of multi-spectral seeker
systems. At the conclusion of the project, each Service will be equipped with an MSSP system specifically tailored
to meet its specific test and facility requirements.

1. INTRODUCTION
Over the past decade, there has been a fundamental change of direction in the test requirements for missile seekers

in HWJL simulation test facilities. This change in requirements has been toward multi-spectral guidance test
support. Four RF bands and three JRlOptical bands have been areas of emphasis:
*

RFBands

*
*
*
*
*

10GHz
18GHz
35GHz
96GHz
JR/Optical Bands
* 3 to 5 microns
* 8 to 12 microns

The additions of the MSSP capability to test facilities at the three Services provide coverage for all of the above
bands. The installed optical systems were primarily refractive. The Air Force MSSP demonstration was done at the
10 GHz RF band, and the JR/Optical band was done at 8 to 12 microns. The camera used for the JR sensor was dual
spectral (MW/LW), but the scene projection system was only used from 8 to 12 microns. The Air Force application
was a developmental effort focusing on dual mode JR/RF test implementation. The program identified critical
issues in dual mode HWJL testing not related to specific program test goals but of major importance to this type of
program support in general. The Air Force was not driven to meet specific project test requirements so it was able

Technologies for Synthetic Environments: Hardware-in-the-Loop Testing VI, Robert Lee Murrer, Jr.,
Editor, Proceedings of SPIE Vol. 4366 (2001) 2001 SPIE 0277-786X/01/$15.00

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29

to examine dual mode test issues outside the scope of the other two efforts. The Air Force established test range
characterization techniques that will undoubtedly play a supporting role in the Navy and Army programs, and assure
Air Force weapons test programs that their HWIL needs can be met at the Eglin facility. Since each of the Services'
applications for the HWIL projection systems is unique, each activity faced specific laboratory integration problems
not affecting the other participants. The final phase of the MSSP program included a great deal of collaboration, and
operational implementation cooperation between each Service to assure the goal of having three operational dual
mode facilities by the third quarter of 2000

2. DEMONSTRATION OVERVIEW
2.1 FACILITY USED
The Air Force selected the Kinetic Kill Vehicle Hardware-In-the-Loop Simulator (KHILS) RE chamber facility
Eglin AFB, FL, for implementing the MSSP demonstration. The facility was originally used for testing AMRAAM,
and was modified to accommodate the MSSP demonstration (See figure 1). During the design phase of the MSSP
program, a lift system that contained all of the positioning system and the dual mode sensor to be tested was built,
making it easier for trouble shooting and calibrating the optics. The alignment requirements necessary for Radio
Frequency Target Simulator (RFTS) antenna array with the RF sensor, and the optics scene projection, collimator,
beam combiner with the IR camera were factored into the design. The RF target generator was also modified to use
the synthesizer as shown in Figure 1 , as well as the RFTS for generating RE signals. The IR scene projection system
was installed on the lift system along with the beam combiner and collimator.

RFCABLES

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2.1.1 LIFT SYSTEM

The lift system was designed to meet the requirements ofthe MSSP demonstration, as well as automating the facility
for conducting open-loop RF seeker testing, and antenna pattern measurements. The lift system was fabricated by
the AFRL/MN model shop. A three-axis computer control positioning system was mounted on the lift system for
holding the item under test. The lift system was mounted to an existing table that slides the lift system in and out of
the chamber, providing a platform allowing the extraction and insertion of the item under test (Figure 2). The lift
system was required because the quiet zone of the chamber was lower than the slide table would have located the

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three-axis positioning system. Since RF and JR sensor and associated optics and positioning system were to be put
on the lift system, it was designed to handle a 4,000 pound load.

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Figure 2: Lift system lowered inside the chamber

2.1.2 NY TARGET GENERATOR

The KHJLS Radio Frequency Target Simulator (RFTS) system is a simulation system initially designed in the late
1970s, integrated in the 1980s, and is continuously being upgraded. The K}JJLS RF chamber is a steel enclosure 25'
long by 20' wide by 15' high. The antenna array wall and the lift system with the three axis positioning system on
the slide table are at opposite ends of the chamber. Figure 3 is a picture of the antenna anay wall in the chamber.

The antenna arrays are populated with NURAD 296 high gain antennas. The antennas are dual, orthogonally
polarized, horn antennas with a minimum of 23 dB gain. The gain of the antenna increases over the 8 to 1 8 GHz
range. Hardware-in-the-loop simulation and testing is accomplished by generating the desired RF phenomena while
the seeker operates in an autonomous mode. During simulation set-up activities, the simulation engagement
computer and the RF control system are loaded with the desired RF engagement data. This properly configures the
simulation system and BY hardware. Several seeker systems have been tested and numerous experiments have been
conducted in the facility.
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Figure 3 : Antenna array wall viewed from the lift system

2.1.3 JR SCENE PROJECTION

The JR scene projector is based on a monolithic micro machined resistor anay teclmology developed by the
Honeywell Technology Center under multiple Government programs. The monolithic chip referred to as a resistor
array, which is just under one inch square, contains a 51 2x5 1 2 matrix of independently controlled active pixels. The

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resistor array is mounted in a vacuum-sealed chip carrier with a ZnSe window, which in turn is mounted to a watercooled copper block. This block and chip carrier assembly is mounted behind a 200-mm collimator. Finally, the
control and drive signal lines, vacuum line, and cooling water lines are attached to the copper block and routed to
the appropriate support equipment. The commanded JR images are generated by a 3-D scene generation system
based on a Silicon Graphics ONYX/Infinite Reality computer system. The digital images from the scene generator

are fed to the Wideband Infrared Scene Projector (WISP) array, and the Wideband Array Control Electronics
(WACE) assembly, which adjust the digital image to account for the non-uniformity of the resistor array. The
WACE then transforms the digital image into a combination of analog drive and digital control signals which are
wired to the resistor array. The projector system is capable of frame rates up to 120 frames per second. For this
demonstration, the system was run at 60 frames per second.

2.2 BEAM COMBINER

The beam combiner is the critical element used to combine RF and JR scenes in the spatial domain for the dual
mode sensor under test. The JR!RF beam combiner optical surface qualities must allow the combination of reflected

JR beams with the transmission of RE beams. MSSP has examined two approaches for producing the beam
combiner. The first is a multilayer thin film reflector on a quartz flat substrate. The thickness ofthe quartz substrate
detennines the transparency ofthe combiner to the RF radiation. This limits the use ofthis combiner to very narrow
wave bands. Standard optical coating processes are used to deposit the multilayer reflective stack on the front of the
combiner. The thin film structure determines the IR band of the reflector. This quartz beam combiner had been

studied prior to the MSSP program by the Research Development and Engineering Center at AMCOM in
Huntsville, AL. The limitations facing this combiner are limited size (<24"), weight (>32 pounds) and high cost.

The second approach examined for IR/RF beam combination in HWIL facilities used a RE transparent foam with a

frequency selectable surface (FSS) that transmits the RE, but reflects JR. The FSS, for a broadband combiner,
consists of an array of square metallic pads deposited on Mylar. The Mylar sheet is then adhesively bonded to the
RF transparent foam. The resulting combiner operates over a broad RF band (1-110 GHz), and all tactical JR bands
(NIR, MWIR, LWIR). After testing the optical quality of the FSS Mylar beam combiner, it was determined that it
could not meet the flatness and optical requirements, so it was dropped.

The beam combiner selected for the MSSP demonstration was the multi-layer thin film reflector on quartz. Two
samples were obtained from the vendor for testing; one was named "Sample #1" and the other "Sample #2".
2.2.1 BEAM COMBINER SAMPLE RF TESTS
The material for the beam combiner is quartz; two 8-inch diameter samples were tested. Sample #1 has a thickness
of .597 inches measured around the circumference. Sample #2 has a thickness of .351 inches measured around the
circumference. The tests were conducted in the KHJLS RF testing facilities.
The test equipment used included a Wiltron network analyzer, two standard gain horns, and an optical fixture for
holding the samples and setting the correct angles

Figure 4: RF setup and fixture used during the testing of the 8" beam combiner sample.

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The first tests were conducted with the standard gain horns vertically polarized as shown in Figure 4. After looking
at the results, it was decided to test the samples the way they would be set up in the chamber. The polarization was
changed to horizontal and the samples were rotated to 0.0 degrees, 22.5 degrees, -22.5 degrees, and the sample
flipped and retested at 22.5 degrees. During the initial tests with Sample #1 ,the material was rotated to see if there
are any polarization effects. There were none. The material was flipped at 0.0 degrees to verify any RF reflection
effects due to the coating. No effects were noticed therefore, data were taken at 22.5 degrees with the coating facing
the received horn (Figure 4). Figure 5 shows the results of the RF transmission insertion loss of the two samples.
The drift in phase for Sample #1 is attributed to the Wiltron's frequency synthesizer drifting with time. This does
not affect the tests results. Based on the RF transmission insertion loss and the stiffness necessary to build the 28"
diameter beam combiner for the demonstration, the thick sample was selected.

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Figure 5: RF transmission insertion loss ofthe two beam combiner samples tested.
( Left, Sample #1. Right, Sample #2)

2.3 OPTICS TRAIN

In addition to the IR/RF beam combiner, the test configuration relied on a refractive, LWIR, 2-to-i zoom collimator
to optically couple the resistor array scene projector module image to the IR sensor. The collimator was mounted on
a 2-degrees-of-freedom translation stage assembly just below the dual-mode sensor assembly (Figures 6 and 7). The
collimator specifications included the following: Continuous Zoom: IFOV iOO to 200 itrad; AR coating from 7.5 to
i lim; FOV 4.15 to 8.24 degrees, Exit Pupil: 5 inches; Distortion less than i% across FOV; Exit Pupil Standoff 36
inches; Encircled Energy 85% within 200 prad.

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Figure 7: Positioning system and optical train on the lift system extension

2.4 COMMON APERTURE DUAL MODE SENSOR

The common aperture dual mode sensor was integrated in-house. The AFRL/MNGS RF Seeker branch had
previously developed a conformal antenna broadband passive interferometer sensor under contract with Ball
Aerospace Corp. The conformal array, end-fire sensor housing was used as the basis for developing the common
aperture dual mode sensor. An extension of the housing was built for incorporating the JR camera (Figure 8.).

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Figure 8: Dual-mode sensor under test

2.4.1 IR SENSOR
The camera is built around a LockheedlMartin 256x256, 40-micron pitch, quantum well, dual-color (MW/LW) focal
plane array (FPA) with neuromorphic processing packaged in a closed-cycle cooled dewar (Figure 9). The camera's
imaging optics is a 200 mm, ff1.6, 4.0-9.6 tm JR lens assembly; the primary lens can be seen at the end of the dualmode sensor in Figures 8 and 9. The optics provided a 3 degree field of view. This FPA was packaged in an SEIR

dewar, and used a sterling, dual-opposing piston, cryo-cooler for cooling. The JR sensor package was then
integrated into a 7-inch diameter, 30-inch long housing which was attached to the front end of the conformal array
sensor housing. The sensor images were read out to a PC based system.

Figure 9: Camera used in the MSSP demonstration. (On the left, camera with 200 mm optical lens. On the right,
camera with the closed cycle dewar and cryo-cooler).
2.4.2 RF SENSOR

The RF sensor consists of a 32 element array cylindrically mounted in a 7" diameter cylinder (Figure 10). The fieldof-view of the RF sensor is 90 deg in elevation and 360 degrees in azimuth. The RF array uses a switch matrix
beam former. The beam former is used for selecting the elements that are active during measurements. Right angle
connectors on the elements kept the cables and switching network along the cylinder wall. This allowed space for
the JR vacuum hoses, control cables, power lines, and data lines through the center of the cylinder supporting the JR
sensor. The switch network uses one Single Pole 4 Throw (SP4T) to select between four SP7T switches. This only

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35

provides connection to 28 elements. It was decided to have the four elements that were not connected at the bottom
of the cylinder, since the JR equipment and optics block the bottom elements. Software was written in Matlab to
provide a top-level control of the RF measurement system, Angle of Arrival (AOA) code, and the Graphical Unit
Interface (GUI) plotting program. Software was written to coordinate the RF measurement system by invoking an
ActiveX executable to initialize the HP8530, control the switch network to activate particular element, and then use

the HP8530 as the RF receiver. The AOA executable code, stored as a Dynamic Link Library (DLL), uses the
complex voltages measured by the RF sensor elements to solve for the polarization and spatial location of the
incoming signal to accurately identify the angle of arrival. The plotting program then displays the status of the
program, and the results of the estimation (Figure 11).

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Figure 11: GUI readout from the PC controlling the RF sensor

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3. DEMONSTRATION RESULTS
The demonstrations conducted under the MSSP program was very successful. The BY was tested in the KHILS BY
chamber without the JR sensor, scene projector and the optics (Figure 1 2). The results were saved as reference for
understanding the effects of adding the optics and projection system. An extension was added to the lift system to
support the optics and projection system. Then, the BY and JR system were tested together (Figure 13). The JR
system was coordinated with the BY system for spatially aligning the BY targets and the JR targets being generated.
A new calibration table was made for the BY due to the shadowing and obstruction effects of the BY signal from the
optics and the anechoic material covering the projection system. The targets were generated as though they were
traveling from right to left, from left to right, and up and down. The BY would start seeing the target first since it
has a wider field-of-view, and then as the target entered the field-of-view of the JR camera, both the BY and JR
would see the target, simultaneously, in the same spatial domain. As the target reached the edge ofthe field of view
of the camera, the BY would continue tracking the target to the end of the BY generator's capability. The target was
tracked 1 5 degrees with the BY sensor, and 1.5 degrees with the JR camera.

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Figure 12: Conformal array sensor testing without JR

Figure 13: The RF and IR target generation as seen from the sensor

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3.1RFRESULTS
There was plenty of interesting RF effects as a result of the particular setup. Many ideas were generated as to how
to make this capability usable for testing a dual mode seeker. The RF sensor in this case had no gimbal system and
it was unique in the sense that it was a conformal anay sensor that measures angles using inteferometry. A lesson
learned was that the beam combiner would have caused less effect on the RF if the dielectric constant of the holder
had more closely matched that of the beam combiner. Figure 14a shows the results of the RFTS target generated

signal versus the measured calibrated signal for the center element of the RFTS anay. Figure l4b shows the
difference in the measured voltages of the RF dual-mode antenna array sensor with and without the optics, scene

projection system, and beam combiner added. This again used the center horn of the RFTS. Much data were
collected that show this typical effect with different polarizations and different angles of arrival. Overall, the RF
sensor worked very well in spite of the effects attributed to the JR target generation hardware, after the RF sensor
was recalibrated.
ANTENNA ARRAY POWER RECEIVED

ANTENNAARRAY POWER RECEWEO

10

15

20

32 ANTENNA ELEMENTS

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30

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35

Figure 14a and 14b: Figure 14a, left, is the actual raw data measured versus the calibration data. Figure 14b shows

the data measured by the RF sensor, with and without the JR target generation hardware.

3.2 IR RESULTS
The JR results were typical of the scene projection system that is normally tested at the KHJLS facility. There are
some new setups that have a dual-color scene generation/projection system, but we did not have resources to
incorporate it in this particular demonstration. Figure 15a and 1 5b, below, show the image generated as input to the
projection system, and the resulting image being received by the JR sensor. This demonstration established baseline
for the performance the optics and scene generation system that would be required if we were to test a dual-mode
seeker.

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i a aici 15b:

i a on the left is scene being generated as input to the WISP array. Figure 15b on
the right is the resulting image that was recorded by the dual-mode sensor camera.
4. CONCLUSION

The MSSP program demonstration was very successful and provided the opportunity to develop methodology and
the capability for testing and simulating dual-mode RF/IR seekers. From the work that was done, many new ideas
were cultivated in the area of testing, equipment, and requirements in order to provide a high level of fidelity for
testing dual-mode seekers. This paper is just a brief outlook into the complexity, and the amount of details that are

required to understand the testing requirements of multi-mode seekers. The lessons learned during this
demonstration will play a part in the future multi-mode seeker simulation and testing.

ACKNOWLEDGEMENTS
A demonstration ofthis magnitude requires plenty ofsupport in different areas ofexpertise. Thanks to the people
who help make the demonstration possible with their dedication, support, and professionalism. Many thanks go to
Jim R. Kircher for providing the expert knowledge and support in testing the optical quality ofthe beam combiners.
Many thanks go to Thomas P. Bergin and Virgil G. Timms for supporting the integration ofthe scene projection
system, calibration of the optics, generating the target images, and supporting the MSSP demonstration. Thanks
also go to Shane Hanna for the support in trouble shooting the RFTS target generation system and supporting the
KHILS RF, chamber facility upgrades. Without the help from these folks, it would have been difficult to
accomplish the objectives.

REFERENCES
1. E.M. Olson, O.M. Williams, R.L. Murrer Jr. and J.R. Kircher, "Resolutionand dynamic range capabilities of dynamic
infrared scene projection systems," in Technologies for Synthetic Environments: Hardware-in-the-loop Testing V, Proc. SPIE
Vol. 4027, 202-213 (2000)
2. O.M. Williams, G.K. Reeves and G.T. Ong, "Performance characteristics of thin film resistor arrays for infrared projector
applications", in Characterization, Propagation, and Simulation of Sources and Backgrounds II, Proc. SPIE Vol. 1687, 71-81
(1992).
3. J. Buford, S. Mobley, D. King, M. Bowden, and A. Mayhall, "Dynamic infrared scene generator (IRSG2) interface for
hardware-in-the-loop testing", Proc. SPIE 3368, April 1998.

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39

4. Jolly, AC., "Target and Scenario Signal Generation for Microwave and Millimeter Wave HWIL Missile Guidance
Simulation," Proceedings ofU.S. Army Missile Command Technology Showcase, August 1990, pp. 409-436.

5. S. Mobley, J. Cole, J. Cooper, and J. Jarem, "U.S. Army Missile Command dual-mode millimeter wave/infrared
simulator development," Proc. SPIE 2741, pp. 3 16-331, April 1996
6. S. Mobley, "U.S. Army Missile Command dual-mode millimeter wave/infrared simulator development," Proc.
SPIE 2223, pp. 100-111, April 1994.
*arredondceglin.af.mil; phone 850 882-5607; fax 850 882-4638; Air Force Research Laboratory, Munitions Directorate 101
West Eglin Blvd, Ste. 213 Eglin AFB, FL 32542, *stockbrieglin.af.mil; phone 850 882-4446; fax 850 882-2363; Air Force
Research Laboratory, Munitions Directorate 101 West Eglin Blvd, Suite. 13 Eglin AFB, FL 32542, **eric.g1attkeeglin.af.mi1;
1th Avenue, Shalimar, FL 32579, *wa1ker(eglin.af.mi1;
phone 850 882-8431; fax 850 882-4128; MacAulay-Brown Inc.,
phone 850 882-5778; fax 850 882-4638; Air Force Research Laboratory, Munitions Directorate 101 West Eglin Blvd, Ste. 213
Eglin AFB, FL 32542, 'K'K copelanr(2ieglin.af.mil; phone 850 882-5778; fax 850 882-4128; Mission Research CorporationFlorida, Combat Applications Division 147 John Sims Parkway Valparaiso, FL 32580-1271

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