Special 2010 Edition

Lead · Innovate · Integrate · Deliver

Systems
Engineering
 IN THIS ISSUE
• People, Collaboration and NASA-Style Innovation — RDECOM Commander Shares Vision
• Fueling Development for Future Force Vehicles
• Innovative Materials Bridge Partnership Between TARDEC and Lawrence Tech
• Total Immersion in Virtual Environments Leads to Engineering Innovation
• TARDEC Chief Scientist Helps Develop Army Ground Systems Technology Focus

SPECIAL DOUBLE ISSUE

Intellectual Rigor a Hallmark of TARDEC Capabilities
Within TARDEC’s labs,
the heavy lifting needed
to provide innovative,
integrated solutions for our
warfighters takes place.
Our sophisticated labora-
tories are only one of the
means through which we
complete our work. It is
the intellectual rigor of our
people, the thoroughness
of our processes and our innovative technologies that
give these labs life. The combination of state-of-the-art
equipment and the expertise of our engineers, scien-
tists and technicians allows us to tackle the challenges
faced by the Army’s ground vehicle fleet.
A particularly powerful capability is our advanced
modeling methods, through which we can simulate
conditions faced by Soldiers in the field. Physics-based
modeling allows us to realistically assess system per-
formance and Soldier responses under realistic condi-
tions, which in turn gives us a deeper understanding
of what warfighters go through and the training they
need to successfully complete their missions. With
these capabilities we are able to infuse intellectual
rigor early in the development phase, which shortens
lead times and makes the integration process more
efficient in both time and cost. We work out the details,
large and small, in the labs so the integration into the
vehicle is part of a seamless, repeatable process.
Part of what makes TARDEC unique is our focus on
systems integration. TARDEC’s more than 50 labs have
the capabilities to evaluate entire vehicle systems,
individual components and all levels in between. Our
Systems Integration Laboratories offer a platform for
engineers to find the best fit for new technology within
an existing vehicle and see how all systems work to-
gether before final integration. The equipment we use
allows us to push vehicles to their limits, checking the
durability and reliability of the system and thereby al-
lowing us to find potential problems before they occur.
That is the case in the High-Performance Computing
Center, which allows us to do classified and unclassi-
fied analysis. One thousand processors spread over
two systems and accounting for a combined 12.4 tera-
flops of memory are used in conducting tests that help
verify vehicles meet the Army’s rigorous requirements.
Vehicle armor also must meet very high standards,
and our Ground System Survivability Armor Ballis-
tics Lab performs ballistic testing on transparent and
opaque armor materials to determine whether they
meet necessary threat levels. Additionally, we must be
able to react quickly as problems arise, and the Cave
Automatic Virtual Environment uses virtual reality
to create 3-dimensional models that significantly cut
down on the time needed for the design process.
Part of our role is to bring systems integration
excellence to the community, which is why we
pride ourselves on the openness of our labs. Private
organizations can use our labs through Test Service
Agreements (TSAs) where all inventions and data
belong to the partner organization, but the work is
performed using TARDEC associates, equipment,
material and facilities.
We continue to bring capabilities to the Ground
Systems Enterprise with the addition of two labs that
focus on areas of growing importance to the military
— power and energy (P&E) and robotics. The new
Ground Systems Power and Energy Laboratory will be
completed in September 2011 and has the capability to
further research into alternative fuels and propulsion
systems and focus efforts to address critical combat
vehicle fuel efficiencies. Once complete, the 8-labs-in-1
complex will have one-of-a-kind research and testing
capabilities and will serve as the cornerstone for the
Army’s next generation of P&E initiatives. Just as P&E
will continue to be a focus, so too will robotics. Au-
tonomous ground systems have incredible potential
to positively impact Soldiers. The U.S. Army TACOM
Life Cycle Management Command’s Joint Center for
Robotics has built a state-of-the-art robotics lab at the
United States Military Academy at West Point. This
facility provides a venue for educational and research
opportunities and familiarizes future military leaders
with the benefits robotic systems can provide.
We provide capabilities that match the broadness and
importance of our mission. Our systems integration
responsibilities mean we must be ready to address
whatever problems — current or future — we are
presented with. The resources available in our labs
provide us what we need to lead, innovate, integrate
S p ecia l 2010 E d it io n
and deliver solutions to meet those challenges.
Dr. Grace M. Bochenek
TARDEC Director
1
 Special 2010 Edition

Lead · Innovate · Integrate · Deliver

On the Cover: The 3-dimensional cubes depict TARDEC laboratory facilities and the integrated
approach our scientists and engineers take to ground vehicle systems engineering and design.
Each cube represents a carefully integrated system-of-systems capability designed to produce
unprecedented battlefield lethality, survivability, mobility and sustainability across the full spectrum
of conflict.
Many of our labs are one-of-a-kind and provide our associates with a leading-edge environment to
build the most capable combat and tactical vehicle fleet in the world. And because the pieces are
engineered to fit together using a system-of-systems approach, the Ground Systems Enterprise has
constructed a solid foundation of laboratories that interlock to provide the American Soldier signifi-
cant overmatch capability in any environment, night or day, against any potential threat.

TARDEC’s laboratory facilities provide a home for the U.S. Army’s and Department of Defense’s Take the time to learn more about Team TARDEC and the awesome capabilities our people bring
advanced science and technology research, development, life cycle engineering and ground vehicle to the design table. We deliver the most technologically advanced integrated solutions and sustain-
systems integration. TARDEC technicians, scientists and engineers partner with other major defense ment expertise possible so that our Soldiers are protected by the best vehicle systems imaginable.
laboratory associates, industry representatives and engineers, and academic researchers, engineers
and scientists to integrate technology into the Army’s and other services’ manned and unmanned
ground vehicle systems. Michael I. Roddin
Editor-in-Chief
This special edition is designed to give the reader an up-close-and-personal look into the science
behind the technology and the systems engineering integration that makes the technology possible.

6 14 20

24 38 50
5 Collaboration Yields Game-Changing Innovation 22 Integrating Systems Engineering for Robotic
for Our Warfighters Battlefield Deployment — Intelligent Ground
Michael I. Roddin Systems (IGS) Laboratory and Vehicle Bay
Michael D. Kaplun
6 People, Collaboration and NASA-Style Innovation —
RDECOM Commander Shares Vision 24 TARDEC’s Battlefield Observation Room (BOR)
Katherine H. Crawford Provides Leading-Edge Teleoperation and
Data-Sharing Capabilities
INTELLIGENT GROUND Matthew Sablan
SYST E M S
28 TARDEC-Funded West Point Robotics Lab
14 Intelligent Ground Systems (IGS) Robotics Builds Future Engineers
Laboratories — Finding Robotics Technology Patrick Pinter
Solutions Through Innovation
Michael D. Kaplun POWER AND MOBILITY
16 VSIL Technology Test and Validation Center 34 TARDEC Associates Display Capabilities
Provides Systems Engineering Integration Capability to ARDEC Visitors
Sp eci a l 2 01 0 Ed i ti o n

Carrie Deming Chris Williams

18 TARDEC Robotics Systems Integration Lab (SIL) 38 Designing a Unique Lab for Advanced
Carrie Deming Military Vehicles
Michael A. Kluger and Felt A. Mounce
20 Technology Integration for Unmanned
Ground Vehicles
Michael D. Kaplun
2
 EDITORIAL ADVISORY BOARD EDITORIAL STAFF
DISCLAIMER: accelerate is published by TARDEC. Dr. Grace M. Bochenek Paul Skalny Michael I. Roddin Matt Sablan
Articles express the written views of the authors and TARDEC Director Director of National Editor-in-Chief Writer/Editor
not necessarily official opinion of the Department of Automotive Center
the Army (DOA). If articles are reprinted, please cite Magid Athnasios Meg A. Carpenter Chris Williams
accelerate, the author and photographer. Executive Director of Terry Gonda Publications Manager Writer/Editor
Reference herein to any specific commercial company,
Engineering Director of Strategic
Transformation Katherine H. Crawford Nojae Kim
product, process or service by trade name, trademark, Managing Editor Henry Marnghitr
manufacturer or otherwise does not necessarily Thomas Mathes
Rhonda Wilt
constitute or imply its endorsement, recommendation, Executive Director of Jennifer Hitchcock
Pete Wardrope Graphic Design
or favoring by the United States government or DOA. Product Development Chief of Staff Senior Editor
The opinions of the authors expressed herein do To contact the Editorial
not necessarily state or reflect those of the United Dr. Paul Rogers Michael I. Roddin Carrie Deming Office, call
States government or DOA and shall not be used for Executive Director of Director of Strategic Writer (586) 582-0288 or
advertising or product endorsement purposes. Research Communications (586) 838-2302
Michael D. Kaplun FAX: (586) 838-2360
POSTMASTER: Please send address changes to U.S. Dr. David Gorsich Writer/Editor e-mail: accelerate@
Army TARDEC, 6501 E. 11 Mile Road, Bldg. 200A, Chief Scientist conus.army.mil
RDTA-ST, Mail Stop #206, Warren, MI, 48397-5000. Patrick Pinter
Writer/Editor

58 64 56 70

74 80
44 Fueling Development for Future Force Vehicles — 70 Advancing Ground Vehicle Research
TARDEC’s Fuels and Lubricants Laboratories and Development
Provide Leading-Edge R&D Michael D. Kaplun
Matthew Sablan
FORCE PROJECTION
48 EARL Runs Batteries Through Paces
Chris Williams 74 Testing Facility Provides Clean Water
Solutions for Soldiers
50 TARDEC Engineers Advance Hybrid-Electric (HE) Patrick Pinter
Technology and Systems Integration
Chris Williams 78 Keeping Warfighters Well-Hydrated — SDTF
Delivers Optimal Water Purification Systems
54 Fueling Station and Maintenance Facility Keep Matthew Sablan
Hydrogen Vehicles Powered
Chris Williams 80 TARDEC Leads Fuel and Lubricant
Technology Development and Design
58 Optimized Combustion and Fuels Focus of Single Patrick Pinter
Cylinder Test Cell
Chris Williams G R O U N D SYST E M S
S p ecia l 2010 Ed i ti o n

S U R V I VA B I L I T Y
60 Systems Engineers Keep Vehicles on Track
Chris Williams 86 Lab Puts Armor Under the Gun to Save
Soldiers’ Lives
64 TARDEC Turns Up Heat on Vehicle Testing Chris Williams
Chris Williams

3
 CALL FOR ARTICLES

Lead · Innovate · Integrate · Deliver

accelerate Magazine is seeking articles for upcoming issues. Are you researching new technologies? Have you faced and overcome
engineering challenges and created innovative designs that will aid Soldiers in theater? If you have, TARDEC, the Nation’s laboratory for
advanced military automotive technology, wants to publish your story. Submit your article and photo images to: accelerate@conus.army.mil.

Inform your colleagues and community by writing for TARDEC’s monthly online news magazine, GVSET News. As a member of the ground
systems enterprise, you have the opportunity to express your professional voice and engage the public by writing for GVSET News, which has
a subscriber base of more than 3,000 readers. If you work in or around ground vehicle systems technology, engineering, robotics, survivability
or power and energy, your expertise would be of interest to our readership. Submit your article or photo images today
to GVSETNews@tardec.info

86 98 102

106 108 116 116

90 Innovative Materials Bridge Partnership Between 114 Assessing Material and Microstructural Failures —
TARDEC and Lawrence Tech Metallurgical and Failure Analysis Laboratory
Matthew Sablan Provides Critical Analysis
Michael D. Kaplun
94 Testing Capabilities Help Mitigate
Explosive Damage 116 Conducting M1A2 Software Maintenance
Patrick Pinter and Enhancement — M1A2 System
Integration Laboratory
98 Laser Protection Research and Integration Michael D. Kaplun
Laboratory — Protecting Soldiers’ Eyes
and Optical Sensors 118 DREN Provides TARDEC’s Computing Power
Michael D. Kaplun Michael D. Kaplun

MODELING AND 120 High-Performance Computing Center Delivers

S I M U L AT I O N Proven Vehicle Solutions
Patrick Pinter
102 Total Immersion in Virtual Environments
Leads to Engineering Innovation 122 Dynamic Structural Load Simulator Laboratory
Patrick Pinter Bridges Capability Gaps (DSLSL)
Sp eci a l 2010 Ed i ti o n

Matthew Sablan
106 A Virtual Environment Gets Soldiers
Ready for Action 124 TARDEC Chief Scientist Helps Develop Army
Patrick Pinter Ground Systems Technology Focus
Michael I. Roddin and Chris Williams
108 Ground Vehicle Simulation Laboratories Simulate
Real-World Testing and Analytics
4
Patrick Pinter and Matthew Sablan
Collaboration Yields Game-Changing
Innovation for Our Warfighters
The U.S. Army Research,
Development and Engineering
Command (RDECOM) Tank
Automotive Research, Develop-
ment and Engineering Center
(TARDEC) supports warfighters
through research, development,
engineering, integration and
delivery of innovative technolo-
gies. In executing this mission,
TARDEC, in close collaboration
with program, project and prod-
uct managers, provides systems
engineering and technology
integration for all manned and
unmanned ground systems.
At the heart of TARDEC’s
science and technology (S&T)
research, demonstration, devel-
opment and full life-cycle engi-
neering collaborative work are
its laboratories. This special issue
of accelerate Magazine highlights
TARDEC’s cooperative work and
world-class facilities, conveying
how the RDECOM enterprise
supports warfighters efficiently
and effectively.
Articles of particular interest in
this edition include:
• People, Collaboration and
NASA-Style Innovation — MG
Justice’s Vision for RDECOM —
an exclusive interview in which
the new RDECOM Command-
ing General MG Nickolas G.
Justice discusses his philosophy
and vision.
• Technology Integration for
Unmanned Ground Vehicles —
TARDEC’s Small Robotics
Laboratory focuses on develop-
ing and integrating technology
advancements for unmanned
ground vehicles, designing and
analyzing advanced behavior
control schemes for future ve-
hicle implementation.
• It's TARDEC-Funded West
Point Robotics Lab Builds Future
Engineers — TARDEC and the
Robotic Systems Joint Project
Office led the construction of a
robotics lab at the U.S. Military
Academy, West Point, NY.
• TARDEC Turns Up the Heat
on Vehicle Testing — to improve
vehicle mobility, TARDEC’s
Ground Vehicle Power and Mo-
bility team is rapidly testing and
evaluating vehicles, ensuring they
are optimally equipped to endure
the harshest environments.
• Keeping Warfighters Well-Hy-
drated — SDTF Delivers Optimal
Water Purification Systems — the
U.S. Navy’s Seawater Desalina-
tion Test Facility (SDTF) enables
the Army and U.S. Marine Corps
to test and develop field water
purification equipment to keep
warfighters replenished and en-
ergized in theater.
• Innovative Materials Bridge
Partnership Between TARDEC
and Lawrence Tech — TARDEC
entered into a partnership
with Lawrence Technological
University in October 2008 to
develop, install and operate
an environmental/loading
chamber to test advanced
materials for vehicle armor
and structural components.
• Total Immersion in Virtual
Environments Leads to Engi-
neering Innovation — the Cave
Automatic Virtual Environment
(CAVE) is an immersive, virtual
reality environment in which
users view 3-dimensional graph-
ics that show an object’s various
sides and components.
• TARDEC Chief Scientist Helps
Develop Army Ground Systems
Technology Focus — TARDEC
Chief Scientist Dr. David Gorsich
leads the center’s S&T portfolio to
better equip and improve current
and future Soldier operations.
These featured articles, and
their companions, focus on the
capabilities that TARDEC and its
partners strive to deliver daily.
Find out how collaboration with
Army partners, industry and
academia helps the Army and
Department of Defense lead,
innovate, integrate and deliver
the most advanced technology
and leading-edge solutions to
our Nation’s warfighters.
S p ecia l 2010 E d it io n
Michael I. Roddin
Editor-in-Chief
5
 People, Collaboration and
NASA-Style Innovation —
RDECOM Commander
Shares Vision
Katherine H. Crawford
S peci a l 2010 E d it io n

RDECOM CG MG Nickolas G. Justice visited a number of technology

displays while attending All-American Bowl Week festivities in San
Antonio, TX, Jan. 7-9, 2010. RDECOM had a large technology display
of its own at the annual event. (U.S. Army RDECOM photo.)

6
I
n his New Year’s message to
the 17,000-strong U.S. Army
Research, Development and
Engineering Command
(RDECOM) workforce,
Commanding General (CG)
MG Nickolas G. Justice directed
his team to move out in triple
time. “We provide America’s
warfighters with strength
through technology,” Justice
declared. “There is no other or-
ganization in the Army that does
what we do, so we must all be
first-string players. We must be
at the forefront of our expertise,
striving to be world-class. Our
Soldiers deserve no less. I’m sure
you’ll agree. Your mindset must
be — Fast. Furious. Now.”
During accelerate Magazine’s
December 2009 interview with
the new commander at RDECOM
Headquarters in Gun Powder,
MD, Justice was fired up with
plans for fusing Soldiers’ experi-
ence with the RDECOM work-
force’s knowledge and expertise
to take science and technology
(S&T) solutions to the next level.
Justice’s Philosophy
and Vision
Justice, a Soldier for more than 38
years, has served most of his career
in electronic warfare communica-
tions systems and software engi-
neering. His most recent leader
role was as Program Executive
Officer, Program Executive Office
Command, Control and Commu-
nications-Tactical (PEO C3T).
He breaks down everything that
he does into four parts: people,
purse (funding), problems and
processes. To him, connecting
these four parts correctly achieves
optimal solutions. If you can
team the people with the funding
and then use processes to solve
problems, you come out with a
product that is better and more
sustainable. Justice believes that to
improve RDECOM and the Army
in general, we all need to work on
processes and make them broader
in scope to better solve opera-
tional problems.
Justice (center) learns more about the TALON
robot from TARDEC Robotics Engineers
Bernard Thiessen (left) and Jeremy Gray at the
RDECOM exhibit at the All-American Bowl.
(U.S. Army RDECOM photo.)
Justice asserted RDECOM should
be defining the requirements and
working with industry to fulfill
those requirements rather than
accepting industry-driven solu-
tions. He stated that RDECOM
has not been precise in express-
ing itself and its needs, but that
the engineers within RDECOM
have the knowledge and exper-
tise to drive innovations and
articulate warfighter needs. By
truly understanding systems
and components and the way in
which they work in the field, as
well as the research, development
and engineering (RD&E) behind
them, better solutions can be
found. As Justice explained, “Be-
ing able to put those understand-
ings and real-world knowledge
into the technologies we pro-
duce allows us to shape how the
problem is solved before we get
a problem that has already been
shaped to an understanding of a
certain solution.”
Power of Collaboration —
Bringing Soldiers and
Technical Experts Together
Justice strongly believes in the
concept of something being greater
than the sum of its parts: “You can
create more capabilities with syner-
gies versus with individual compo-
nents.” His goal is to partner do-
main experts with those from each
subject area and have them col-
laborate so that their systems work
together. “Look at the strength of
what I’m doing: I’m taking those
unique, one-of-a-kind experts,
and I’m multiplying them to the
power of the number of experts I
put together, not just adding them
together. It just becomes geometric
in what you can accomplish.”
“We provide America’s
warfighters with strength
through technology. There is
no other organization in the
Army that does what we do.
We must be at the forefront
of our expertise, striving to
be world-class. Our Soldiers
deserve no less. Your
mindset must be —
Fast. Furious. Now.”
Another way in which Justice
plans to build the strength of
his organization’s people is to
leverage the power of the mili-
tary personnel within RDECOM.
There are approximately 200 Sol-
S p ecia l 2010 E d it io n
diers within RDECOM, and their
insight and input is invaluable
because they come to the problem
with a different perspective. A
firm believer in the idea that you
can’t solve a problem until you
7
 understand the problem, Justice
is keen to harness the know-
ledge and experiences of these
service members who have been
in the field. “We’ve got noncom-
missioned officers [NCOs] and
officers here who have experi-
ences that our folks with S&T and
engineering backgrounds don’t
have. These NCOs are just as
valuable, if not more so, because
that’s where the clarity of the
problems will come,” he com-
mented. Additionally, these mili-
tary personnel can easily establish
a network of people to work on a
specific task, project or problem.
“They’re used to moving around,
and they have friends and associ-
ates they’ve known on a personal
basis around the Army, and they
can easily establish a network of
people because that network is
already there.”
To this end, Justice plans to bring
five senior NCOs to the Army’s
research, development and engi-
neering centers to ask challenging
questions of the engineers and
S peci a l 2010 E d it io n
Justice visited the Detroit Arsenal to get an up-close look at the RD&E conducted by TARDEC. From left: TARDEC Executive Director of Re-
search Dr. Paul Rogers, TARDEC Director Dr. Grace M. Bochenek, TARDEC Military Deputy COL Eric Fletcher and Justice speak with TARDEC
Associate Dr. Mark Brudnak in TARDEC’s Ground Vehicle Simulation Laboratory. (U.S. Army TARDEC photo by Elizabeth Carnegie.)
8
technicians working on the equip- Power of Collaboration —
ment that these NCOs’ fellow Creating Common Systems
military personnel will be using in Justice applies this same strat-
the field. RDECOM’s Command egy of networking to developing
Sergeant Major Hector Marin platform architectures. One of
will be responsible for bringing in his major objectives is to bring
qualified crewmembers who can commonality to everything —
operate as a unit rather than as systems, components, platforms,
individuals. The idea is to “bring etc. His ideal is an infrastructure
the reality and the practice of that can host many components,
what we do back into the labo- the idea of “one-to-many versus
ratories to see it,” Justice stated, many-to-many.” If various pieces
and “connecting the right people of architecture aren’t compatible
— the innovators and the user with one another, it just wastes
community — to create a product time and money. “Commonality
that is better than either could is incredible,” Justice explained.
develop alone to make the Army “It will reduce the costs in the
the best in the world at solving contracts for components because
particular problems.” you’ll be able to build components
RDECOM should be defining the requirements and
working with industry to fulfill those requirements
rather than accepting industry-driven solutions. By truly
understanding systems and components and the way in
which they work in the field, as well as the RD&E behind
them, better solutions can be found.

Justice gets a driver’s-side view from the cab of a Mine Resistant Ambush Protected
vehicle in TARDEC’s Prototype Integration Facility (PIF). PIF Associate Director Luis
Hinojosa (front) describes vehicle components and platform-unique capabilities to him.
Justice believes in bringing together experienced NCOs, researchers, developers and
technicians to achieve great things for RDECOM and the Army as a whole. (U.S. Army
TARDEC photo by Elizabeth Carnegie.)
to specification and know that
you’ve already got the infrastruc-
ture to plug into.”
Currently, he noted, the Army’s
usual practice is to replace a
system and the whole infra-
structure, which causes costs to
skyrocket. Justice used a house-
hold example to illustrate his
point: “What if every time you
replaced a TV in your house
you had to replace all the elec-
trical wiring, too? That sounds
crazy for me to say that, right?
But that’s oftentimes what the
Army would do. We’d replace a
system, but we’d have to replace
the complete infrastructure. Not
only the infrastructure, but the
parts supply. We’d also have to
replace the repair facilities. When
you start doing that, your costs
go orders of magnitude more
than the actual capability you’re
putting into the combat forma-
tions. What we want to do is
get down to where we are fund-
ing those things that directly
make a difference and make an
improvement to combat forma-
tions without having to replace
complete infrastructures.”
Justice gave another household
example to show that common-
ality is possible, noting that we
have standards for various specifi-
cations in our homes. “Everybody
knows exactly what the specifica-
tion is for a 110-volt, 60-cycle
power outlet on your wall. You
know exactly how to plug it in
and how it’s got to be wired, so
anybody in the country who can
produce electronics knows what
the power that will be available
for that device is, and they know
how to configure it and have it
ready for your home.” Justice
seeks to bring this same type of
standardization to Army equip-
ment and platforms and have
RDECOM set the standards for
“What we want to do is get
down to where we are
funding those things that
directly make a difference
and make an improvement
to combat formations
without having to replace
complete infrastructures.”
industry and academia. “What we
want to do is get into the position
of setting those standards, defin-
ing them and being the under-
writer’s lab equivalent for the
Army, and that means focusing
very heavily on the engineering
component,” he observed.
Justice knows that this type of
commonality can be achieved by
bringing the right communities
together and fostering collabora-
tion. He spoke of witnessing, in
his previous role, the communica-
tions and electronics community
and the vehicles and sensors com-
munity getting together to “create
a common driving infrastructure
that allowed integration to occur.”
Once a common platform was
created, ultimately, “They created
more capability than the individ-
ual components had organic to
themselves by creating synergies
across the components.”
The other crucial consideration
that RDECOM scientists and
engineers must always take into
account is product and system
longevity. RDECOM must an-
ticipate future requirements and
design components that will have
a long life cycle and can take on
many potential systems. “One of
the things I see us doing is design-
ing components to use infrastruc-
ture that we know will have a
fairly long life cycle, and we need
to find touch points of modern-
ization with that infrastructure
that allow us to grow its capability
and capacity to a potential capac-
ity that we never realized in the
initial fieldings,” he emphasized.
For example, “I want my commu-
nications systems to be capable
S p ecia l 2010 E d it io n
of 50 or 100 megabits per second,
though I may field them with five
megabits per second, and I want
to be able to take small compo-
nents of that and change them
out. That will give me a doubling
9
 or a 10-times capability in that
network but not have to replace
everything there.”
Reaching to the Stars —
Harnessing NASA’s
Expeditionary Mindset
Justice is always planning for
the “Army after next,” seeking
strategies to modernize and
looking for long-term solu-
tions. He firmly believes that
RDECOM and the Army need to
think longer-term and be better
at anticipating future needs and
technologies. “We want to plan
things that fall over at least three
generations of packaged capabil-
ity — packaged capability is all
the equipment in there — so that
the infrastructure crosses mul-
tiple generations of equipment.
Don’t solve my problem today —
solve my problem today that has
legs to the future and the ability
to be modernized,” he remarked.
The Army needs to be able to see
“disruptive” technologies coming,
like cell phone technology was 10
years ago, and plan for it so that
it’s not stuck with legacy systems
that cannot be adapted or will be
too expensive and time-consum-
ing to modernize.
Standardizing equipment and
ensuring that it is built for a
long product life cycle also al-
lows Soldiers to become more
expeditionary. If you “standard-
ize equipment so that the vehicle
comes ready for plug-and-play
kind of applications, then every
piece of equipment that goes in
that vehicle doesn’t have to have
its own installation kit, its own
installation crew to support that,
its own maintenance, its own
S peci a l 2010 E d it io n
tail of supply that’s out there in
the unit,” Justice observed. This
allows the Army to lighten its
load of parts and people, yield-
ing a more mobile and agile force.
“Being expeditionary means that
10
you need to lighten your load as
quickly as possible,” he noted. “We
want to empower our portion of
that combat brigade with a smaller
footprint, a much more sustain-
able equipment set, so that those
kits allow a unit to pack and move
faster than they’re able to do today
with very large supply tails.”
“We have an insatiable
appetite for things that save
lives and make us more
effective, that close time and
distance problems, so you
see us in this same geometric
demand cycle for things
like bandwidth and energy
and many other things, but
bandwidth and energy are
two things that fall into the
big infrastructure pieces.”
Justice views the Soldier as his or
her own self-sustaining system
that’s equipped and plugged into
the network — each is his or her
Justice (center) examines the 3rd Infantry Division’s course to integrate PEO C3T equipment into
its predeployment exercise at the National Training Center, Fort Irwin, CA, in August 2007. (U.S.
Army RDECOM photo by Richard Mattox.)
Justice receives the RDECOM colors from
U.S. Army Materiel Command CG GEN
Ann E. Dunwoody during a Dec. 4, 2009,
Change of Command Ceremony. (U.S.
Army RDECOM photo.)
own expeditionary force. The
human as its own closed, self-sus-
taining system is the same idea as
an astronaut, and he’s looking to
NASA for inspiration on ways of
bringing this thinking to the Army.
Justice noted that all the future
platforms the Army is moving to
are for 2- or 3-men crews, which
is similar to the Apollo program,
and so it may be useful to see if
there are any lessons that can be
gleaned from history. “Some of
the things that we achieved with
NASA in the late 1950s and 1960s
are the kinds of engineering that
we want to do in this organization.
They’re directly related to what we
do in the Army on the battlefield.
The Soldier is the astronaut. The
spacecraft becomes the combat
vehicle — it’s tailored to a specific
mission, it’s expeditionary.”
This collaboration with NASA is
real and, in fact, Justice is talk-
ing with Astronaut William M.
Shepherd regarding potential
opportunities for collaboration.
This is just part of his forward-
thinking strategy for bringing
innovation and new partnerships
to RDECOM to achieve techno-
logical breakthroughs.
Justice used the NASA analogy
during the U.S. Army All-Amer-
ican Bowl held in January in San
Antonio, TX. He escorted Secre-
tary of the Army John McHugh
through the Army Strong Zone,
which demonstrated the Army’s
future vehicle concepts, Soldier
gear and technology. Standing
next to a Soldier wearing com-
posite armor, Justice explained,
“This is the astronaut version of a
Soldier. He can live in any envi-
ronment. He can do anything.
If I add the ‘Sense through Wall’
technology being demonstrated
behind me, he can see through
walls. He’s got X-ray vision.”
Exploring TARDEC
In the past six months, Justice has
visited U.S. Army Tank Automo-
tive Research, and Development
Center (TARDEC) four times, and
he is learning more about other
disciplines and domains, particu-
larly “getting to work with the
vehicles — that’s just exciting.” It is
this type of hands-on interaction
that he thrives on. Justice said he
is thrilled to visit the various labs
and see the innovative work being
done firsthand. He is particu-
larly impressed by the multitude
of capabilities TARDEC offers.
“It was interesting to look at the
Justice views equipment during a demonstration by a staff member at Tobyhanna Army Depot,
PA, to PEO C3T on March 17, 2009. (U.S. Army RDECOM photo by Richard Mattox.)
wealth of test equipment that
TARDEC has for measuring the
stresses on vehicles — some of the
shake, rattle, roll kind of devices
that TARDEC has in its labs. I
was surprised to find a couple of
supercomputers, and the kind of
modeling and simulation they were
doing, the fabrication facilities, how
they were able to produce things
— actually make components in its
facilities — that’s just fascinating,”
he exclaimed, adding, “This was the
first time I had a chance to go into
those facilities and see what was
going on.”
Justice also took note of the many
young TARDEC associates, com-
menting, “There are lots of bright,
young kids up there who know
what they’re doing.” TARDEC has
done an exceptional job of build-
ing its future workforce, and these
“kids” comprise another piece of
the collaboration puzzle — bring-
ing diversity of age and experi-
ence to tackling difficult chal-
lenges. As Justice stated, “That’s
the kind of thing we want to do:
bring the power of networking,
bringing the bright, talented
people we have who are experts
in the problem and experts in the
sciences and experts in the en-
gineering capability, bring those
people together and see if we can’t
solve some of these things.”
For the near-term, Justice will be
focusing RDECOM’s innovative
and collaborative resources on
two critical challenges facing the
Army — bandwidth and energy.
“We have an insatiable appetite
for things that save lives and
make us more effective, that close
time and distance problems, so
you see us in this same geomet-
ric demand cycle for things like
bandwidth and energy and many
other things, but bandwidth and
energy are two things that fall
into the big infrastructure pieces.”
His main tool for tackling these
challenges will be people. “It’s all
about the people, and we’ve got
the talent pool, we just need to
get them into the network — the
people with the problems — and
get them out there working, and
the power of people is amazing.
Other than that, it’s all to be dis-
covered, and that’s what I need to
do,” he concluded.
Katherine H. Crawford is the
Managing Editor for TARDEC’s
GVSET News and accelerate Magazine
and a Senior Publications Manager
S p ecia l 2010 E d it io n
with BRTRC, providing contract
support to TARDEC’s Strategic
Communications team. She has a
B.A. in English from Boston College
and an M.A. in literature from the
University of New Hampshire.
11
INTELLIGENT GROUND SYSTEMS (IGS)
 Intelligent Ground
Systems (IGS) Robotics
Laboratories — Finding
Robotics Technology Solutions
Through Innovation
T
he Intelligent Ground
Systems (IGS) Robotics
Laboratories (RL) pro-
vide the U.S. Army Tank
Automotive Research,
Development and Engi-
neering Center (TARDEC) with
S peci a l 2010 E d it io n
an extensive laboratory setup,
compromising facilities, tools
and equipment to design, inte-
grate, test and validate diverse
robotic systems to meet Soldier
needs and requirements.
14
Michael D. Kaplun
UGV Current Operations Support Team Leader
Lonnie Freiburger (left) and Robotics Systems
Manager MAJ Seth Norberg install the TARDEC-
developed Tanglefoot tripwire mitigation device to
a FasTac 510 PackBot. IGS Robotics Laboratories
engineers are at the forefront of TARDEC’s robotics
R&D. (U.S. Army TARDEC photo by Bill Dowell.)
IGS RL engineers and tech-
nicians primarily focus on
researching and developing
hardware, software and sensors.
Development is being performed
on a Velodyne Light Detection
and Ranging (LIDAR) — a
360-degree, high-resolution laser
range-finding sensor — Segway
robots; 360-degree cameras;
open architecture; Java-based
robotic control software; and
Joint Architecture for Unmanned
Systems-based software —
among other projects.
These facilities also have networked
computers (Windows and Linux)
to support R&D efforts. Com-
puter software includes Visual
Studio, used mostly for C++ de-
velopment; Eclipse, an integrated
development environment for
Java; modeling software, such
as SolidWorks; and other, more
specialized software.
“IGS Robotics Laboratory
initiatives, such as the
Velodyne LIDAR project and
the Segway Robotic Control
project, help enhance robotic
development in a time of ever-
growing technology.”
Key recent IGS Robotics Labora-
tory projects include:
• Velodyne LIDAR — performed
advanced characterization of
LIDAR performance, especially
in detecting people; utilized
 people from 360 degrees around
a vehicle; used radar to perform
obstacle detection and avoidance,
focusing on smaller unmanned

INTELLIGENT GROUND SYSTEMS

Pictured here is a Segway robot at TARDEC’s IGS
Robotics Laboratories at the Detroit Arsenal in
Warren, MI. System developments, such as the
robot, are expanding TARDEC’s role in robotics
innovation to augment Soldier capabilities. (U.S.
Army TARDEC photo by Carrie Deming.)
information from LIDAR to
perform obstacle detection.
• M/A-COM Radar — performed
radar characterization to deter-
mine performance in detecting
ground vehicles (UGVs).
• Segway robotic control —
roboticized Segways and put
mannequins on systems to sim-
ulate humans moving through
hostile environments.
• Pressure-sensitive Membrane
— utilized a material that
changes resistance based on
pressure to create a circuit
capable for use on manipulator
end-effectors.
• iPod Touch — used an iPod
Touch to control the Omni-
Directional Inspection System-
T3 vehicle and an iRobot PackBot.
• Electronic Ink (e-ink) — used
the display to compare the day-
light readability of e-ink versus
other displays.

UGV Current Operations Support Team Leader

TSGT Jeffrey Wasik kneels next
to a TALON explosive ordnance
disposal (EOD) robot. Systems
like the EOD robot help to
defeat seen and unseen threats
while minimizing Soldier vul-
nerability in theater. (U.S. Army
photo by MSG Brian Davidson.)
Lonnie Freiburger helps Robotics Systems
Manager MAJ Seth Norberg strap on the Squad
Support UGV (SSUGV) control pack. TARDEC
is helping develop the SSUGV for the U.S.
Marine Corps. (U.S. Army TARDEC photo by
Bill Dowell.)
“IGS Robotics Laboratory
initiatives, such as the Velodyne
LIDAR project and the Segway
Robotic Control project, help
enhance robotic development in
a time of ever-growing tech-
nology,” remarked TARDEC
Engineer Matthew Skalny.
Through IGS associates’ R&D
efforts, TARDEC has taken the
lead in the advancement of vital
robotics technologies, provid-
ing state-of-the-art solutions to
meet critical warfighter needs.
S p ecia l 2010 E d it io n

Michael D. Kaplun is a Writer/Editor

with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He holds a B.A. in
English and media and society from
Hobart and William Smith Colleges.
15
 VSIL Technology Test and
Validation Center Provides
Systems Engineering
Integration Capability
Carrie Deming
S peci a l 2010 E d it io n

TARDEC Intelligent Ground Systems engineers collect data from recent

VSIL tests. The VSIL testing and validation laboratory helps to formulate
a common technical language for industry, academia and DOD robotics
technologies. (U.S. Army TARDEC photo by Carrie Deming.)

16
T
he Robotics Vehicle technology, research and end goal to provide interface
Simulation Integra- experimentation tools, which testing for validating unmanned
tion Laboratory (VSIL) allows for robust partnerships systems for industry controllers
provides potential solu- with other U.S. Army Research, and to provide an environment

INTELLIGENT GROUND SYSTEMS

tions to the universal
challenge of developing
technology that can “plug and
play” with other robotic tech-
nology across the Department
of Defense (DOD). The lab
provides a test environment
where industry members can
evaluate new technology be-
fore rolling it out. Technology
still under development can be
plugged into the VSIL testing
system to validate its utility
for Army and Marine Corps
ground systems robotics.
Development and Engineering for sensor hardware evaluations
Command organizations, as to aid autonomous navigation
well as other military branches and human detection algo-
and academia. rithms,” explained a TARDEC
“The VSIL is a continually evolving, virtual
environment with the end goal to provide interface
testing for validating unmanned systems for industry
controllers and to provide an environment for sensor
hardware evaluations to aid autonomous navigation
and human detection algorithms.”

Currently, the VSIL is working
in conjunction with TARDEC’s
Concepts, Analysis, System
Simulation and Integration
(CASSI) group on modeling
mobility, arm manipulator
components and providing a
simulation environment for new
robotic technologies. By using
CASSI’s simulation environ-
ment, the VSIL has the ability to
apply modeling architecture for
A Future Combat Systems (FCS) Lead Sys-
tems Integrator performed a bezel study on
the FCS Robotics Common Controller. The
study involved technologies developed as
part of the TARDEC Robotic Vehicle Control
Architecture program, and simulations were
developed as part of the TARDEC JCR VSIL.
Soldiers evaluated different bezel placements
Presently, the VSIL is collaborat-
ing with the U.S. Army Night
Vision and Electronic Sensors
Directorate team on comprehen-
sive munitions and sensor servers,
which are used to model tactical
unmanned ground sensors and
electrooptical infrared sensors.
The VSIL is also integrating tech-
nology with the aviation mobility
server for modeling unmanned
air systems flight dynamics from
the U.S. Army Aviation and
Missile Research, Development
and Engineering Center, as well
as providing infantry warrior
simulations for modeling infan-
try behavior from the U.S. Army
Natick Soldier Research, Develop-
ment and Engineering Center.
Additionally, the VSIL is focused
on building a cost-effective,
integrated profile testing ca-
pability for small unmanned
ground vehicles (SUGVs). The
capability would allow for a test
bed for SUGVs that would sup-
Embedded Distributed Simula-
tion team member.
The VSIL is funded by the
TACOM Life Cycle Management
Command’s Joint Center for
Robotics (JCR) and is currently
supporting Battlefield-Extraction
Assist Robot (BEAR) testing at
the Maneuver Battlefield at Fort
Benning, GA. The testing objec-
tive is to evaluate the need for
robot assistance in recovering
wounded Soldiers on the battle-
field. Through testing at the VSIL,
the TARDEC robotics team can
ensure that the mature technol-
ogy they integrate today onto
robotic platforms can provide a
strong foundation upon which
to build integrated solutions for
tomorrow’s unmanned ground
vehicle systems, DOD-wide.
S p ecia l 2010 E d it io n

port the Robotics Systems Joint

and alignments using reconfigurable touch
screen technologies for controlling the FCS
SUGV performing an urban area search.
SUGV functionality and the virtual urban
environment were modeled using VSIL
technologies. (U.S. Army TARDEC image
courtesy of Paul Bounker.)
Project Office with modeling
and simulation, demonstration
and transfer assistance. “The
VSIL is a continually evolving,
virtual environment with the
Carrie Deming is a Writer with BRTRC
and provides contract support to
TARDEC’s Strategic Communications
team. She has a B.A. in creative writing
from The Evergreen State College.
17
 TARDEC
Robotics Systems
Integration Lab (SIL)
Carrie Deming

TARDEC engineers test and validate emerging technologies by using the crew station
in the Robotics SIL. Currently, IGS is reducing Soldier workload for both manned and
unmanned systems through the development of products such as autonomous driving
aides. The driving aides allow for vehicles to drive in autonomous mode, thereby freeing
Soldiers to perform other tasks. (U.S. Army TARDEC photo by Carrie Deming.)

T
he U.S. Army Tank Automo-
tive Research, Development
and Engineering Center’s
(TARDEC’s) Intelligent
Ground Systems (IGS) and
the Joint Center for Robot-
S peci a l 2010 E d it io n
robotic systems’ applicability
and Soldier-machine interfaces
with emerging technologies,
many systems are tested at
TARDEC’s Robotics SIL. The
SIL houses two major com-
Behavior Simulator
The behavior simulator pro-
vides an initial look at human
performance when using certain
technologies that would exist as
part of a Soldier-machine inter-

ics (JCR) serve as robotics research
hubs for the Department of
Defense (DOD). Reducing Sol-
dier workloads and increasing
Soldier safety is at the fore-
front of their missions. To test
18
ponents for testing: a vehicle
behavior simulator and mod-
eling and simulation (M&S)
equipment that can work in
concert or independently of
one another.
face on a crew station, such as a
route planning aid. Scott Lohrer,
a TARDEC Engineer with the
Embedded Distributed Simula-
tion team, explained, “The M&S
environment provides battlefield

Many robotic systems are tested at TARDEC’s Robotics SIL, including the Multi-
Mission Work Station (MMWS). Soldiers in the back of a Stryker Fire Support
Vehicle navigated an experimental unmanned vehicle robot in autonomous mode
around obstacles just by moving a set waypoint using the MMWS touch screen,
which was tested at TARDEC’s SIL. (U.S. Army TARDEC photo by Larry Siegh.)
stimuli to stress the Soldier as if
he or she were in battlefield con-
ditions. One of the capabilities we
try to expand on is what type of
Soldier tasks can be automated
so that they can perform other
[higher order] tasks.”
Currently, IGS is reducing Sol-
dier workload for both manned
and unmanned vehicles. One
example of task automation is
autonomous driving aides, which
allow vehicles to drive in autono-
mous mode, thereby freeing the
Soldier to perform other tasks,
such as scanning for local situ-
ational awareness.
M&S
The SIL’s M&S component assists
in developing software by providing
stimulation to different subsystems
JCR and TARDEC’s IGS serve as robotics
research hubs for DOD. The IGS mission
for crew station development is to maximize
Soldier-system effectiveness, reduce warfighter
training burdens and increase control of a
variety of unmanned systems. (U.S. Army
TARDEC photo by Carrie Deming.)
that must be controlled by the
crew station. “The crew station
must be able to control the driv-
ing for manned and unmanned
INTELLIGENT GROUND SYSTEMS
systems,” IGS Engineer Paul
Bounker related. “M&S provides
models of vehicles moving within
a virtual world so that the driving
control software can be tested and
debugged as needed in the lab set-
ting. This saves time and funding
and reduces safety concerns with
the development of new software.”
“M&S provides models of
vehicles moving within a
virtual world so that the
driving control software can
be tested and debugged as
needed in the lab setting.”
By capturing simulated and
modeled tactical behavior for
platforms and human actions
through a tasking network, IGS
engineers can test new technolo-
gies and see how those technolo-
gies may affect the performance
of a vehicle or Soldier interface
simply by running a program
through the SIL laboratories.
Through the TARDEC IGS SIL’s
capabilities, robotic engineers
can more successfully test robotic
technologies’ systems-of-systems,
predict how the technology will
affect Soldiers and determine
how new technologies can be in-
tegrated into existing platforms
and software.
S p ecia l 2010 E d it io n
Carrie Deming is a Writer with
BRTRC and provides contract
support to TARDEC’s Strategic
Communications team. She has a
B.A. in creative writing from The
Evergreen State College.
19
 Technology Integration for
Unmanned Ground
Vehicles
Michael D. Kaplun

T
he U.S. Army Tank Automotive Research, Development and
Engineering Center’s (TARDEC’s) Small Robotics Laboratory
(SRL) is focused on developing and integrating technology ad-
vancements for unmanned ground vehicles (UGVs), such as the
PackBot and TALON. UGV laboratory work includes designing
and analyzing advanced behavior control schemes for future
vehicle implementation. The facility, which serves as a System Inte-
gration Laboratory for implementing internal and external sensor
packages, also provides for indoor mobility testing, sensor/payload
integration and testing, platform characterization and training.
S peci a l 2010 E d it io n

An explosives ordnance disposal technician maneuvers a robot to disarm a mock

improvised explosive device (IED) during a training exercise. Robotic systems are
advancing to better protect warfighters on a diverse battlefield. (U.S. Armed Forces
photo by CPT David Faggard.)

20
Intelligent Ground Systems
(IGS) personnel, particularly
the UGV Operations Support
team, provide support to orga-

INTELLIGENT GROUND SYSTEMS

nizations such as the Robotic
Systems Joint Project Office
(RS JPO) by creating, acquiring
and evaluating diverse robotic
payloads. Recently, the team led
an effort to integrate and test a
payload called “Tanglefoot” in
response to an operational field
request. The SRL is also used
for characterizing and testing
new platforms. Periodically,
IGS will receive new platforms
from Small Business Innova-
tion Research Programs, and IGS engineers at TARDEC’s SRL integrate robotic technologies for small and medium platforms
the platforms’ initial evaluations for IED removal and an ever-expanding range of operational capabilities. IGS personnel provide
occur in the SRL. support to organizations, such as RS JPO, by acquiring, creating and evaluating payloads. (U.S.
Army TARDEC photo by Carrie Deming.)

The Multi-function, Agile, Remote Control Robot (MARCbot) is one

piece of technology helping in the fight against IEDs in the theater of
operations. The MARCbot is one of several robotic systems that can be
used to safely disengage threats without putting Soldiers in harm’s way.
(U.S. Armed Forces photo.)

Another significant together to build subassemblies

laboratory aspect is its
ability to provide infor-
mation for platforms
or sensors/payloads. If
a robotics organization,
such as RS JPO, needs
technical information
on a particular plat-
form, the SRL serves as
the information source.
“The SRL’s various
system developments
will continue to
while also preparing to perform
full SSUGV assembly and testing
once the system is built.
“The SRL’s various system
developments will continue to
expand TARDEC’s role and ca-
pabilities in the field of robotics
as well as increase our in-house
expertise,” remarked TARDEC
Acting Administrator for IGS Jeff
Jaster. TARDEC’s SRL future de-
velopment and integration efforts
are improving future UGV capa-
bilities for our Soldiers today.

expand TARDEC’s role

and capabilities in the
field of robotics.”
S p ecia l 2010 E d it io n

Currently, TARDEC Michael D. Kaplun is a Writer/Editor

is building the Squad
Support UGV (SSUGV)
in the SRL. Addition-
ally, IGS and contractor
personnel are working
with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He holds a B.A. in
English and media and society from
Hobart and William Smith Colleges.
21
 Integrating Systems
Engineering for Robotic
Battlefield Deployment —
Intelligent Ground Systems (IGS)
Laboratory and Vehicle Bay
Michael D. Kaplun

T
he U.S. Army Tank Automotive Research, Development and Engineering Center’s (TARDEC’s) IGS
Laboratory and Vehicle Bay integrates component technologies, such as perception systems, human
detection and intent analysis hardware/software, onto unmanned ground vehicle (UGV) platform
components, while also integrating these component technologies onto platforms for testing and
evaluation. TARDEC engineers and industry partners perform critical research, development and
engineering in the IGS Laboratory to enable better transition of components and subsystems to
the complex designs, systems, integration and test phases for UGV platforms. The facility’s components
and subsystems are assembled and integrated onto platforms to be tested in relevant operational scenarios
in the field.

The MARCbot is a result of TARDEC’s IGS Laboratory

S peci a l 2010 E d it io n

and Vehicle Bay’s component technology integration

efforts. The MARCbot is a lightweight robot that provides
warfighters with remote, look-only capabilities. This
MARCbot can look around a corner while a warfighter
observes from a safe standoff distance. (Photo courtesy of
American Reliance, Inc.)

22

TARDEC’s IGS Laboratory and Vehicle Bay integrates systems to enhance Soldier capabilities on
the battlefield. Systems like the APD are an example of successful integration efforts. The APD
can reach speeds of up to 50 miles per hour and can operate at 113 degrees Fahrenheit. (U.S. Army
TARDEC photo.)
The high bay houses small- to
mid-sized robots that are cur-
rently in theater or getting ready to
be fielded or deployed. Presently,
through a Robotic Systems Joint
Project Office (RS JPO) charter,
IGS engineers ensure upgrades are
implemented to improve reliabil-
ity, maintainability and ease of
tactical UGV use in the theater of
operations. By building the system
to better standards and ensuring
the drawing package is production-
quality, facility engineers are cur-
rently assembling and integrating
a teleoperated, 2,600-pound Squad
Support UGV (SSUGV), which is
capable of being integrated with a
remote tactical capabilities.
The UGV assembly involves
TARDEC IGS, a local automotive
supplier’s research, development,
design and fabrication expertise,
the participation of other cross-
disciplinary TARDEC personnel
and the RS JPO. “Working with RS
JPO continues to be a productive
relationship, and TARDEC remains
excited to work so closely with its
customer,” remarked TARDEC’s
Shanna Render, UGV Current Op-
erations Support Engineer.
TARDEC’s Shanna Render, UGV Current
Operations Support Engineer, helps TARDEC’s
IGS Laboratory and Vehicle Bay integration op-
erations, increasing the center’s role in robotics
technologies. The 2,600-pound SSUGV is cur-
rently undergoing assembling and integration
with a remote tactical capabilities. (U.S. Army
TARDEC photo by Bill Dowell.)
INTELLIGENT GROUND SYSTEMS
TARDEC Engineer Sean Hadley works on an SSUGV
robotics system in TARDEC’s IGS Laboratory and
Vehicle Bay. At the facility, component technologies,
such as perception systems, human detection and
intent analysis hardware/software and unmanned
ground vehicle platform components, are developed
and integrated. (U.S. Army TARDEC photo by
Carrie Deming.)
IGS technicians and engineers solve
battlefield and operational challeng-
es that call for intelligent, automated
ground vehicle systems capable of
engaging threats while interact-
ing with and through their Soldier
operators. Through autonomous
perception and navigation, intel-
ligent tactical behavior, command
and control, IGS further develops
the Army’s significant capability to
deliver near real-time situational
awareness, and foresee and diagnose
potential battlefield threats.
From small robotic systems, such
as the Omni-Directional Inspec-
tion System and Multi-Function
Agile Remote Control Robot
(MARCbot) surveillance system,
to the full-size Autonomous
Platform Demonstrator (APD),
TARDEC researchers and engi-
neers are pushing the boundaries
of robotic technologies to provide
our warfighters more safety and
an operational advantage.
S p ecia l 2010 E d it io n
Michael D. Kaplun is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He holds a B.A. in
English and media and society from
Hobart and William Smith Colleges.
23
 TARDEC’s B Battlef
attlefield
ield
Provides Leading-Edge
and Data-Sharing
Matthew Sablan

T
he BOR, a facility operated by the U.S. Army Tank Automotive
Research, Development and Engineering Center (TARDEC), was
originally established in 1994 to complete simulations for TARDEC.
Simulations were performed off-site throughout the Nation and
S peci a l 2010 E d it io n

were linked through the Systems Integration Lab (SIL). Each loca-
tion had the capability to virtually control simulated assets.

24
Observation Room (BOR)
Teleoperation
Capabilities

S p ecia l 2010 E d it io n

A 4th Infantry Division Soldier communicates via

radio while a Bradley Fighting Vehicle crew pro-
vides site security. TARDEC engineers routinely
use the BOR to help spiral unmanned ground ve-
hicle technology into Bradley and Stryker vehicle
platforms. (U.S. Army photo by SPC John Crosby.)
25
 inputs to various destinations,
both internal and external,”
remarked TARDEC Computer
Science Specialist Matthew
DeMinico. After routing this
information, the BOR also will
be able to act as a central hub for
viewing various tests and pull
data from any of its sources. The
SIL is one of these data sources,
and, in the future, these sources
could include facilities anywhere
around the world.

“The BOR will serve as an

observation and control facility
for vehicle testing,” DeMinico
explained. The BOR will
also allow remote viewing of
robotics tests alongside manned
The BOR serves as an observation and control facility for vehicle testing. Images, data and
videos are displayed to allow TARDEC engineers immediate access to field data. (U.S. Army
TARDEC photo by Carrie Deming.) “The BOR is available for use by
The BOR is becoming a central the country. “The planned BOR any organization within TARDEC
hub of powerful audio and video upgrade will use a sophisticated
that requires its observation and
capabilities to remotely view control system that allows the
tests as they are conducted at user to select input data from control functions.”
training centers and labs around multiple sources and route those
S peci a l 2010 E d it io n

A TALON and MARCbot are displayed during the TARDEC

Ground Systems Power and Energy Laboratory Tour, Aug. 17,
2009. TARDEC’s BOR has been used to test various robotic plat-
forms that Soldiers use to assist with dangerous tasks in theater.
As the technology and operator systems mature, unmanned
ground vehicle systems will be rapidly fielded to support ground
combat operations. (U.S. Army TARDEC photo by Carolyn Baum.)
26
 Vehicles proceed along a test course. Every day, TARDEC engineers and scientists bring remote teleoperation closer to reality through
concentrated research and development, modeling and simulation, and a rigorous field test schedule. (U.S. Army TARDEC photo.)
platform test observation. In
combination with the SIL, the
BOR will observe robots during
testing at external locations,
while operators in the SIL
control the robots. In the future,
crew stations will allow remote
operation of robots, with the
BOR serving to route data
between the operator and assets
at the test facility.
“The planned BOR upgrade
will use a sophisticated
control system that allows
the user to select input data
from multiple sources and
route those inputs to various
destinations, both internal
and external.”
A crew station operator in the SIL can
teleoperate a robot from the BOR. In the future,
crew stations will allow remote operation of
robots, with the BOR routing data between the
operator and assets at external test facilities.
(U.S. Army TARDEC photo.)
While testing these robots,
the BOR will allow TARDEC’s
engineers to remotely gather
data. TARDEC associates could
then analyze this data to find
and solve potential engineering
or design problems with the
technology before fielding it,
INTELLIGENT GROUND SYSTEMS
providing the Army with cost
savings and better preparing
warfighters in the field.
The BOR continues to expand
its capabilities and support
TARDEC’s mission. “The BOR
is available for use by any
organization within TARDEC
that requires its observation and
control functions,” DeMinico
offered. “Due to the BOR’s large
size and powerful audio/video
capability, it is also capable
of serving as a meeting or
conference facility when it is not
in use as a lab.”
S p ecia l 2010 E d it io n
Matthew Sablan is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic
Communications team. He has a B.A. in
English and history from Marymount
University in Arlington, VA.
27
 TARDEC-Funded
West Point Robotics Lab
Builds Fu
Future
ture Engineers
Patrick Pinter
S peci a l 2010 E d it io n

28
West Point cadets show off some of their robotic
skills while operating an iRobot PackBot. This lab’s
development led to robotic platform integration
throughout the electrical engineering curriculum.
(U.S. Army TARDEC photos by Patrick Pinter.)

T
he battlefield is an ever-changing environment that constantly
presents new threats to Soldiers. Developing new innovative
technologies to protect Soldiers’ lives is something engineers and
S p ecia l 2010 E d it io n

scientists are working around the clock to accomplish. To keep

Soldiers out of harm’s way, one key area the U.S. Army is focusing
its research and development (R&D) resources on is robotics.

29
 West Point faculty member Dr. John Rogers shows TARDEC
Robotics Systems Manager MAJ Seth Norberg a battery from a
small robot his cadets recently completed.

Realizing the value of advanc-
ing this emerging capability, the
U.S. Army has taken an aggres-
sive stance in developing robotic
technologies. Toward this end,
the U.S. Army Tank Automotive
Research, Development and En-
gineering Center (TARDEC) and
the Robotic Systems Joint Project
Office (RS JPO) took lead roles in
constructing a robotics lab at the
U.S. Military Academy (USMA),
West Point, NY. “There is a mu-
tual operating agreement with
RS JPO, which is the acquisition
authority for the lab,” explained
TARDEC Joint Center for Robot-
S peci a l 2010 E d it io n
Greg Hudas. “RS JPO is directly in-
volved, too. They provided us with
the setup and insights on what
they would like this lab to do. RS
JPO knows this is necessary. This
effort is going to help out in the
area of generating future robotic
requirements. We want to create
future robotic experts here.”
In 2008, TARDEC’s JCR initiated
the effort to construct a state-
of-the-art, fully instrumented
and reconfigurable experimen-
tation facility centrally located
at USMA so faculty and cadets
would have access to a world-
funded by the JCR, is a way to
increase robotic educational
and research opportunities. The
lab allows future U.S. Army sci-
entists and engineers to become
more familiar with robotic sys-
tems and to conduct research.
“We need cadets to drive these
requirements. We want cadets
to be aware of the technologies
that are out there,” remarked
Hudas. “We don’t want them to
be shell shocked when they get
out and see these platforms for
the first time.”
Since the project’s initiation, the

ics (JCR) Deputy Director Dr. class facility. The robotics lab, USMA Electrical Engineering and
Computer Science Department
“We want cadets to be aware of the technologies that are out renovated an old small-ballistics
there. We don’t want them to be shell shocked when they get out laboratory and converted it to a
dedicated support facility that
and see these platforms for the first time.” contains educational and fielded
30
robotic platforms. “A large part of
the research done here in robot-
ics is in the capstone projects
done by the seniors,” commented
LTC Robert McTasney, Assistant
Professor at USMA. “They use
robotic platforms to explore
navigation and safety, as well as
a number of other topics. Here,
with this lab, we are just trying to
leverage everybody’s strengths to
reach certain goals. A large part of
funding is coming from TARDEC,
which has allowed us to do some
great things here.”
A cadet operating a robotic controller attempts to pick up a pen with a PackBot’s articulating arm and
pincers. The robotic technologies that cadets are using in the laboratory are the same ones that are being
used in the field by Soldiers today.
The idea for a dedicated robot-
ics lab took shape in 2003 when
Army leaders realized that there
was a definite need to apply
more focus to the robotics field.
To do that, USMA restructured
its electrical engineering major
to offer more in-depth courses in
robotics, which led to integrating
robotic platforms throughout
the electrical engineering cur-
riculum. “We started thinking
“Now that we have this lab, 2006, USMA established a Co-
operative Autonomous Robotics
we want to start funding for Military Applications work-
specific experiments. We ing group consisting of nearly
INTELLIGENT GROUND SYSTEMS
20 faculty and staff from several
want to bring in original academic disciplines interested in
equipment manufacturers and robotics research opportunities.
That spirit of collaboration in
have their platforms integrated which the lab was begun contin-
ues today. “We want to make sure
into the curriculum.” all departments are coordinat-
ing with each other and working
about ways to enhance learning together. This is systems engi-
in the robotics field,” commented neering technology,” commented
McTasney. “We were working to Hudas. “Now that we have this
lab, we want to start
funding specific ex-
periments. We
want to bring in
original equipment
manufacturers and
have their platforms
integrated into the
curriculum. I want
them to be working
on relevant platforms.”
The Army’s use of
robotic systems in
Iraq and Afghanistan
has demonstrated
these systems’ ability
to assist Soldiers in
a range of missions.
Robotic systems pro-
duce the capability to
conduct reconnais-
sance, surveillance
and mine mitigation.
With continued study
and applied R&D in
this technology area,
integrate robotics in computer sci- robotics may enable the Army to
ence and information technology. discover entirely new capabilities.
Once we got things off the ground,
cadets were showing that they
really liked the robotic programs
here. It has been a good vehicle
S p ecia l 2010 E d it io n
to tie everything in engineering Patrick Pinter is a Writer/Editor with
together within a single program.” BRTRC and provides contract support
to TARDEC’s Strategic Communica-
Since then, the use of robotics as tions team. He has a B.A. in journalism
a common educational platform and political science from Western
has increased dramatically. In Michigan University.
31
POWER AND MOBILITY
 TARDEC Associates
ARDEC
Chris Williams

R
epresentatives from two U.S. Army research facilities
held a “meeting of the minds” and discussed
future collaborative opportunities during a recent
tour of the U.S. Army Tank Automotive Research,
Development and Engineering Center’s (TARDEC’s)
facilities at the Detroit Arsenal, in Warren, MI.

ARDEC representatives visited TARDEC in December 2009 to tour the labs and see
S peci a l 2010 E d it io n

the test equipment in operation to gain a better understanding of TARDEC’s R&D

capabilities. TARDEC’s Team Leader for Motion Base Technologies Harry Zywiol
(left) describes TARDEC’s modeling and simulation capabilities to ARDEC Senior
Associate for Future Weapon Concepts and Business Development Mike Zecca
(right) in TARDEC’s Ground Vehicle Simulation Laboratory. (U.S. Army TARDEC
photos by Elizabeth Carnegie.)

34
Display Capabilities to
Visitors
Three associates from the U.S.
Army Armaments Research,
Development and Engineering
Center (ARDEC) at the Picatinny
Arsenal, NJ, visited the Detroit
Arsenal. ARDEC Senior Associ-
ate, Future Weapon Concepts and
Business Development Mike Zec-
ca, Program Integrator for Small
and Medium Caliber Armaments
and Remote Robotic Armaments
Vince Matrisciano and ARDEC’s
Enterprise and Systems Integra-
tion Center (ESIC) Director COL
Scott Flynn toured TARDEC’s
facilities and received an up-close
look at the organization’s facilities
and capabilities.
During the visit, TARDEC associ-
ates shared how they are using
their expertise to deliver advanced
technology solutions to improve
the Nation’s ground vehicle fleet.
The tour highlighted the Detroit
Arsenal’s state-of-the-art mod-
eling and simulation facilities,
including the three-dimensional
video and audio Cave Automatic
Virtual Environment (CAVE),
S p ecia l 2010 E d it io n
the Vehicle Inertia Properties
Evaluation Rig and Ride Motion
Simulator. Engineers from
35
 CGVDI engineers and technicians provide systems engineering integration for all of the Army’s combat and tactical ground vehicle fleets.
The CGVDI integrates vehicle technologies that increase battlefield survivability and systems performance. ARDEC team members were duly
impressed by TARDEC’s unprecedented ground vehicle engineering capabilities and capacity.

TARDEC’s Ground Vehicle Power

and Mobility (GVPM) Team
highlighted the critical role TAR-
DEC is playing in the progression
of advanced automotive batteries,
hybrid-electric technology and
track and suspension. GVPM
associates also highlighted the
capabilities of TARDEC’s fu-
ture Ground Systems Power and
Energy Laboratory, which opens
its doors in September 2011 with
eight state-of-the-art laboratories
in one building.
S peci a l 2010 E d it io n

As robotic systems continue to

play a crucial role in keeping
warfighters out of harm’s way,
From left: Mike Zecca, Vince Matrisciano and TARDEC Team Leader for Lightweight Structures
both TARDEC and ARDEC – Survivability Donald Ostberg discuss armor solutions in TARDEC’s CGVDI, formerly the
are seeking ways to utilize the Prototype Integration Facility.
36
 at the work being done by the
organization and opportunities
for future collaboration. “During
our visit to TARDEC it quickly

POWER AND MOBILITY

Foreground: TARDEC Engineer Jonathan Aboona (left) and TARDEC CGVDI Associate
Director Luis Hinojosa (right) give an overview of the work conducted in the CGVDI
to (back row, from left): Acting Associate Director for IGS Jeff Jaster, Mike Zecca, Vince
Matrisciano and ESIC Director COL Scott Flynn.
capabilities of those systems.
Associates from TARDEC’s
Intelligent Ground Systems
(IGS) detailed the work being
conducted in their technical
areas. The tour also included a
visit to TARDEC’s newly formed
Center for Ground Vehicle
Development and Integration
(CGVDI), which merged the
capabilities of the Prototype
Integration Facility and Ground
Vehicle Integration Center to
align and expand research and
development (R&D) activities
and establish a new military
nucleus for public-private
ground vehicle systems
collaborative partnerships. In
the CGVDI, ARDEC associates
were shown TARDEC-developed
auxiliary power units and
received a demonstration of
how armor is integrated onto a
ground vehicle platform.
ARDEC is an internationally
acknowledged hub for the
advancement of armaments
technology and engineering in-
novation. As one of the special-
ized research, development and
engineering centers within the
U.S. Army Materiel Command,
ARDEC has the responsibility
for meeting this critical demand.
ARDEC’s workforce provides life-
cycle support for nearly 90 per-
cent of the Army’s lethality used
every day by the U.S. warfighter.
Last October, TARDEC Director
Dr. Grace M. Bochenek and her
ARDEC counterpart Dr. Joseph
Lannon hosted a joint panel at
the National Defense Industrial
Association’s Ground Combat
Vehicle Conference, where they
emphasized the importance
of collaboration between the
Army’s Research, Development
and Engineering Centers and
industry partners.
The ARDEC visitors remarked
that the time spent at TARDEC
provided an eye-opening look
became apparent that the orga-
nization has made great strides
in its efforts to further develop
core competencies, including
new areas such as the robotics
team,” remarked Flynn. “I com-
mend TARDEC leadership on
the outstanding improvements
to its facilities and, more impor-
tantly, to its renewed operational
focus. I am very excited about the
tremendous opportunities for
ARDEC and TARDEC to expand
our collaboration in armaments
integration for both manned and
unmanned platforms, as well as in
systems engineering.”
From left: ARDEC Program Integrator for
Small and Medium Caliber Armaments and
Remote Robotic Armaments Vince Ma-
trisciano; ARDEC Senior Associate for Future
Weapon Concepts and Business Development
Mike Zecca; TARDEC GVPM Testing, Evalu-
ation and Assessment Team Leader Michael
Reid; TARDEC Deputy Associate Director
for Platform Mobility Michael Blain; and
TARDEC Deputy IGS Associate Director Terry
Tierney tour TARDEC’s GVPM test cells.
Chris Williams is a Writer/Editor with
BRTRC and provides contract support
to TARDEC’s Strategic Communica-
tions team. He has a B.A. in communi-
S p ecia l 2010 E d it io n

“I am very excited about the tremendous opportunities for cation from Wayne State University in
Detroit, MI, and has previously written
ARDEC and TARDEC to expand our collaboration in armaments for The Source newspaper in Shelby
Township, MI, and The Macomb Daily
integration for both manned and unmanned platforms, as well and C & G Newspapers in Macomb
County, MI.
as in systems engineering.”
37
 Designing a Unique Lab for
Michael A. Kluger and Felt A. Mounce

A new Army facility will support warfighters with next-generation ground vehicles.
S peci a l 2010 E d it io n

A Combat Tactical Vehicle Technology Demonstrator, a test bed for the Joint Light Tactical Vehicle family of vehicles, under-
goes testing at the Nevada Automotive Test Center in Carson City, NV. TARDEC’s new GSPEL will support the Army with
engineering systems integration for next-generation ground vehicles and equipment. (U.S. Navy photo by John F. Williams.)

38
Advanced Military Vehicles
The pace at which cutting-edge
vehicle technologies are being devel-
oped to support warfighters’ needs
continues to increase dramatically.
Vehicles are being designed with
experimental engines, alterna-
tive fuels, nontraditional power-
trains, high-density energy storage
capabilities, high-voltage electrical
systems, armor plating, high-density
electronics and navigational systems
with complexity rivaling that of a
fighter jet, and sophisticated battle-
field communications, command
and control.
Evaluating those systems and
integrated vehicle platforms
requires development, validation
and commissioning so they are
battle-ready and highly reliable.
These qualities are critically im-
portant and extremely challeng-
ing to deliver. The challenges are
further compounded by the fact
that military vehicles are operated
at extremely high power levels,
S p ecia l 2010 E d it io n
must be tested at extreme condi-
tions and typically contain new
and experimental technologies.
To meet these challenges, the U.S.
Army determined it needed a
39

SwRI provided this artist’s rendering of TARDEC’s GSPEL. The specification for the GSPEL facility
contains a number of unique components, including this environmental chamber with wind and
solar simulators (orange, at center). (Image courtesy of SwRI.)
one-of-a-kind, fully integrated test
facility, the likes of which had not
been attempted before. The first
step toward creating such a facility,
to be located alongside the Army’s
existing U.S. Army Tank Automo-
tive Research, Development and
Engineering Center (TARDEC)
laboratories in Warren, MI, was to
prepare a specification defining
the different laboratories and their
testing equipment, operational
requirements and facility infra-
structure requirements.
To create the specification, the Army
sought a collaborating research
organization that would have:
• A strong vision of where future
vehicle technology is headed.
• A broad awareness of current
vehicles and drivetrain systems.
• A deep grounding in vehicle
and component testing and
laboratory test equipment.
S peci a l 2010 E d it io n
rigid schedule to be eligible for
congressional funding.
Ground Systems Power and
Energy Laboratory (GSPEL)
The new GSPEL is expected to
require two years to construct and
will become operational by Sep-
tember 2011. The Army engaged
Southwest Research Institute
(SwRI), which has been involved
with advanced and unique
engine, vehicle and emissions
research laboratories over many
years, as a consultant to rapidly
provide engineering support
services for GSPEL.
The Army had a concept in mind
but sought out SwRI to develop
the demanding equipment and
The goal was to create a facility to evaluate light transport,
such as HMMWVs, to heavy combat vehicles, such as military
tanks with HE and fuel cell configurations, and to evaluate
facility specifications necessary to
embody the centralized, state-of-
the-art facility containing eight
engineering laboratories. The goal
was to create a facility to evalu-
ate light transport, such as High
Mobility Multipurpose Wheeled
Vehicles (HMMWVs), to heavy
combat vehicles, such as military
tanks with hybrid-electric (HE)
and fuel cell configurations, and
to evaluate components, such
as engines, transmissions, axles,
electric motors, batteries, ul-
tracapacitors, engine auxiliary
systems, air filters, radiators and
heat exchangers. To develop the
specifications, SwRI assembled a
team of 31 engineers with a wide
variety of backgrounds.
For more than six decades, SwRI
has operated the Army-owned
TARDEC Fuels and Lubricants
Research Laboratory on the SwRI
grounds in San Antonio, TX.
TARDEC Ground Vehicle Power
and Mobility operates its primary
facility at the Detroit Arsenal in
Warren, MI, where engines and
vehicles are evaluated on dyna-
mometers under extreme envi-
ronmental conditions.
The team, drawn from SwRI’s
automotive engineering divisions,
began by consulting with TARDEC
engineers to gain an understand-
ing of the vision for the laboratory,
conceptualizing many options and
eventually arriving at a preferred
solution for each of the laborato-
ries. Estimates of electrical, water,

• The ability to integrate multiple

engineering requirements asso-
components, such as engines, transmissions, axles, electric
ciated with mechanical, electri-
cal and electronic systems. motors, batteries, ultracapacitors, engine auxiliary systems, air
• The ability to complete speci-
fications under a demanding, filters, radiators and heat exchangers.
40
steam and gas utility requirements
were developed for the overall
building specification. Detailed
projections based on expected
The team, drawn from SwRI’s automotive engineering divisions,
began by consulting with TARDEC engineers to gain an
understanding of the vision for the laboratory, conceptualizing

POWER AND MOBILITY

utilization, equipment and discus-
sions with TARDEC engineers re-
vealed opportunities for efficiency
gains as the team created a set of
facility requirements. The require-
ments were provided to the U.S.
Army Corps of Engineers to aid in
the preparation of a bid request.
Green Laboratory Mandate
Beyond the efficiency gains
that would be expected from a
new laboratory, the Army today
mandates that all new construc-
tion be certified under the “Silver”
category of the U.S. Green Build-
ing Council’s Leadership in En-
ergy and Environmental Design
(LEED) Green Building Rating
System. LEED is a third-party cer-
tification program that encour-
ages sustainable “green” build-
ing and development practices
through universally accepted tools
many options and eventually arriving at a preferred solution for
each of the laboratories.
and performance criteria. Further-
more, GSPEL will help expedite
the integration of state-of-the-art
HE and fuel cell technologies
into advanced military vehicles to
reduce fuel consumption, improve
overall vehicle operation and em-
ploy the most efficient use of
energy sources.
The new laboratory design ex-
pands the Army’s technological
thrust into cutting-edge power
and energy management technol-
ogy. The proposed facility will
have labs and offices and related
spaces for a staff of more than
60. Laboratories are provided for
vehicle environment, power, elec-
trical power architecture systems
integration, electric components,
pulse power and directed energy,
thermal fluids, fuel cells and air
flow filtration. Taken as a whole,
the laboratory will be able to ex-
amine various vehicle systems
as well as the entire vehicle.
Some of the selected equipment
features include:
• Eleven alternate current electri-
cally regenerative dynamom-
eters with ratings from 2,500
foot-pounds (ft-lb) of torque
and 14,000 revolutions per
minute (rpm), up to 26,500
ft-lb and 1,000 rpm.

S p ecia l 2010 E d it io n

M1151 up-armored HMMWVs sit inside the 1st Battalion, 401st Army Field Support Brigade vehicle maintenance facility at Camp As Sayliyah,
Qatar, Oct. 10, 2009. The state-of-the-art GSPEL will contain eight engineering laboratories to create a facility to evaluate light transport, such as
HMMWVs. (U.S. Army photo by Dustin Senger.)
41

The authors stand behind a scale mock-up of TARDEC’s GSPEL. Felt A. Mounce (left) assisted
with the specification design, build and installation of dynamometer test stands. Michael A.
Kluger leads SwRI’s effort for automotive-related test stand development for applications with
high-power and high-speed requirements. (Photo courtesy of SwRI.)
• A full-size vehicle chamber
with environmental controls
for temperature, humidity
and solar simulation.
• Seven environmental chambers.
• Three extremely high-voltage
and current power supplies.
S peci a l 2010 E d it io n
• One of the world’s largest calo-
rimeters for testing radiators,
engine coolers and transmis-
sion coolers.
• Four air filter test stands of
various sizes with combined
42
with yearly power consumption
of more than 2 million kilowatt-
hours. Cooling water needs were
projected at 2,500 gallons per
month. Power supplies to the
facility will be rated to 800 volts
direct current and 1,000 amps.
The environmental air han-
dling system will be able to flow
175,000 cubic feet per minute
with 90 tons of heating and cool-
ing to control air temperature
and humidity.
Meeting LEED certification stan-
dards for such a facility is extremely
challenging. Therefore, the SwRI
engineering team created methods
for quantifying LEED improve-
ments, enhancements and solu-
tions and for exploring multiple
equipment- and energy-related
issues. Some of those issues involved
different dynamometer operating
power scenarios during electrical
motoring and regenerative operat-
ing modes; dynamometer energy
recovery; electrical motor operation
in off-peak conditions; and preci-
sion power supply charge-discharge
cycles. For each lab within the facil-
ity, the dominant energy-consum-
ing or energy-producing items were
selected for individual study. For
example, dynamometer efficiency
was studied at various partial-load
conditions to produce accurate
electrical consumption estimates for
the facility.
GSPEL will help expedite the
dust media insertion. integration of state-of-the-art
• Four fuel cell test stands.
HE and fuel cell technologies
The design team projected the
into advanced military
facility’s electrical usage over 30
years, based on various dyna- vehicles to reduce fuel
mometer operating schedules,
consumption, improve overall
environmental chamber thermal
cycles, power supply duty cycles, vehicle operation and employ
calorimeter test procedures and
air filtration testing requirements. the most efficient use of
The projected electrical service was
energy sources.
determined to be 4.7 megawatts
Broad-Based Design
Capabilities
The creation of a specification for
a facility as broad and far-reach-
ing as the GSPEL was an extremely
challenging task. The GSPEL
facility requires equipment to
work at levels that are unprec-
edented in today’s engineering
laboratories and, in many cases,
will represent the largest such
capabilities in the world. Satisfy-
ing such capabilities is a require-
ment to allow for testing of future
military vehicles that will have
performance well beyond that of
current vehicles. The SwRI team
was able to help the Army define,
and then integrate, a wide range
of laboratories and equipment
into a single facility that will allow
vehicle testing and development
across demanding test conditions
and in dramatically reduced time.
This, in turn, will allow the Army
to continue the development of
future generations of military
vehicles, integrating current and
alternative vehicle propulsion,
power generation, energy storage,
power management and control
systems for current and emerg-
ing classes of vehicles that are
both wheeled and tracked, and
manned and unmanned.
The SwRI team defined and
prepared this specification using
its broad experience in testing
engines, transmissions, axles, elec-
trical power components and ve-
hicles over the past 60 years. This
experience has been enhanced
with real-world knowledge based
on operating more than 240
dynamometers at its San Antonio
facility, which is believed to be the
largest dynamometer grouping of
its kind in the world. In addition,
much of this testing is extremely
challenging, as it involves the
next generation of powertrain
components and vehicles that
typically incorporate advanced
The SwRI team was able to help the Army define, and then integrate, a
wide range of laboratories and equipment into a single facility that will
allow vehicle testing and development across demanding test conditions
and in dramatically reduced time.
technologies. Testing these types
of components requires the use
of intensive engineering to pro-
vide creative and innovative
approaches and solutions,
whether by modifying existing
testing equipment or fabricating
custom equipment.
GSPEL specification develop-
ment involved the generation and
integration of massive amounts
of information associated with
extremely high-power electrical
equipment, high-speed rotating
equipment, very high voltage and
amperage levels, extreme heating
and cooling, humidity control,
and massive airflow. Comple-
menting this equipment was an
extensive suite of instrumentation
for measuring torques, speeds,
pressures, flows and temperatures.
Acting as the client’s advocate by
creating test stand and test facility
specifications is a long-standing
service that SwRI has provided
for more than 30 years. By its very
nature, it is a challenging and de-
manding discipline because of the
breadth of technologies and oper-
ating conditions that engineering
testing involves. Because of the
many types of components SwRI
is involved with on a daily basis, it
provides such specifications and
test stands for applications involv-
ing the next generation of heavy
lift helicopter gearboxes, subma-
rine propulsion systems, advanced
engines used in military vehicles,
drilling motors used in oil rigs,
transmissions used in 18-wheel
trucks and precision hydraulics
used in high-pressure applications.
POWER AND MOBILITY
The document SwRI prepared
was integrated into a request for
proposal by the Army and adver-
tised for a design-build contract
to construct the GSPEL labora-
tory. Multiple bids were received
and were reviewed to determine
if they met the specified facility
and equipment requirements. A
construction contract was award-
ed by the Corps of Engineers and
construction has already begun.
Editor’s Note: This article was previously
published in the Spring 2009 issue of Technol-
ogy Today. The article is reprinted with the
authors’ permission and has been edited for
style and to bring the content up to date.
Michael A. Kluger is a Senior Program
Manager in the Fuels and Lubricants
Research Division at SwRI, where he
leads the organization’s efforts for
automotive-related test stand develop-
ment, with an emphasis on unique
and novel test stands for applications
requiring high-power and high-speed
requirements. Kluger holds a B.S. in
mechanical engineering from Arizona
State University, and he is a Registered
Professional Engineer, State of Arizona.
Felt A. Mounce is a Research Engineer
in the Fuels and Lubricants Research
Division at SwRI, where he supports
the development of broad-based, inte-
grated test stand fabrication and facility
specifications involving the integration
S p ecia l 2010 E d it io n
of mechanical, electrical and electronic
components and systems. Mounce
holds a B.S. in mechanical engineering
from New Mexico State University and
is a member of the American Society
of Mechanical Engineers and Society of
Automotive Engineers.
43
 Fueling Development for
TARDEC’s Fuels and

A History of Innovations: The TARDEC Fuels

and Lubricants Research Facility (TFLRF)
supports battlefield fuel and lubricant needs
for the Army and the other services. Its
unique location draws on Southwest Research
Institute’s (SwRI’s) interdisciplinary approach
to problem solving among its 11 on-campus
technical divisions. (U.S. Army TARDEC image
courtesy of the TFLRF.)
S peci a l 2010 E d it io n

44
Future Force Vehicles —
Lub ricants Laboratories
Provide Leading-Edge R&D
Matthew Sablan

S p ecia l 2010 E d it io n

45
 A
fter World War II, the Army noted fuels and lubricant problems
that occurred in vehicles operating in harsh environments. To find
solutions to these engineering problems, the Army established
the Army Fuels and Lubricants Laboratories on May 9, 1957.
Over the years, the lab has evolved into a world-class research
facility with a much-expanded mission. Now known as the U.S.
Army Tank Automotive Research, Development and Engineering Center
(TARDEC) Fuels and Lubricants Research Facility (TFLRF), it is located
on the Southwest Research Institute (SwRI) campus in San Antonio, TX.
The SwRI location was already well-established with well-known experts
in the automotive and fuels and lubricants areas, so it was an obvious
choice for the Army to move its research, development and testing focus
to the facility. Today, the TFLRF offers unprecedented synergy that brings
unique strengths to TARDEC.

The Crossroad for Fuels and
Lubricants Research and
Development (R&D)
The TFLRF occupies more than
29,000 square feet on five acres of
land. The facilities are government-
owned and contractor-operated,
and SwRI itself is an independent,
nonprofit applied R&D organization.
SwRI’s grounds place the laboratory
in a “hub and crossroads of fuels
and lubricants research,” stated Steve
Marty, TFLRF Director. “SwRI is the
largest independent, nonprofit fuels
and lubricants lab in the world.” The
work done here considers all aspects
that impact the performance of pow-
ertrain products.
Various technologies all impact the
automotive engine — combustion,
lubricant composition, fuel composi-
tion and hardware design all must be
considered. Changes in any of these
can impact other areas, and having a
facilities hub collocated with all these
technical areas together is a signifi-
cant benefit for the Army. SwRI’s
State-of-the-art equipment is available from
SwRI for TARDEC’s use. The equipment
pictured here — combined with SwRI SME
expertise — gives TARDEC unparalleled
access to fuels and lubricants knowledge and
test results. (U.S. Army TARDEC photo by
Bill Dowell.)
location and expertise in these techni-
cal areas are available at one location,
not spread across the country. Better
still, the lab is dedicated to Army work.
“SwRI is the largest
independent, nonprofit fuels and
lubricants lab in the world.”

The commercial laboratories sur-

rounding the TFLRF allow TARDEC
to work in an R&D complex focused
solely on relevant projects. Facil-
ity personnel have instant access to
a variety of experts in automotive
and other technology areas to ad-
dress unique problems. TARDEC can
access these experts and correspond-
ing data as soon as they are needed
using a variety of means. “Being in the
middle of this complex lets us lever-
age world-renowned people to solve
problems,” Marty explained. “We have
S peci a l 2010 E d it io n

access to resources that just wouldn’t

be available elsewhere. Sometimes, if
we’re having a problem, rather than
hunt down a Ph.D. across the country,
An SwRI associate conducts an experiment. SwRI has established subject-matter experts (SMEs) in
the automotive and fuels and lubricants areas, and their resources and facilities provide numerous I can go find, or bump into, the needed
opportunities for TARDEC to leverage their expertise. (U.S. Army TARDEC photo by Bill Dowell.) expert at the cafeteria.”
46
Conducting One-of-a-Kind
Testing
The TFLRF’s mission is to support
the Current Force’s vehicle fleet.
However, the lab keeps an eye to the

POWER AND MOBILITY

future. The future mission involves
being able to move away from
conventional fuels and lubricants,
while making sure that new and
current vehicles can use the newly
developed fuels, lubricants and
synthetics fuels. By keeping the new
technologies backwards-compati-
ble, the laboratory can prepare the
way for Future Force vehicles while
fulfilling its Current Force mission.
Additionally, SwRI assists TAR-
DEC’s National Automotive Center
with hybridization and alternative
fuel research.

To accomplish the mission, the

laboratory makes use of vari-
ous capabilities and equipment.
Alongside the facility’s engine test
cells is the combustor facility, which
simulates the first stage of a jet tur-
bine. It generates high temperatures
and airflow, making the facility able
to conduct tests that are impossible
elsewhere, such as fuel nozzle fouling
tests. The laboratory's on-grounds
ballistics test site allows SwRI to test
whether fuels or other technologies
can withstand specific threats. Unique
air and liquid filtration systems and
fog-producing effects round out the
facility’s equipment.
The TFLRF, alongside TARDEC’s
Fuels and Lubricants Technology
Team, is currently researching the
Single Common Powertrain Lu-
bricant (SCPL). SCPL will work in
engines and replace other vehicle
lubricants as well. “Think logistics,”
Marty explained. “If this one lubri-
cant works in engines and gears, then
we can reduce supply chains. But,
think further. Wouldn’t it be neat
if it worked in the Arctic and the
Soldiers from 1st Battalion, 401st Army Field Support Brigade, test drive a Stryker
medical evacuation variant on a test track outside the Stryker battle damage repair facility
at Camp As Sayliyah, Qatar, Sept. 21, 2009. Research at SwRI ensures that the Soldiers
mounted in Strykers and other vehicles have more fuel-efficient and safer tactical vehicle
platforms. (U.S. Army photo by Dustin Senger.)
viscous base stock that will, ultimate- lubricants, often initiating the gold
ly, reduce fuel consumption. standard for lubricants’ performance
in the most challenging operational
“Being in the middle of this environments. “If you go into [a mar-
ket] and buy a quart of engine oil, the
complex lets us leverage world- technology used in it was at one point
renowned people to solve a military standard,” Marty remarked.
problems. We have access to The TFLRF at SwRI continues to
resources that just wouldn’t be provide valuable R&D unobtain-
able from any other location in the
available elsewhere.” world. As they have for more than 50
years, these labs continue support-
Marty sees the laboratories as “a ing TARDEC’s mission, providing
TARDEC facility, but also a Depart- cutting-edge research for supporting
ment of Defense support facility for America’s current and future tactical
fuels and lubricants.” The Air Force, and combat ground vehicle fleets.
Navy, Marine Corps and Coast Guard
also have run projects through the
laboratories. Additionally, the facility
can assist in commercial work when
assets are not required for military
research. “This lets the facility see
S p ecia l 2010 E d it io n

desert?” A product that can tolerate
these extremes without requiring an
oil change will enhance posture and
readiness. The SCPL would also allow
the Army to reduce costs, as the SCPL
would be using a synthetic and less
activity on both sides of the fence,”
Marty stated. “This is only possible
because of our location.”
The Army has always been a driving
force behind commercial fuels and
Matthew Sablan is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He has a B.A. in
English and history from Marymount
University in Arlington, VA.
47
 EARL Runs Batteries
Through Paces
Chris Williams

The Advanced Reconfigurable Spaceframe

(AReS) combat vehicle features a hybrid-
electric propulsion system integrated into an
advanced space frame hull structure. Work
conducted in TARDEC’s advanced battery lab-
oratories is dedicated to improving the power
and capabilities of advanced power storage
systems to power hybrid-electric vehicles like
the AReS. (U.S. Army TARDEC photo.)

A
s the U.S. Army and its partners pursue new developments
in alternative energy, advanced energy storage systems The team also is exploring vari-
have become a crucial focus area for improving fuel effi- ous Li chemistries and nickel-zinc
ciency and providing improved power to vehicle systems. (Ni-Zn) batteries. “In the advanced
With the addition of new electronic equipment leading to Li-ion area, we’re evaluating dif-
increased power requirements and the Army continuing ferent batteries that will provide
its pursuit of "silent watch" capabilities, advanced batteries have higher energy and higher power
become a critical tool in powering the Army’s current and future capability,” Olszanski stated. “We’re
ground vehicle systems (GVS). also looking at Ni-Zn as a poten-
tial backup, which is a low-cost,
Located at the Detroit Arsenal in understand the battery cell capa- water-based electrolyte system.
Warren, MI, the U.S. Army Tank bilities and modules provided by We are also continuing to research
Automotive Research, Develop- those partners and determine how advanced lead acid systems.”
ment and Engineering Center’s they can be integrated into vehicle
(TARDEC’s) Electrochemical systems. “Part of our job is to per- Testing Equipment
Analysis and Research Labora- form the screening process on these The TARDEC laboratory utilizes
tory (EARL) exists to increase the cells and batteries to say, ‘Yes, that’s various programmable cyclers
Army’s understanding of advanced good,’ or, ‘Let’s not pursue that to test batteries, which allow
batteries and how they can be in- any further.’ Typically we perform characterization of the units
tegrated into GVS. The laboratory a series of characterization tests,
selects research and development where we make sure the battery or
undertaken by Army engineers and cells operate to the manufacturer’s
industry partners and applies it to claims,” explained TARDEC Battery
Army technologies. Test Engineer Ted Olszanski.
S peci a l 2010 E d it io n

Understanding Capabilities The team works with a variety of

TARDEC’s Energy Storage Team
works with partners in industry
and academia to develop advanced
batteries for Army ground vehicles.
The EARL’s major function is to
48
chemistries and battery types, in-
cluding lithium ion (Li-ion), which
lasts longer, weighs less and has
greater energy and power densities,
than standard lead acid batteries.
A TARDEC engineer tests a Li-ion battery
module. Lithium chemistry batteries provide
higher energy and longer life cycles than lead
acid batteries. (U.S. Army TARDEC photo
courtesy of Ted Olszanski.)
under various operational
and environmental conditions.
Associates also measure resistance
and power through a Hybrid
Pulse Power Characterization test.
“This allows us to characterize
the resistance and the power at
various states of charge,” Olszanski
stated. “Ultimately, we’ll be doing
life-cycle testing to see how long
these cells last and what their fade
characteristics are.”
The team utilizes an impedance
spectrometer to measure a cell’s im-
pedance at various frequencies. The
tool allows TARDEC researchers to
understand how one cell performs
when compared to another, the
effect of current collection and the
way it is manufactured. “It’s a diag-
nostic tool,” Olszanski clarified. “It’s
used for identifying areas that need
to be improved or improvements
that someone may have made as
they provide us with different types
of cells. Impedance and resistance
help us determine how much
power a cell will provide.”
“Part of our job is to perform
the screening process on these
cells and batteries to say, ‘Yes,
that’s good,’ or, ‘Let’s not pursue
that any further.’”
Environmental conditions can im-
pact the amount of power batteries
can provide. To better understand
how cells and modules are affected
by environmental changes, char-
acterization tests are conducted
at room temperature, as well as
at high- and low-temperature
extremes. “At lower temperatures
the batteries do not provide as high
a capacity, and at some point they
won’t operate,” Olszanski illustrat-
ed. “Below -25 degrees Fahrenheit
seems to be the critical number
where we know we need to improve
upon and develop a thermal man-
agement system. It’s harder for the
battery to actually give up or accept
energy at lower temperatures. In
the high-temperature range, how-
ever, the batteries wear out faster
and yield less energy over time,
giving them a lower cycle life.”
A TARDEC engineer conducts tests on a
battery module. TARDEC’s Power Storage
Team conducts several tests to understand
advanced battery characteristics, capabilities
and life cycle duration. (U.S. Army TARDEC
photo courtesy of Ted Olszanski.)
The Call for More Power
As the demand for increased bat-
tery capability grows, TARDEC’s
Energy Storage Team faces a num-
ber of challenges. New technol-
ogy drives up energy demands on
vehicles and takes up space, leaving
engineers with the task of develop-
ing batteries with greater energy
and power densities. “We’re trying
to hit a moving target in terms of
what the power and energy require-
ments are because it keeps moving
in an upward direction,” Olszanski
revealed. “There’s never enough
available power, energy or space
on a vehicle.”
The team is currently studying the
application of advanced batteries
in electric and hybrid-electric-
powered vehicles. More impor-
tantly, however, is the capability
advanced batteries may provide
in powering vehicle equipment
and providing Soldiers with silent
watch capabilities, a must-have
on the battlefield. “The push is
to provide more power to the
Army’s ground vehicles,”
Olszanski emphasized. “Batter-
ies are needed to provide power,
especially in silent watch or
starting, lighting and
ignition applications.”
The EARL is currently located in
POWER AND MOBILITY
two buildings at the Detroit Arse-
nal, and both laboratories will be
incorporated into the new Ground
Systems Power and Energy Labora-
tory (GSPEL), which celebrated
its groundbreaking at the Detroit
Arsenal in August 2009. The GSPEL
location will provide greater testing
capabilities, including the ability to
test the actual battery packs that are
used to power vehicles. “Right now,
we’re testing cells and modules, but
modules are what ultimately get put
onto a battery pack, and the battery
pack is what ultimately goes on a
vehicle. So we’re moving toward
increasing the capability of the lab
to test battery packs,” Olszanski
remarked. “Within the GSPEL,
we will be able to test cells, battery
modules and battery packs, which
can provide 300–600 volts.”
The Army’s fleet of ground vehicle’s
energy and power needs continue
to grow in order to allow Soldiers to
safely and efficiently complete mis-
sions in the field and keep the fleet
moving. With the addition of the
new GSPEL facility and its ability to
allow testing of larger batteries safe-
ly, along with the existing EARL, the
TARDEC Energy Storage team will
be capable of performing research,
development and testing of batteries
up to pack size and thus help meet
the many energy challenges facing
today’s Army vehicle fleet.
Chris Williams is a Writer/Editor with
BRTRC and provides contract support
to TARDEC’s Strategic Communications
S p ecia l 2010 E d it io n
team. He has a B.A. in communication
from Wayne State University in Detroit,
MI, and has previously written for The
Source newspaper in Shelby Township,
MI, and The Macomb Daily and C & G
Newspapers in Macomb County, MI.
49
 TARDEC Engineers Advance
Technology and Systems

Increased fuel efficiency requirements and power demands have made HE

power an integral component for developing the Army’s future ground vehicle
fleet. TARDEC, as the Army’s ground vehicle systems integrator, tests HE
components and systems for future implementation on a range of wheeled
and tracked vehicles using the HE Reconfigurable Movable Integration Test
(HERMIT) bed. (U.S. Army TARDEC photos provided by Ghassan Khalil.)
S peci a l 2010 E d it io n

50
Hybrid-Electric (HE)
In tegration
Chris Williams

A
s automakers face new fuel-efficiency requirements and the
U.S. Army develops new ways to power vehicles, the role of HE
vehicles (HEVs) has become more prominent. To further the
Army’s development of HE technology, the U.S. Army Tank
Automotive Research, Development and Engineering Center
(TARDEC) operates two laboratories that specialize in devel-
oping, testing and optimizing HE systems.
S p ecia l 2010 E d it io n

51
 The HERMIT is a critical tool in TARDEC’s Hybrid P&E labs. Recently moved to the Detroit Arsenal in Warren, MI, from
Santa Clara, CA, the HERMIT provides engineers with the capability to test integrated systems on a vehicle platform.
Electric Component Evalua-
tion Laboratory (ECEL)
The Army’s demonstrator HEVs
require advancing some enabling
electrical component technolo-
gies for the vehicles to meet their
performance objectives. Located
at the Detroit Arsenal in Warren,
MI, TARDEC’s ECEL technicians
and engineers test and verify the
performance of new HE compo-
nent concepts for acceptable and
safe operation.
“It’s a very important capability
to have because there are some
technical challenges that need to
be resolved before we can imple-
ment HE technologies,” explained
Ghassan Khalil, TARDEC HE
Team Leader. “We have to mature
the technology, and we do that
through testing and evaluation
and further development at the
system level.”
The ECEL includes capabilities to
S peci a l 2010 E d it io n
test all electrical components
that make up an HE system,
including electric motors and
their controllers, power condi-
tioning converters and advanced
batteries. An alternating cur-
52
rent dynamometer is used to
test motors and generators up
to 350 kilowatts to provide an
understanding of the test items’
power, torque, efficiency and
thermal management.
“Even though we test individual
components and understand
their performance, we need to
gain an understanding of how
they behave when they are
integrated together.”
The laboratory provides TARDEC
associates with the ability to
understand electric component
capabilities prior to integrating
them into a system, a crucial fac-
tor in developing vehicle systems.
“The importance is to verify
the component’s predicted and
advertised performance,” stated
Khalil. “When you buy a machine,
it comes with certain ratings re-
lated to torque, power, speed and
an advertised efficiency. Efficiency
varies with speed, load, power
and torque, and we need to verify
that these ratings are correct and
then characterize the machine by
measuring its efficiency at several
points to create an efficiency map.”
Power and Energy (P&E)
Systems Integration
Laboratory (SIL)
Once electrical components have
been tested on their own, they
must be evaluated as part of an
integrated system. TARDEC’s
P&E SIL, initially located in Santa
Clara, CA, now has a large por-
tion of the facility’s equipment
moved to TARDEC. This allows
on-site researchers to understand
how a component’s capabilities
are affected when it is connected
to a system. “Even though we
test individual components and
understand their performance, we
need to gain an understanding of
how they behave when they are
integrated together,” remarked
Khalil. “How are they connected
together, how does one system
affect another system, what’s their
burden for integration purposes,
how many cooling circuits will
they require and what are the
different temperatures that need
to be maintained for each com-
ponent? All of these things are
extremely critical before com-
ponents are integrated into the
vehicle, and the SIL gives us the
capability to understand those
issues,” Khalil explained.
“There are many constraints in
integrating a vehicle,
and you never know how
a system reacts to those
constraints until you package
the different subsystems into
the vehicle platform.”
A component’s performance can
be drastically affected when it’s
connected to another compo-
nent. A motor may operate at
97-percent efficiency on its own,
but that efficiency will decrease
when controllers, fans or other
components are attached to it.
The work conducted in the P&E
SIL allows TARDEC engineers to
connect the components together
in one room and understand the
system’s performance capabilities,
allowing them to discover problems
and challenges before the system
is integrated into a vehicle for fu-
ture fielding. The measurements
gained through testing in the
SIL rapidly and cost-effectively
validate and transition advanced
electrical technology to a ve-
hicle and provide a cost-effective
means to develop and evaluate
The HERMIT can be reconfigured to allow for the placement of systems through-
out the platform, allowing engineers to test integrated systems for any vehicle.
The Hybrid P&E SIL in Santa Clara and TARDEC’s ECEL at the Detroit
Arsenal provide engineers with the capability to test electrical compo-
nents and understand how they perform as part of an integrated system.
a combat vehicle architecture’s
effectiveness. “When you test
these components as part of an
integrated system, things start
appearing,” Khalil revealed. “You
may learn that a component
works fine by itself, but there’s
an issue when it’s combined with
other components. The SIL allows
us to discover and fix these issues
before the vehicle is fielded, when
it would be too late.”
One key P&E SIL test tool is the
HE Reconfigurable Movable Inte-
gration Test bed (HERMIT). The
HERMIT provides engineers with
the capability to test the integrat-
ed systems on a vehicle platform.
The HERMIT allows TARDEC
associates to understand how the
system performs when compo-
nents are connected under the
POWER AND MOBILITY
constraints of a system, where
electrical interference and space
and weight restrictions may affect
the system’s overall capabilities.
“The idea is to see how tight the
space is going to be when you
put all these components to-
gether and see if you have enough
space available for what you have
designed,” Khalil noted. “There
are many constraints in integrat-
ing a vehicle, and you never know
how a system reacts to those
constraints until you package
the different subsystems into the
vehicle platform. The SIL can
operate without a vehicle plat-
form because we can put different
components in different places
and fill up an entire room. With
the HERMIT, we bring them all
into this small space to gain an
understanding of how they all
work together,” Khalil concluded.
Chris Williams is a Writer/Editor with
BRTRC and provides contract support
to TARDEC’s Strategic Communications
S p ecia l 2010 E d it io n
team. He has a B.A. in communication
from Wayne State University in Detroit,
MI, and has previously written for The
Source newspaper in Shelby Township,
MI, and The Macomb Daily and C & G
Newspapers in Macomb County, MI.
53
 Fueling Station and
Maintenance Facility Keep
Hydrogen Vehicles Powered
Chris Williams

A
s the U.S. Army pursues advancements in
alternative energy, hydrogen has proven to
be a potentially viable fuel source for many
smaller ground vehicles. As the Nation’s energy
security hub, the U.S. Army Tank Automotive
Research, Development and Engineering Cen-
ter’s (TARDEC’s) National Automotive Center (NAC)
oversees two facilities that support the Army’s fleet of
hydrogen-powered vehicles.
S peci a l 2010 E d it io n

54
 The sports utility vehicle, seen here at the 2009 Memorial Day Parade in
Dearborn, MI, was developed by TARDEC’s NAC in partnership with
outside organizations. The vehicle is one of 10 converted hybrid-electric
sports utility vehicles to operate on compressed hydrogen. (U.S. Army
TARDEC photos by Chris Williams.)

Hydrogen Fueling Station
One challenge to the acceptance
of hydrogen-powered ground
vehicles is the lack of a robust
infrastructure for fueling those
as it works to create a nationwide
fueling infrastructure for hydro-
gen vehicles. “We’ve had a couple
of different officials from the auto
industry come out here recently
The station’s dispenser, which is
designed after a basic gasoline
pump, uses a specialized locking
mechanism to ensure that neither
the vehicle nor station will suffer
S p ecia l 2010 E d it io n

systems. The Hydrogen Fuel-
ing Station, located at the Self-
ridge Air National Guard Base
(SANGB), MI, provides a location
for that task and serves as an ex-
ample to the automotive industry
to take a look,” stated Steven Eick,
a TARDEC hydrogen projects
engineer. “They were looking
not just at the station, but at how
alternative energy as a whole fits
into a military base.”
leaks during fueling. Designed in
accordance with the California
Fuel Cells Partnership (CFCP)
designs, the nozzle also features
a data connection between the
vehicle and dispenser that
55
 TARDEC’s Hydrogen Fueling Station, located at SANGB, provides a location to
fuel the Army’s growing fleet of hydrogen-powered ground vehicles.

monitors tank size, temperature
and pressure, factors essential to
an accurate filling. “When you’re
dealing with gaseous fuels, you
have to be a lot more careful about
temperature and pressure because
it relates to how much volume
S peci a l 2010 E d it io n
and mass you get,” Eick explained.
“With liquid fuels like gasoline,
it doesn’t vary that much — you
heat it up, and it expands just a lit-
tle bit. If you heat up a little bit of
hydrogen, it drastically increases
the pressure and adds additional
strain. The reason you want that
communication between the ve-
hicle and station is to adequately
control that relationship between
temperature, pressure and volume
during refueling.”

In partnership with Chevron,

“They put together an organization for vehicle
the facility formerly generated
manufacturers, gasoline retailers and energy retailers and its own hydrogen using a steam
natural gas reformer. The part-
developed a protocol that would fit with both groups and nership is currently in the final
said, ‘This is what we’re going to do.’” stages, with the reformer in the
56
 “The earliest implementation areas right now that I see are
basically forklifts and tow tractors, because the power required
for them is a lot less than a standard vehicle.”
process of being removed. “It was
a steam-methane reformation
process. It takes steam and natu-
ral gas and breaks the natural gas
down into carbon dioxide and hy-
drogen. From there, the hydrogen
is separated out, compressed and
then put into storage banks,” re-
vealed Eick. “Now when we need
hydrogen, we have a hydrogen
company deliver a full tube trailer
and use the same compressor to
back feed into the tanks. When it
starts to get low, we order another
tube trailer.”
By adhering to CFCP standards,
the station serves as a model for
how consumers may eventually
fuel their own hydrogen-powered
vehicles. Under the partnership’s
standards, similar dispensers
would be used throughout the
country, ensuring a common
infrastructure for refueling hy-
drogen vehicles. “California was
the forerunner with hydrogen
in terms of infrastructure and
refueling,” Eick remarked. “They
put together an organization for
vehicle manufacturers, gasoline
retailers and energy retailers and
developed a protocol that would
fit with the groups and said,
‘This is what we’re going to do.’
As other states start to develop
a hydrogen capability, they will
likely follow the same protocols.
The benefit is that you have the
standardization in place to help
companies work together instead
of fighting.”
Hydrogen Maintenance Facility
The Hydrogen Maintenance Fa-
cility, also located at SANGB, of-
fers a safe, state-of-the-art facility
for repairing the Army’s fleet of
hydrogen ground vehicles. While
much of the work conducted on
the vehicles is similar to work
done on conventionally powered
systems, the high pressures and
sensitive nature of working with
hydrogen require specialized
precautions to prevent potentially
dangerous leaks. The facility,
which meets all federal, state and
local requirements for conduct-
ing maintenance on hydrogen
vehicles, is equipped with hydro-
gen and flame detectors that will
sound an alarm and evacuate the
gasses in the event of a leak. “The
main danger comes from han-
dling high-pressure gasses,” Eick
expounded. “The hydrogen itself
is actually no more dangerous
than gasoline, but the fact that it’s
at very high pressures makes it a
little more difficult. It’s like deal-
ing with a high-pressure propane
tank or a compressed natural gas
tank, where the high pressure has
to be handled in a specific way
because any weakness in the sys-
tem can cause a leak. The systems
are designed to withstand and
avoid problems like that.”
Currently, contractual obligations
require that the hydrogen vehicles
be maintained by vehicle manufac-
turers. In the future, Eick believes
that TARDEC associates will be
more involved in hydrogen vehicle
maintenance as their knowledge
of the systems increases and that
the presence of manufacturers on
the base provides the opportunity
for a strong working relationship
between the Army and its industry
partners. “It benefits them because
they get the hands-on experience
of fixing problems and dealing
with user problems,” he stated.
“It helps us in the sense that we
know what problems to look for or
design to in the future if we want
to do a beta version or second
POWER AND MOBILITY
prototype. It benefits us, and it
benefits the auto industry because
they know, based on our research,
what to do, what changes to make
and how to make this move even
closer to commercialization, which
is their end goal.”
Hydrogen’s Future
Hydrogen vehicles are still rela-
tively new to the Army. Only a
handful of bases currently have hy-
drogen fueling stations, and most
are still considered demonstrators.
Only a few vehicles, such as the
Ford Escape Internal Combus-
tion Engine (ICE) and hydrogen-
powered forklifts, are currently on
the bases, although Eick believes
the technology will increase in the
future. “I think it’s a viable source
because the vehicles are centrally
fueled and have well-known usage
profiles,” he acknowledged. “The
earliest implementation areas right
now, that I see, are basically fork-
lifts and tow tractors, because the
power required for them is a lot
less than a standard vehicle. Their
speeds are lower, their weights are
lower and the fleet is isolated to
one location. Even though they’re
lifting and towing, they don’t
require an 80-kilowatt (kW) fuel
cell to do it. They need, maybe, a
15-kW cell, and that decreases fuel
costs, which makes it a lot easier to
implement,” Eick concluded.
Chris Williams is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic
Communications team. He has a B.A.
S p ecia l 2010 E d it io n
in communication from Wayne State
University in Detroit, MI, and has
previously written for The Source
newspaper in Shelby Township, MI,
and The Macomb Daily and C & G
Newspapers in Macomb County, MI.
57
 Optimized Combustion and Fuels
Focus of Single Cylin
Cylinder
der Test Cell
Chris Williams

A mechanic checks each part of a new engine on a Mine Resistant Ambush Protected vehicle at Camp Liberty, Baghdad, Iraq. TARDEC’s mobility labo-
ratories research engine performance and combustion phenomena to provide Soldiers with reliable and safe ground vehicle systems in tremendously
challenging operational environments. (U.S. Army photo by SPC Howard Alperin.)

E
ngine combustion is a complex phenomenon. Understand- flexible engine controller. Engi-
ing it is crucial to effectively and efficiently powering the U.S. neers control the entire testing
Army’s fleet of ground vehicles. The U.S. Army Tank Automotive process, including fuel rate, en-
Research, Development and Engineering Center’s (TARDEC’s) gine operating condition, coolant
Single Cylinder Test Cell and Evaluation Laboratory, located at system and oil system. “Every-
the Detroit Arsenal in Warren, MI, is dedicated to studying com- thing is controlled precisely on
bustion phenomena and increasing the Army’s understanding of how that engine,” Schihl remarked.
various factors may affect vehicle engines and performance. “We take measurements that
allow us to indirectly measure
Isolating the Phenomenon TARDEC Senior Research what’s going on in the cylinder
The laboratory features a state-of- Engineer Dr. Peter Schihl. “For ex- with the combustion event and
the-art, high-output, single-cylinder ample, we measure the in-cylinder thus the fuel spray.”
research engine that provides pressure, which we normally don’t
researchers with the capability do when we test a multicylinder Studying Combustion Behavior
of isolating engine combustion, engine. We measure what’s go- Currently, the laboratory is being
allowing them to gain greater ing on with the injection system used to test a variety of poten-
insight through low-speed and precisely — measurements that tial military alternative fuels to
high-speed parameter measure- you wouldn’t find in production. understand how they impact
S peci a l 2010 E d it io n

ments that evaluate overall engine
performance and in-cylinder
combustion behavior. “We have
measurements that you wouldn’t
find when we set up a multi-
cylinder engine,” explained
58
This allows us to really study the
combustion event in an engine.”
The research engine has been
modified with a flexible prototype
injection system and an associated
engine systems. The process for
such testing begins with gather-
ing a baseline, in which North
American diesel fuel is run at
several different operating points
through the engine, which is

TARDEC’s Single Cylinder Engine Laboratory allows researchers to isolate cylinder combustion
to better understand engine performance and behavior. Researchers are currently studying data
gathered in the laboratory to understand how alternative fuels react during combustion events.
(U.S. Army TARDEC photo courtesy of Laura Hoogterp.)
calibrated to give the best fuel
economy and highest thermal
efficiency at a given torque. “We
start with the baseline, and we un-
derstand that very well, meaning
that we have a certain torque we
want, and we’ve optimized it for
efficiency or fuel economy,” Schihl
explained. “Then we very carefully
study the combustion behavior.”
With the baseline gathered, engi-
neers start running various fuels
through the system to understand
how and why the measurements
change. “We’ve run a 50-50 blend of
jet propellant-8 (JP-8) and synthetic
JP-8, a 100-percent pure synthetic
JP-8, and we have other samples of
fuels that we’ve been running that
are possible synthetic JP-8s,” Schihl
described. “We start evaluating these
different fuels with the same control
strategy, document what the torque
differences are and then study the
combustion event to figure out why
the change occurred. We’re in the
process right now of finishing up
the fifth fuel. We’ll be making some
special blends to adjust the ignition
quality of the fuel and probably run
another four or five fuels through-
out the remainder of 2009.”
Benefits
“The information gleaned from
the testing that occurs within the
Single Cylinder Engine Test Cell
can provide beneficial informa-
tion to Army engine suppliers and
Army engineers when develop-
ing engines and considering new
SSG Ronald Gasper, a fuels lab technician
assigned to the 379th Expeditionary Logistics
Readiness Squadron, fills a bottle with JP-8
fuel to perform a bottle method test, which is
used to test a fuel truck's filter separator and
measures the amount of impurities in the fuel.
Testing at TARDEC’s Single Cylinder Engine
Laboratory is currently studying the effects of
JP-8 and alternative fuels on vehicle engines to
improve engine performance, fuel efficiency
and economy. (U.S. Army photo by TSGT
Michael Boquette).
“We start with the baseline,
and we understand that very
well, meaning that we have
POWER AND MOBILITY
a certain torque we want,
and we’ve optimized it for
efficiency or fuel economy.
Then we very carefully study
the combustion behavior.”
fuels for future ground vehicle
systems,” Schihl stated. “It pro-
vides an understanding of what’s
going on in that cylinder as you
vary combustion affecting fuel
properties,” he explained. “This
is important in the case of new
engine development because as
you look to the future, especially
engines that the Army would like
to have the capability to be more
flexible with the fuel, you’ll have
information upfront that allows
you to come up with a combus-
tion strategy that is more tolerant
of these various fuels.”
The research also prepares TARDEC
engineers for questions that may
arise in the field, allowing them to
quickly and effectively meet Sol-
diers’ needs. “As you run into prob-
lems with engines in the field, you
already have an idea of what might
be causing it, or you have a quick
way to study it,” Schihl stated. “I’m
a big advocate for the more you
understand about that situation,
the better chance you have helping
the Army or a program manager
resolve a given engine issue.”
Chris Williams is a Writer/Editor with
BRTRC and provides contract support
to TARDEC’s Strategic Communica-
S p ecia l 2010 E d it io n
tions team. He has a B.A. in communi-
cation from Wayne State University in
Detroit, MI, and has previously written
for The Source newspaper in Shelby
Township, MI, and The Macomb Daily
and C & G Newspapers in Macomb
County, MI. 59
 Sys
ystems
tems Engineers

T
rack for the U.S. Army’s fleet of tracked vehicles is expensive to replace,
and, if it fails, the vehicle and crew can potentially be stranded in hostile
territory. To keep warfighters safe and prevent costly failures, the U.S.
Army Tank Automotive Research, Development and Engineering Cen-
ter (TARDEC) operates two labs that study the performance of tracked
vehicle components.
0 0n9
00

An M1A1 Abrams Main Battle Tank provides covering fire during a clear, hold and build exercise. The Elas-
t em bEerd it2io

tomer Improvement Program (EIP) has established baseline hyperelastic data that successfully developed,
optimized and delivered an Abrams T-158LL bushing model so warfighters have the reliability they depend
temb
a l 2010

on for maneuverability and battlefield survivability. (U.S. Marine Corps photo by LCPL Kelsey J. Green.)
l y -Sep
peci
J uly
Ju
S - Sep

60
Keep Vehicles on Track
Center Guide Wear Simulator
Center guides are small compo-
nents that play a major role in
keeping tracked vehicles on track.
The component is part of the
vehicle’s track shoe and runs be-
tween the road wheels to keep the
track aligned and on the vehicle.
During the vehicle’s operation,
the center guide’s contact with
other tracked components causes
wear and degradation.
To understand how the compo-
nents interact before they are
Chris Williams
integrated into a vehicle, TARDEC
officials test the components on
the Center Guide Wear Simulation
Machine located at an off-site aca-
demic research center. “You tend
to get a lot of side load, friction
and wear between the center guide
and the back of the road wheel,”
explained Eric Blash, a mechani-
cal engineer on TARDEC’s Track
and Suspension Team. “The
Center Guide Wear Simulation
Machine is basically a large drum.
We fasten center guides to it
and spin it around, simulating a
vehicle moving at 20 mph. The
center guides ride against the
wear surface of a road wheel with
a specified contact load between
the components. It’s a quick and
cost-effective way to see if a mate-
rial is suitable for the application
before we spend a lot of money
on vehicle testing.”
JSul
uly
pyecia
-Sep
- Sepl t2010
As the Army develops lighter
vehicles, the simulator plays an
emb er
essential role in testing new mate-
E d200
2it0io0 9n
rials and components. Track shoes
are traditionally made from steel.
61

Soldiers change the tracks on their Bradley
Fighting Vehicle. Testing done at TARDEC
provides an understanding of how a vehicle’s
components interact when in use, a capability
that stand-alone component testing cannot
provide. (U.S. Army photo by SGT Dan Purcell.)
In an attempt to decrease vehicle
weight, the Army has experi-
mented with various lightweight
materials, including aluminum
metal track with silicon carbide
inserts that were placed on the
center guides and a diverse array
of materials and coatings for wear
rings and road wheels.
When new materials and compo-
nents are added to the test shoe,
the simulation machine is used to
gauge how quickly the components
will wear. “When you use a lighter-
weight aluminum road wheel, you
typically have a steel wear ring
attached to it,” explained Blash.
“That wear ring is going to be what
actually contacts the center guide.
It’s expensive to build that wear ring
and then fasten it to the road wheel.
There’s been experimentation with
different coatings that improve the
S peci a l 2010 E d it io n
wear properties of the aluminum
wheel. So, we can use the simulation
machine to test the center guide
material itself, or we can test new
materials for the wear ring or the
road wheel.”
62
The testing provides TARDEC
engineers with an understanding of
how the components interact with
each other when in use, a capability
that stand-alone component testing
cannot provide. The simulation
machine also allows researchers to
understand the wear properties of
various materials, properties that
would be difficult to gauge with-
out physical tests. “Wear is a funny
beast,” Blash remarked. “We can
do a standardized wear test that
compares materials, but until you
simulate the actual working condi-
tions you won’t know exactly how
those two materials are going to
interact with each other.”
The simulation machine does
not replace Army qualification
standards but, rather, is used to
understand tracked vehicle com-
ponents as they interact before
they are integrated into a vehicle
system. “We really utilize it for
the cost-savings benefit,” Blash
revealed. “It’s not a qualifica-
tions test — it’s an engineering
evaluation. It basically provides
another data point for us to make
the decision of whether or not
we should spend the money on a
field test.”
Bushing Testing and Evaluation
The most common track failures
stem from the system’s elastomeric
A construction mechanic greases the tracks of a land excavator. Before integrating tracks and other
components into a vehicle, TARDEC officials test the components on the Center Guide Wear Simu-
lation Machine to reduce maintenance costs, improve life-cycle performance and keep warfighters
out of harm’s way. (U.S. Army photo by PFC Eric Liesse.)
components, such as bushings,
which hold essential pins in place
to keep tracks aligned. TARDEC’s
Elastomer Improvement Program
(EIP), a state-of-the-art research
and development (R&D) facil-
ity designed for testing, catego-
rizing and improving rubber
compounds for tracked vehicle
systems at the Detroit Arsenal,
features a bushing tester, which
allows engineers to understand
bushing properties without incur-
ring the cost of a vehicle test.
“The EIP exists to come up with
more relevant tests, protocols and
techniques to better duplicate our
failure modes and make better
intuitive decisions on direction for
research,” explained Bill Bradford,
an R&D scientist with TARDEC’s
Mobility R&D Center. “In the past,
we conducted screening and quali-
fication testing based on materials
R&D methodology developed
in the 1960s. Advances in mate-
rial, testing equipment, sensors,
computers and electronics have
improved test equipment sensitiv-
ity and reliability. Laboratory tests
with components will always be
at risk with respect to duplicating
actual field performance. How-
ever, understanding the predomi-
nant failure modes, optimizing
state-of-the-art test equipment
and methodology to closely

R&D Scientist William Bradford uses a DMTA testing tool to examine bushing properties. DMTA
testing provides a true assessment of bushing properties during the component’s life cycle and
insight into required material improvements. (U.S. Army TARDEC photo by Chris Williams.)
mimic field failures, brings us one
step closer to screening improved
components in the laboratory,”
Bradford continued.
The result was the procurement
of an R&D bushing test stand and
development of test methodology
that would leverage production
bushings and identify radial and
torsional loads that would result
in duplicating the failure mode to
the T-158LL track bushings. Over
the last 18 months, this capability
has provided two new improved
bushing designs that are expected
to improve the durability of the
T-158LL bushing by more than
50 percent.
EIP testing determined that bushings undergo
55-percent deterioration after assembly, which
can lead to track and component failure. TAR-
DEC researchers are trying to create bushings
made of a more durable, consistent material
that will improve track durability and perfor-
mance in harsh terrain. (U.S. Army TARDEC
photo by Chris Williams.)
In conjunction with the test stand
development, the EIP lab has estab-
lished baseline hyperelastic data that
was used to successfully develop,
optimize and deliver a Finite
Element Analysis (FEA) model
for the Abrams T-158LL bushing.
This capability is a major break-
through, providing a functional
FEA model for design optimiza-
tion with respect to maximum
stress, energy input per loading
step and the impact of insertion,
radial and torsional loads. This
capability, in concert with the
elastomer test screening process,
has provided the roadmap for-
ward for improving the compo-
nent’s durability by 50 percent,
resulting in significant savings.
The EIP uses a new testing
methodology to extract rubber
bushings from track components
through specialized shiving tech-
niques that produce consistent
sample geometry for dynamic
mechanical thermal analysis
(DMTA). This testing provides
a true assessment of the compo-
nent’s properties during its life
cycle and insight into required
material improvements.
Bushing testing is also conducted
off-site on another type of bush-
ing tester. Although officials at
the off-site research center and
TARDEC are enhancing bushing
testing capabilities through the
EIP, the off-site bushing tester is
still a useful tool in understanding
whether new bushing materials
meet rigorous Army standards.
“If a contractor comes in and says
they have a new material that they
want to use for military track, they
go through a series of material
POWER AND MOBILITY
property tests, and then we have
them produce production-grade
T-130 bushings,” Blash stated. “We
insert them into simulated bores
and run radial and torsional load
profiles until the bushing meets
a certain failure criteria. At that
point, we tell them whether or
not that is an acceptable mate-
rial to use to build military track.
The failure criterion is based on a
certain deflection — once the pin
moves a certain amount, we say
that bushing has failed. We take
the cycle count at that point and
look at whether it meets the mini-
mum acceptance criteria.”
Bradford believes the R&D ac-
tivities conducted by TARDEC
will continue to expand the Army’s
understanding and knowledge base
to continuously improve track du-
rability, performance and translate
into more reliable track systems and
reduce life cycle costs. “Our goal is
to develop better laboratory R&D
tests that mimic actual field failures,
increasing the probability of success
and reducing the burden and costs
associated with full vehicle tests.
These laboratories provide us with
the capability to evaluate new mate-
rials and designs for improved track
components, bushings, road wheels,
ground pads and road wheel backer
pads to support our warfighters,”
Bradford concluded.
Chris Williams is a Writer/Editor with
BRTRC and provides contract support
to TARDEC’s Strategic Communications
S p ecia l 2010 E d it io n
team. He has a B.A. in communication
from Wayne State University in Detroit,
MI, and has previously written for The
Source newspaper in Shelby Township,
MI, and The Macomb Daily and C & G
Newspapers in Macomb County, MI.
63
 TARDEC
TARDE C Turns Up Heat
on Vehicle Testing
Chris Williams

M
obility is a necessary capability of every U.S. Army
ground vehicle. Soldiers may have access to the best
equipment and weaponry, but it is all rendered useless
without reliable transportation to get them to the fight.
Whether or not warfighters have the ability to move from
one location to another can mean the difference between
success and failure on an increasingly challenging battlefield.

A Mine Resistant Ambush Protected vehicle undergoes testing in Cell 9.

Computer-activated heat lamps in the test cell can bring temperatures
S peci a l 2010 E d it io n

up to 160 degrees. Likewise, winds of up to 20 mph can be generated

from eight different directions, allowing engineers to understand how
environment affects a system and its components. (U.S. Army TARDEC
photo by Ted Beaupre.)

64
Providing Soldiers with reliable
and efficient ground vehicles is
a key mission for the U.S. Army
Tank Automotive Research,
Development and Engineering
Center (TARDEC). A collection
of laboratories run by TARDEC’s
Ground Vehicle Power and
Mobility (GVPM) team exists to
ensure that engines and vehicle
components operate properly,
both before integration into a
larger system and under harsh
desert or mountain conditions.
Full Load Cooling
Test Chamber
Located in Test Cell 9 at the
Detroit Arsenal, TARDEC’s
Full Load Cooling Test Cham-
ber provides engineers with an
understanding of how vehicles
operate in harsh environments.
The facility is the Army’s largest
indoor test lab. Two 1,000-horse-
power (hp) fans bring in outdoor
air at up to 1,200,000 cubic feet
per minute, and the chamber
can be heated to 160 degrees
Fahrenheit, while simulating the
sun’s solar radiation with the use
of computer-controlled solar
lights. Winds of up to 20 mph
can be generated and directed
across the vehicle in up to eight
different directions with the
use of movable panels. “It was
designed and set up for full load
cooling tests, which is where you
bring in a vehicle, connect it to
a dynamometer and simulate
torque,” explained Michael Reid,
Team Leader for GVPM’s Testing,
S p ecia l 2010 E d it io n
65
 Evaluation and Assessment Team. allow for tactical vehicle test- Currently, the GVPM Test Team
“We simulate that maximum load ing. Researchers then power the is doing engineering and thermal
while the vehicle is at desert oper- system and study how the various insulation testing in the cham-
ating conditions because we want components and systems oper- ber for TARDEC’s Engineering
to ensure that the vehicle isn’t ate in desert conditions, which Business Group, bringing in
going to fail while the Soldiers are is important because the harsh different technologies such as
fighting in desert-like conditions. climates of Iraq and Afghanistan thermal blankets and insulating
We’re able to evaluate the vehicle’s can affect vehicles in ways that components that can be adhered
performance and provide solu- cooler weather does not. “The to the vehicle to help reduce in-
tions to any cooling system issues temperatures are severe in those terior temperatures. The cell also
that may exist.” areas, and it’s easy to overheat has been used to test the impact
of added vehicle armor on the
“We simulate that maximum load while the vehicle is at temperature of the Army’s Family
of Medium Tactical Vehicles and
desert operating conditions because we want to ensure
for understanding the impact
that the vehicle isn’t going to fail while the Soldiers are of air-conditioning on vehicle
systems. “We’ve been doing a lot
fighting in desert-like conditions.” of air-conditioning tests in there
because, generally, the military
The chamber features two large engine coolant, transmission oil never had air-conditioning in a
gear boxes, which can be connect- and engine oil, which can cause lot of the vehicles,” Reid noted.
ed to tracked vehicles’ sprockets. those components to fail,” Reid “What they’re seeing in desert
Two 2,500-hp dynamometers are remarked. “The advantage of do- operating conditions is that the
located below and can absorb a ing it in a test chamber is that we interior of the vehicle is getting
tracked vehicle’s load and provide can replicate those conditions 365 over 160 degrees Fahrenheit, so
engineers with an understand- days a year. We don’t have to go to they’re seeing a lot of failures
ing of the power generated by Yuma Proving Ground for a week of interior components, such as
the engine in hot climates. Ad- when the temperature might be touch screens, on certain vehicles
ditional portable dynamometers that hot.” and power electronics.”

A vehicle is prepared for testing in TARDEC’s Full Load Cooling

Test Chamber. Located in Cell 9, the test chamber replicates climate
conditions in high-temperature environments and allows engineers
to test the entire vehicle at high-temperature extremes. (U.S. Army
TARDEC photo by Elizabeth Carnegie.)
S peci a l 2010 E d it io n

66

Bradley Fighting Vehicles (BFVs) are capable of transporting Soldiers into battle on a
variety of terrains. TARDEC’s testing facilities allows researchers to further analyze ground
platforms, and the facilities will better prepare vehicles for the air quality present in desert
and mountain conditions. (U.S. Army photo by PFC Rebekah Lampman.)
Air Filtration and
Calorimeter Labs
Desert conditions historically
present problems for vehicle air
cleaning systems. Dirt and sand
can clog engine air filter systems,
and high temperatures can wreak
havoc on engine and transmis-
sions if the radiators, oil coolers
and charge air coolers are not
correct. TARDEC’s Air Flow and
Coolant System Component Eval-
uation Laboratory was developed
specifically to help researchers
understand what must be done to
avoid failures with those compo-
nents. “All of our vehicles have air
cleaners for the engines and some
for the crew compartments,”
explained TARDEC Mechanical
Engineer Michael Richard. “What
basically happens is that you end
up shutting down the vehicle if
the air filter gets plugged. If that
happens when you’re on a mis-
sion, obviously, you’re in trouble.”
The lab includes a radiator
calorimeter and two filtration
test benches that can simulate
a variety of real-world condi-
tions for evaluating radiators and
air-filtration systems that assess
component-level performance,
measuring heat rejection, restric-
tion, filtration efficiency and ca-
pacity parameters. “We’re making
significant advancements in the
testing and development of air
cleaners,” Richard stated. “When
I first started here, tactical ve-
hicles had a 4-hour dust capacity
requirement on a test bench and
armored ones were tested for 20
hours. Now we’re going for 200
hours across the board.”
“Our systems have
gotten so much larger
over time, so we’re really
pushing the envelope,
especially as the power
requirements increase
on the vehicles.”
The lab has the capability to
test radiators on a calorimeter,
although the range is limited.
Testing can be done on compo-
nents for vehicles as large as an
M1 Abrams Main Battle Tank.
The lab, which was constructed
in the early 1950s, is currently be-
ing refurbished and an advanced
POWER AND MOBILITY
laboratory will be part of the
Ground Systems Power and En-
ergy Laboratory, which is expect-
ed to be completed by September
2011. “Our systems have gotten
so much larger over time, so we’re
really pushing the envelope, espe-
cially as the power requirements
increase on the vehicles,” Richard
remarked. “In the new lab, we’re
adding the capabilities of being
able to test charge air coolers and
oil coolers, whether they’re air-to-
air or air-to-coolant. Right now
we can’t test that here — we have
to go to an outside partner. And
for the filtration lab, we’ll have
the capability to test M1 air clean-
ers or larger.”
The new lab will provide re-
searchers with the capability
to test larger, more powerful
vehicle systems as they are
developed. “Right now we can’t
test Palletized Load Systems and
larger vehicle air cleaners. We
don’t have the capability to test
them, so we end up having to go
to outside partners. The new lab
is going to be able to test any air
cleaner within the Army system,”
Richard revealed. “It’s going to
increase our capabilities so that
we can do this work in-house.
On the calorimeter, we’ll be able
to stack our heat exchangers
and test them simultaneously as
they’re configured in the ve-
hicle. That’s something we can’t
do now — I don’t know if it’s
something anybody can do at
this time.”
S p ecia l 2010 E d it io n
Dynamometer Labs
Although Test Cell 9 is the Army’s
largest indoor test laboratory,
several other TARDEC labs are
able to replicate conditions in the
field and their effects on engines
67
 and vehicle systems. The Vehicle
Transmission and Drive Axle
Evaluation Test Cell and Labo-
ratory, for instance, is capable
of conducting critical engine,
transmission, driveline or total
propulsion system performance
and evaluation testing at the
vehicle or component level.
The facility’s dynamometers
have the capability to absorb
output torque up to 44,000 foot
pounds (ft-lb) per side and
68,000 ft-lb at stall and accom-
modate a broad range of ve-
hicle platforms from light-duty
High Mobility Multi Purposed
Wheeled Vehicles (HMMWVs)
to Main Battle Tank applica-
tions and the Bradley Fighting
Vehicle System.
“This dynamometer allows us to do transient testing,
so we can simulate a vehicle’s mission profile.”
The cell also provides the capability
to replicate desert temperatures
and winds. Tandem dynamometers
allow for testing tank transmissions
and rear axles, and the cell’s size
makes it possible to test engines
for various systems and can ac-
commodate other vehicle systems
for full-system testing should the
need arise, although the cell ac-
commodates smaller vehicles than
the Full Load Cooling Test Cell.
The nearby Power and Inertia
Simulator Test Cell and Labora-
tory houses a $20 million direct
current (DC) dynamometer
arrangement. The DC dyna-
mometer is capable of simulat-
ing steering maneuvers, steady-
state operation and transient
operation at the vehicle level for
S peci a l 2010 E d it io n
up to a 40-ton platform or 800
brake horsepower (bhp) under
standard and elevated tempera-
ture conditions. “This dyna-
mometer allows us to do tran-
sient testing, so we can simulate
68
a vehicle’s mission profile,”
Reid stated. “In most of our test
cells, the type of dynamometers
we have are used to do steady-
state or slow transience. The
DC motor allows us to do that
transient testing. It’s a benefit to
our program managers because
we’re able to evaluate different
mission profiles to evaluate dif-
ferent hardware.”
The GVPM team’s six dyna-
mometer labs allow researchers
to conduct performance, endur-
ance, qualification and accep-
tance testing on a variety of
engine and transmission config-
urations. Each cell features por-
table dynamometers capable of
testing engines from 100–3,000
bhp, and researchers can con-
trol the labs’ temperatures and
the flow rates of fuels, coolants
and engine oils. The cells are
used to evaluate engine technol-
ogy and conduct research and
design programs. The GVPM
Test Team also conducts 400-
hour NATO durability tests,
considered to be the minimum
qualifier of any engine that goes
into a NATO country’s vehicles.
A Soldier training as a gunner enters an up-armored M1114-
HMMWV during lane training for duty in Iraq. TARDEC’s
mobility laboratories ensure vehicles operate properly in
harsh environments. (U.S. Army photo by 1LT Ryan Pace.)
A Soldier in a BFV identifies potential
threats during a training session. The
GVPM team’s six dynamometer labs al-
low researchers to conduct performance,
endurance, qualification and acceptance
testing on a variety of engine and trans-
mission configurations. (U.S. Army photo
by PFC Rebekah Lampman.)
Preparing for the Field
Rigorous testing is essential to
ensuring that vehicles will oper-
ate optimally in the field. Many
Army ground vehicles use com-
mercially available engines, which
are developed to operate at North
American conditions on diesel
fuel. However, military vehicles
must be able to operate at condi-
tions that are often considered
far from optimal. “The military’s
environment is more severe, and
our primary fuel is jet propellant
8 (JP-8), which is harsher and has
some detrimental effects to en-
gines,” Reid revealed. “One of our
benefits is that we’re testing these
engines on the 400-hour NATO
cycle, which we make more severe
by running at desert operating
conditions on JP-8 fuel. We’ve
 Other than the dirt, grit and dust generated in operational field environments, TARDEC labs
can simulate desert operating conditions for testing at maximum loads and accommodate
vehicles up to and including the M1 Abrams Main Battle Tank. Here, an M1A2 Abrams fires its
main gun during a live-fire exercise. (U.S. Army photo by SPC John Crosby.)
uncovered several fuel-related
issues, such as fuel pumps and in-
jectors that aren’t really compat-
ible with JP-8 fuel. We’re uncover-
ing those issues and working with
the manufacturers and suppliers
to help resolve them.”
The GVPM Test Team coordinates
with other teams throughout
TARDEC to assist with compo-
nent- and system-level testing.
The cells’ large dimensions make
them easy to modify and adjust to
various testing, including evaluat-
ing alternative fuels, batteries and
fuel cells. The GVPM test team
also works with several indus-
try partners to optimize engine
systems and components. “We
work as a team,” Reid emphasized.
“We work together running
these tests, and then we
provide them with real-time
data that they can feed into
their programs to help develop
and mature technology before
it gets to the Soldier.”
“We work together running these
tests, and then we provide them
with real-time data that they can
feed into their programs to help
develop and mature technology
before it gets to the Soldier.”
The various cells allow for
components and systems to
be thoroughly evaluated and
improved before they are inte-
grated into vehicle platforms.
This capability allows TARDEC
researchers the opportunity to
understand how the environ-
ment impacts the vehicle’s oper-
ating capability and also provides
cost savings. “The laboratory is a
controlled and easily replicated
environment,” Reid explained. “If
you’re testing it as a full vehicle
on a proving ground, there are
a lot of other factors that play
into what the test results might
be, but we’re able to isolate on a
particular component or tech-
nology and evaluate it. By having
the full vehicle test cell, we can
also replicate it in a full vehicle
system. If you’re testing a tank
system engine improvement, it’s
a lot easier to run that in a test
cell as opposed to buying a tank,
POWER AND MOBILITY
integrating the component into
it and then running that whole
system, where other subsystems
could fail while you’re doing
that,” Reid concluded.
TARDEC engineers, technicians
and scientists continue to develop
breakthrough technologies that,
ultimately, give Soldiers unmatched
capabilities on the battlefield.
Thanks to the operation and
test environments replicated in
TARDEC’s test chambers and
labs, TARDEC associates continue
to evaluate and analyze vehicle
systems and subsystem compo-
nents to ensure vehicles reach
their breakpoints in a laboratory
setting and not on the battlefield.
Chris Williams is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic
Communications team. He has a
S p ecia l 2010 E d it io n
B.A. in communication from Wayne
State University in Detroit and has
previously written for The Source
newspaper in Shelby Township, MI,
and The Macomb Daily and C & G
Newspapers in Macomb County, MI.
69
 TARDEC Engineer Jonathan Aboona walks guests through
TARDEC’s PIF during a visit on Sept. 14, 2009. TARDEC PIF
facilities, such as the Design and Rapid Prototyping Center, are
revolutionizing ground vehicles in a time of constant adaptation
and change. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

Advancing Ground
Vehicle Research and
Development
Michael D. Kaplun

S
upporting current and future ground vehicle research and development (R&D)
initiatives is the U.S. Army Tank Automotive Research, Development and
Engineering Center (TARDEC) Prototype Integration Facility’s (PIF’s) mission.
The PIF, comprising more than 100 engineers, technicians and support staff,
develops system and subsystem designs and fabricates and integrates advanced
technologies on current and future ground vehicle prototype systems, while
S peci a l 2010 E d it io n

also providing vehicle life cycle support. Since 2003, the PIF’s major focus has been
to react and support rapid and urgent in-theater requirements. However, the PIF’s
design and manufacturing engineers also undertake complex technology demon-
stration and integration projects that support advanced technology objectives and
program manager vehicle system enhancements.
70
The PIF provides an experienced
staff of engineers and technicians
who leverage years of expertise
spread throughout diverse tactical
and combat vehicle systems. Me-
chanical, electrical/electronics and
system design teams have more
than 46 design engineers who pro-
vide timely, cost-effective design,
engineering and digital mock-up
support, while also creating 3-
dimensional interactive, realistic,
real-time computer-generated
environments and models. Hard-
ware is manufactured daily by the
PIF’s trained and certified welders,
machinists, material handlers, tes-
ters, vehicle mechanics and other
dedicated technicians. The PIF
also contains extensive, specialized
equipment that supports diverse
components and assemblies devel-
oped by design engineers, includ-
ing laser and water jet cutters,
computer numerical controlled
machines, vertical mills and eight
welding stations.
“The PIF provides an
experienced staff of engineers
and technicians who leverage
years of expertise spread
throughout diverse tactical and
combat vehicle systems.
The PIF’s Electrical/Electronic
Integration Team (EIT) includes
14 experienced design engineers
and technicians with expertise
in circuit board manufacturing
and electronic fabrication. “The
EIT’s expertise in design and
integration has led to extensive
and impressive repeated col-
laboration with several Program
“The EIT’s expertise in design and integration has led to extensive
and impressive repeated collaboration with several PEO Ground
Combat Systems, PEO Combat Support and Combat Service Support,
and Special Operations Command partners.”
Shown here is an MRAP with the TARDEC-developed Overhead Wire Mitigation (OWM) kit, which
protects Soldiers and helps to preserve the local infrastructure. TARDEC developments like the OWM
kit better equip and protect present and future Soldiers. (U.S. Army TARDEC photo.)
Executive Office (PEO) Ground
Combat Systems, PEO Combat
Support and Combat Service
Support, and Special Operations
Command partners,” remarked
TARDEC Acting Associate Di-
rector Luis Hinojosa.
Pictured is an MRAP being serviced in
TARDEC’s PIF. The PIF’s Design and Rapid
Prototyping Center develops system and sub-
system designs and fabricates and integrates
advanced technology in current and future
ground vehicle systems, such as the MRAP.
The center houses a 50-foot high bay with
16-inch reinforced concrete flooring to handle
even the largest Army vehicles and weapon
systems. (U.S. Army TARDEC photo.)
In 2008, the PIF had a central
role in TARDEC, receiving a U.S.
Army Top Ten Greatest Inventions
POWER AND MOBILITY
award for the Mine Resistant
Ambush Protected (MRAP) ve-
hicle Expedient Armor Program
Add-on-Armor Kit. In 2009, the
PIF was instrumental in TAR-
DEC receiving the Department
of the Army Research and Devel-
opment Laboratory of the Year
Award for Collaboration Team
of the Year for the Lightweight
Vehicle Underbody Protection
System in partnering with the
Army Research Laboratory. “Both
awards highlight the facility’s
capabilities — rapid response and
innovative technology develop-
ments that save Soldiers’ lives,”
Hinojosa affirmed.
The PIF revolutionizes ground
vehicle systems in a modernizing
world. The facility’s associates
develop, fabricate and integrate
operational requirements and
specifications to keep the cur-
rent and future vehicle fleets well
equipped for critical missions.
S p ecia l 2010 E d it io n
Michael D. Kaplun is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He holds a B.A. in
English and media and society from
Hobart and William Smith Colleges.
71
FORCE PROJECTION
 Testing Facility Provides Clean
Patrick Pinter
S peci a l 2010 E d it io n

74
Water Solutions for Soldiers

H
aving a clean water source is a necessity, and providing that
necessity in a war zone is often difficult. Supplying Soldiers
with usable water is a problem that is being tackled at the
U.S. Army Tank Automotive Research, Development and
Engineering Center’s (TARDEC’s) Water Treatment Test
Facility at Selfridge Air National Guard Base (SANGB), MI.

TARDEC’s Water Treatment Test Facility at SANGB has the capability to operate small to
full-sized water treatment systems and components. Treatment facility researchers develop the
equipment and capabilities to provide deployed Soldiers with clean water solutions, regardless
of where their missions take them. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

S p ecia l 2010 E d it io n

75
 “The goal is to take Army requirements for the area of water treatment and storage handling systems
and develop materiel solutions for those. We provide engineering support for that purpose.”

A Water Treatment Test Facility engineer records data collected from one of several testing units that are currently housed at the SANGB facility. Current
units include LWPs, TWPS and ROWPUs. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

The Water Treatment Test Facility,
located on Lake Saint Clair, has the
capability to operate small to full-
sized water treatment systems and
components. “The facility, which is
right on the water, is large enough
for us to do all kinds of testing
relating to research, development
and engineering support. We
provide engineering support to
Project Manager Petroleum and
Water Systems,” remarked Bob
Shalewitz, Water Treatment and
Handling Equipment Team. “The
goal is to take Army requirements
for the area of water treatment
and storage handling systems and
develop materiel solutions for those.
We provide engineering support for
S peci a l 2010 E d it io n
even in the winter months while
the rest of the lake is frozen over.
“During the winter months, we
can close the roll-up door that goes
over the water and encloses the well.
The room is heated, so this unique
capability allows us to operate all
year long,” explained TARDEC
Project Engineer Andrea Oehus.
“A major benefit at this facility is
our ability to address problems
from the field, test a solution and
send a tested fix to the field, not
“A major benefit at this
facility is our ability to
address problems from the
field, test a solution and send
just send something on paper you
think will work.”
The facility houses several water
purification systems, which
include Lightweight Water
Purifiers (LWPs), Tactical Water
Purification Systems (TWPS)
and Reverse Osmosis Water
Purification Units (ROWPUs).
“At this facility, we perform
research and development on
water purification equipment,”
commented Oehus. “We currently
have all of our production models
that we support here in the
facility. There is at least one of
each model, but for most there
are two or more here.”

that purpose.”
The LWP utilizes ultrafiltration
The building includes a boat well a tested fix to the field, not and reverse osmosis technologies
in a heated room, which allows for just send something on paper to provide 125 gallons per hour
year-round testing. The boat well (GPH) of potable water from
provides a freshwater testing source you think will work.” a freshwater source and 75
76
GPH from a saltwater source.
Its purpose is to provide a safe
water supply to Soldiers on the
battlefield. “The LWP is intended

FORCE PROJECTION
for special operation units that
are away from the main major
water source. Because of its light
weight, the system’s intent is to
go with the first group of
Soldiers in and most far forward
on the battlefield,” commented
Oehus. “It travels on the back of
a High Mobility Multipurpose
Wheeled Vehicle and is portable
by four Soldiers.”

In addition to the LWP,

associates at the Water
Treatment Test Facility have
worked significantly on the
TWPS, which is a 1,500 GPH
drinking water system for
A facility engineer conducts water testing. Most work being done at the Water Treatment Test
Facility relates to developing several water purification systems, including LWPs, TWPS and
ROWPUs. Ongoing testing looks at everything from chemical processes and desalination to
ultrafiltration and reverse osmosis. (U.S. Army TARDEC photo by Elizabeth Carnegie.)

division and brigade units in

remote areas. The system also
has been used for disaster relief
operations, humanitarian efforts
and peacekeeping missions.
“A couple of things that we focus on here are preplanned product
improvements. We look at new components, more effective ways of
running the systems and new technologies.”

The units housed at the facility
can be used as test beds for
evaluating the performance of
commercially available and ex-
perimental components for their
usefulness on military water
treatment equipment, and
also can be used to train water
treatment system operators on
military and commercial water
treatment systems. “A couple of
things that we focus on here are
preplanned product improve-
ments. We look at new compo-
nents, more effective ways of
running the systems and new
technologies. We can do anything
from the component scale all the
way to full-system testing here
at the facility,” remarked Oehus.
“We also share equipment with
the U.S. Army TACOM Life Cycle
Management Command New
Equipment Training team. It is a
win-win for everybody having
everything located here at SANGB.”
S p ecia l 2010 E d it io n

Patrick Pinter is a Writer/Editor with

BRTRC and provides contract support
to TARDEC’s Strategic Communica-
tions team. He has a B.A. in journalism
TARDEC’s Water Treatment Test Facility runs off in-house power but also has several and political science from Western
generators on-site, which are used for different types of testing. (U.S. Army TARDEC photo Michigan University.
by Patrick Pinter.) 77
 Keeping Warfighters Well-Hydrated —
SDTF Delivers Optimal
Water Purification Systems
Matthew Sablan

T
he Port Hueneme, CA, Seawater Desalination Test Facility
(SDTF) is located at the entrance to Naval Base Ventura
County’s harbor. It houses state-of-the-art equipment for
executing tests and research otherwise unavailable to the
U.S. Army Tank Automotive Research, Development and
Engineering Center (TARDEC).

From left: U.S. Marine Corps (USMC) SGT
Julian Munoz instructs PFC Alejandro
Camargo and LCPL Jeremy A. Doty on using
an Reverse Osmosis Water Purification Unit
(ROWPU). The ROWPU can filter every-
thing from saltwater to nuclear, biological
and chemical-infected water to produce con-
S peci a l 2010 E d it io n
Storage tanks are connected to a water-
dispensing unit at the Joint Security Station
Shawra Wa Um Jidir water distribution site in
Iraq. The line that pumps the raw water runs
from a well-water bag to a ROWPU that puri-
fies water for distribution. The ROWPU is one
of the many pieces of equipment TARDEC
Four freshwater pumps are used to draw water
from the Euphrates River to supply ROWPUs
operated by Marines at a Tactical Water Dis-
tribution System (TWDS) during Operation
Iraqi Freedom (OIF). TARDEC and NAVFAC
also test water packaging and water distribu-
tion systems for the Army and Marines.

sumable water for ground forces. (USMC and NAVFAC have partnered to test. (U.S. (USMC photo by MSG Edward D. Kniery.)
photo by Leigh Campbell.) Army photo by SSG Matthew Meadows.)

78
Establishment and Partnership
The SDTF was first established in
1983 at the Naval Civil Engineer-
ing Laboratory. In 2000, TARDEC
entered into an agreement with
the Naval Facilities Engineer-
ing Command (NAVFAC) and
Engineering Services Center (ESC)
to station two engineers at Port
Hueneme. These engineers sup-
port the SDTF’s unique operations
and bring the facility’s capabilities
to TARDEC. “The SDTF conducts
research, development, testing and
evaluation of water purification
systems,” TARDEC Engineer Jere-
my Walker explained. “The SDTF’s
primary purpose is to conduct
research, development, test and
evaluation of water purification
systems and ancillary equipment
with particular interest in opera-
tions on seawater.”
Tests allow the Navy and TARDEC
to address any problems with
equipment before delivery to
warfighters. This allows engineers
to develop solutions before these
problems are encountered in the
field. The facility also conducts
pilot and demonstration studies
on water purification technolo-
gies for potential future military
systems. The SDTF has supported
various private sector companies,
the Bureau of Reclamation and
the U.S. Army, U.S. Navy and U.S.
Marine Corps (USMC).
Water Purification Systems
The SDTF tested and developed
Army and USMC field water pu-
rification equipment, and NAV-
FAC partnered with TARDEC to
develop, test and evaluate
water purification technology.
Some equipment this partner-
ship has been involved in pro-
ducing includes:
• Tactical Water Purification
System, used by the Army
and USMC.
• Lightweight Water Purifier, used
by the Army and USMC.
• Water packaging, used by the
Army and USMC.
• Maintenance, training and tech-
nical support for the 600 gal-
lons per hour (GPH) and 3,000
GPH Reverse Osmosis Water
Purification Unit (ROWPU).
• 45–90 day shipboard Reverse
Osmosis certifications for SSN-
688- and LPD-17-class vessels.
Water is processed prior to testing,
and the facility can process one
million gallons of seawater a day.
The equipment the SDTF offers
includes water purification sys-
tems with incandescent and laser
turbidimeters, particle size analyz-
ers, silt density index meters and
fluorescence meters to measure the
seawater’s fouling potential.
The SDTF is also available for
certain commercial test and
evaluation entities. If you have
any questions or would like more
information about the SDTF or
NAVFAC ESC, please contact the
NAVFAC ESC Public Affairs Of-
fice at (805) 982-1069.
Matthew Sablan is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He has a B.A. in
English and history from Marymount
University in Arlington, VA.
A Marine operates a ROWPU for
the TWDS, which contains three
50,000-gallon collapsible water
tanks, during OIF. TARDEC and
NAVFAC collaborate on main-
tenance, training and technical
support for all fielded Army and
USMC ROWPUs. (USMC photo
by MSG Edward D. Kniery.)
S p ecia l 2010 E d it io n
79
 TARDEC Leads Fuel and
Lubricant Technology
Development and Design
Patrick Pinter
S peci a l 2010 E d it io n

80
W
hen we think about protecting Soldiers and their vehicles
on the battlefield, often the first thing we think about is
integrating armor or adding weapons. Sometimes it is
not about adding power or protection to the vehicle, but
making sure the engine runs properly or at an optimal level
to handle the current operational environment and terrain.

S p ecia l 2010 E d it io n

The Grease and Fluid Lab’s mission is to make sure that the
proper fluids make ground vehicles run smoothly in diverse
operating environments and weather conditions. (U.S. Army
TARDEC photos by Elizabeth Carnegie.)

81
 “It’s important to remember that A TARDEC scientist performs testing
analysis in the Grease and Fluid Lab.
fuels and lubricants are an integral
part of the equipment.”

Without research and develop-

ment (R&D) in the areas of fuels
and lubricants, air and ground
equipment would not be able
to operate reliably at the level
Soldiers demand and require on
the battlefield. One of the U.S.
Army Tank Automotive Research,
Development and Engineering
Center’s (TARDEC’s) goals is to
be the Department of Defense’s
(DOD’s) leader for fuel and
lubricant technologies for ground
equipment systems. That goal is
ambitious, but the work being
done at TARDEC-managed labs
is helping to achieve new levels of
product excellence and efficiency.
“In a true systems-of-systems
engineering approach, we have
to consider everything, including
fuels and lubricants,” remarked
Luis Villahermosa, Fuels and Lu-
bricants Technology Team (FLTT)
Leader. “We have unique require-
ments we are working with. It’s
important to remember that fuels
and lubricants are an integral part
of the equipment.”
When it comes to fuel and lubri-
cant technologies, TARDEC is
responsible for R&D; specification
development; product qualifica-
tion; general petroleum, oil and
lubricants (POL) standardiza-
tion; testing support for other
TARDEC organizations; and fluid
filtration assessment. This is in
support of the mission responsi-
bility assigned to TARDEC under
Army Regulation 70-12, Fuels and
S peci a l 2010 E d it io n
Fuels and Lubricants Vehicle lubricants (e.g., engine oils, gear
Filter Test Equipment lubricants and transmission fluids)
This test equipment is capable of to enable introduction of new
evaluating vehicles’ fuel and lubri- technologies and development of
cant filters using the latest Interna- new performance standards. In ad-
tional Organization for Standard- dition, FLTT team members also
ization (ISO) test procedures. The conduct assessment of environ-
equipment allows evaluation of mental compliance and develop
expected life, efficiency and other environmentally friendly products.
parameters needed to establish fil-
ter performance for vehicles. “The Grease and Fluid Laboratory
filter test rig is intended to assess Here, tasks are performed in
the filter’s performance. A fuel or developing, evaluating and re-
lubricant filter is hooked up to the searching hydraulic fluids, semi-
test rig to find its capacity to re- solid lubricants, solid lubricants,
move particles, the size of particles greases, antifreeze and solvents to
removed, how long it will last and enable introduction of new tech-
how many particles it can retain,” nologies and development of new
commented Villahermosa. “The performance standards. FLTT
test tool was used in the evaluation team members also use this lab to
of the cleanable filter system that assess environmental compliance
the Stryker vehicle started with and develop environmentally
and was found to be inadequate.” friendly products. “In the labora-
“We have a long history working with alternative fuels,
specifically with analysis, testing and evaluation, which
continues today with the laboratory and technical expertise
provided to TARDEC’s NAC Alternative Fuels Team.”

Lubricants Standardization Policy
for Equipment Design, Operation
and Logistic Support. TARDEC
accomplishes this with its state-
of-the-art POL testing equipment
and facilities.
82
Fuels and Powertrain
Lubricants Laboratory
In this laboratory, tests are per-
formed for developing, evaluating,
qualifying and researching fuels,
alternative fuels and powertrain
tory, we have a wide variety of
chemical and physical property
testers,” stated Villahermosa.
“One example is the environ-
mental chamber. We can put
samples of products and materials
in it and test them at different
temperatures or humidity.”
Developing Solutions that
Improve Efficiency
With these labs and test tools,
TARDEC is able to develop fuel
and lubricant solutions for DOD.
These developments help maxi-
mize equipment efficiency and
reliability, promote fuel source
diversity and reduce costs and
maintenance over a vehicle’s life
cycle. In the end, these solutions
help minimize maintenance and
logistics burdens. “With the
experience here in the lab, techni-
cians and scientists are able to
make sure the equipment does
what it is supposed to do,” Vil-
lahermosa explained. “Through
testing here, we are able to pro-
vide equipment validation.”
“The NAC and FLTT have a truly
symbiotic relationship on the
alternative fuels effort.”
The work TARDEC does in its
labs is on the following types of
fuels and lubricants:
• Traditional fuels (e.g., diesel, jet
propellant 8, etc.)
• Multipurpose engine oils
• Gear lubricants and greases
• Hydraulic fluids
• Preservative engine oils
• General purpose preservatives
and lubricants
Part of TARDEC’s mission in
fuels and lubricants is to mini-
mize the number of products
needed to support a vehicle or
equipment system and standard-
ize those that remain. For this
reason, lubricant products are
designed and developed so they
can be utilized in as many com-
ponents as possible. Take military
engine oils as an example. They
have additional requirements to
operate in military transmissions
and also are capable of being
used in hydraulic systems. Using
one product in three components
reduces the number of products
needed for maintenance, reduces
misapplications and waste, and
simplifies training.
Scientists collect information in TARDEC’s
Grease and Fluid Lab. Various types of testing
takes place in these labs, including research,
analysis and testing of biodegradable fuels and
lubricants, fluid filtration, brake fluids, coolants
and antifreeze.
At the TARDEC laboratories,
extensive work also is being done
with alternative
fuels. “There is TARDEC scientists discuss test results in the Grease and Fluid Lab. The
equipment housed within the lab is capable of evaluating vehicles’ fuel
always something and lubricant filters using the latest ISO test procedures and standards.
going on in the
lab. We have test-
ing going on regu-
larly,” remarked
Villahermosa. “We
provide a lot of
support in engine
testing and fuel
testing. In addi-
tion, we are deeply
involved with alternative fuels. We
have a long history working with
alternative fuels, specifically with
analysis, testing and evaluation,
which continues today with the
laboratory and technical expertise
provided to TARDEC's National
Automotive Center (NAC) Alter-
native Fuels Team and the overall
Army Alternative Fuels Certifica-
tion effort. The NAC and FLTT
have a truly symbiotic relationship
on the alternative fuels effort.”
TARDEC also does significant
testing and research in other
areas, such as biodegradable
greases and hydraulic fluids, fluid
filtration, brake fluids, coolants
and antifreeze. “Here in the labs,
FORCE PROJECTION
we have the capabilities to test
products’ biodegradation,” com-
mented Villahermosa. “We try to
do environmental programs as
much as we can, while keeping in
mind that the mission comes first.
Durability and performance is the
prime focus, and we do our best
from there.”
Without the work being done in
the areas of fuels and lubricants,
engines and vehicles would not
be able to run properly. Research,
development and design in
these areas are critical parts of
the vehicle design process. “The
one thing people don’t realize
is that fuels and lubricants are a
fairly neglected technology area,”
remarked Villahermosa. “They are
not always acknowledged during
the primary design of equipment,
even though it is an integral
part of the process.” And that is
where the FLTT makes its greatest
contributions to ground vehicle
systems fleet management.
S p ecia l 2010 E d it io n
Patrick Pinter is a Writer/Editor with
BRTRC and provides contract support
to TARDEC’s Strategic Communica-
tions team. He has a B.A. in journalism
and political science from Western
Michigan University.
83
GROUND SYSTEMS SURVIVABILITY
 Lab Puts Armor Under the
Gun to Save Soldiers’ Lives
Chris Williams

PVT Alfred Dorsey cleans the window of a Mine Resistant Ambush Protected (MRAP) vehicle door
at Camp Taji, Iraq, prior to a route clearance mission, while SGT Ryan Bednarski loads a .50-caliber
machine gun. Ballistics testing done in the SABL is conducted at temperatures similar to those
S peci a l 2010 E d it io n

experienced in Iraq to ensure armor safety in hot climates. (U.S. Army photo by SGT Doug Roles.)

86
S
ometimes a sheet of glass
is all that separates a Soldier
from harm. Transparent
armor (TA) is a crucial
component in many of
the U.S. Army’s ground
vehicles, allowing Soldiers to
keep a watchful eye on their sur-
roundings while protecting them
from attack. Should Soldiers find
themselves caught in an ambush,
bullet-resistant windows can
withstand several hits, provid-
ing Soldiers with critical time to
escape or respond.
The U.S. Army Tank Automo-
tive Research, Development and
Engineering Center’s (TARDEC’s)
Ground Systems Survivability
(GSS) Survivability Armor Bal-
listics Laboratory (SABL) plays a
key systems engineering, integra-
tion and collaborative role in
the process of equipping ground
vehicles with effective TA protec-
tion. The SABL’s primary mission
is to conduct ballistic testing on
transparent and opaque armor
materials, which is required
before they are integrated onto
vehicle platforms. “The Army
Research Laboratory’s [ARL’s]
primary mission is materiel
development; the Army Test and
Evaluation Command [ATEC]
conducts testing on the entire
vehicle during system testing,”
explained SABL Range Man-
ager Steve Hoffman. “We fit in
between such that when a spe-
cific material or particular armor
recipe is proposed for system
integration, the SABL conducts
the testing that qualifies whether
the proposed TA solution satisfies
the threat levels defined for the
specific vehicle platform.”
Custom Testing
SABL engineers and technicians
constantly strive to better under-
stand what parameters must be
tweaked to repeatedly replicate
a projectile strike on armor that
consistently simulates a specific
threat in a lab environment. To
accomplish this, each round is
tailor-made by selecting the pro-
jectile and hand measuring the
propellant to achieve the required
test goals for threat, caliber and
velocity. “We can simulate a
100-yard standoff or a 200-yard
standoff just by changing the ve-
locity at which the projectile hits
the target,” stated Hoffman. “To
do that, each round is disassem-
bled, and the propellant charge
is adjusted and reassembled to
obtain the velocities we’re look-
ing for at impact.”
“The SABL's primary
mission is to conduct
ballistic testing on
transparent and opaque
armor materials...“
“Some of the projectiles are
non-standard — they’re not
what you would see elsewhere,”
commented Hoffman. “We can
simulate pretty much any stan-
dard, military-type, small-arms
threat. There are different ways
of shooting it. It’s all just a means
to get the projectile down range,
which is our primary function —
to get the projectile into a target
at a controlled velocity.” Another
projectile used by the SABL is the
Fragment Simulator Projectile
(FSP), which replicates materials
present in improvised explosive
devices (IEDs). The impact that
an actual IED fragment may
have on a vehicle varies based on
speed and orientation of impact,
so FSPs were designed to corre-
spond with a chart showing what
percentage of IED fragments
each FSP corresponds to. The
FSP is a U.S. and NATO standard
test projectile used by other Army
laboratories, providing a consis-
tent means of data comparison.
The Big Bang
GROUND SYSTEMS SURVIVABILITY
Once the projectiles are ready
for firing, they are taken to the
launcher. Projectiles are shot from
a customized launcher that allows
engineers to fire rounds electroni-
cally from a secure control room,
reducing risk to the test team and
providing them with a location to
study impact effects. Firing posi-
tions are precisely aligned by laser,
allowing accurate aim for each
test. “We’ll take a few shots to
make sure we have our velocities
and everything where we need
it. We’ll adjust the laser, move
the target and use the laser as an
aim point designator,” explained
David Sass, a Senior Electrical
Engineer. “It’s the best thing we’ve
found. Otherwise, you basically
just look down the barrel and try
to line it up. It’s a lot faster with
the laser.”
The SABL initiated the develop-
ment and controls the distribu-
tion of the Armor Tech Product
Description (ATPD 2352), which
has gained widespread Army use
on TA testing since its first release
on Jan. 3, 2008. ATPD 2352 defines
a standardized 4-shot pattern,
which was characterized by work
done in conjunction with the
NATO STANAG 4569 “Protec-
tion Levels for Armored Vehicles”
group. This pattern is now used
The impact that an actual IED
fragment may have on a vehicle
varies based on speed and
orientation of impact, so FSPs
were designed to correspond
S p ecia l 2010 E d it io n
with a chart showing what
percentage of IED fragments
each FSP corresponds to.
87
 throughout the Army to provide
consistent criteria in the evalua-
tion of multiple impacts on TA
armor. “Glass isn’t bulletproof, it’s
resistant,” commented Hoffman.
“What it does is buy the people
inside the vehicle time to react or
leave the area. That’s the reason
for a multi-hit pattern — how
many seconds of time under at-
tack can we buy those people?”
Projectiles are fired at the armor
samples, called coupons, which
are placed in the impact cham-
ber. Each coupon is tested at
high, low and ambient tempera-
tures to gain an understanding
of the material’s performance in
various environments. Test teams
have 25 minutes to fire four
rounds into the target before the
temperature begins to change.
The qualification testing
for transparent armor looks
for one important piece of
information: will the impact
cause harm to Soldiers?
they’re looking for might be
separation in the plies. They may
be looking for patterns that are
different, a bulge in the back,” re-
marked Sass. “They’re looking for
anomalies. When we worked with
ceramic opaque armor, some of
the visuals were different than
we’re used to seeing. We make
it a point to always coordinate
with the TA developers when
we see results that are different
than what we are used to seeing.
We do this mostly when we’re
doing research. When we’re doing
qualification testing, it’s a simple
pass or fail.”
The qualification testing for
transparent armor looks for one
important piece of information:
will the impact cause harm to
Soldiers? Each coupon has a wit-
ness plate placed behind it. If the
projectile or any debris perforates
tghe witness material, the armor
coupon has failed the qualifica-
tion testing.

“Glass isn’t bulletproof,

it’s resistant.”
“The armor responds very differ-
ently to different temperatures,”
Sass explained. “Right now we
are deployed in regions that are
subject to both hot and cold
weather extremes. That is why we
have a hot and cold test require-
ment — because we don’t have
a single vehicle that operates in
only one climate.”

Evaluation
A number of different tools are
available to the SABL team to
understand what occurs during
impact. High-speed video equip-
ment provides a detailed look at
the event, and computers record
the velocity, temperature, humidity
and other environmental factors
that may skew the test results. A
S peci a l 2010 E d it io n

test engineer is always on hand to

provide a visual assessment of the
test results, i.e., studying the armor
for fracture patterns, character- U.S. Air Force Special Agent Nate Notargiacomo, Office of Special Investigations, Kandahar
izing bumps, holes and collecting Airfield, Afghanistan, conducts rear security from an MRAP. Testing done in TARDEC’s SABL
debris for further analysis. “What ensures that the ballistic glass windows provide adequate protection from ambush and attacks.
(U.S. Army photo by SSG James L. Harper Jr.)
88
 It’s this mission —
TARDEC SABL Engineer Scott Wiseman
examines an armor coupon after testing saving warfighters’
in the SABL. (U.S. Army TARDEC photo
by Ted Beaupre.) lives — that is the most

GROUND SYSTEMS SURVIVABILITY

fulfilling part of the
SABL’s work.

The SABL team has worked

and is working with program
managers for nearly every Army
ground vehicle system fielded
today in the qualification and
acceptance of TA armor. The
SABL is also working closely
with research teams throughout
TARDEC in developing and
integrating new and improved
opaque and TA into vehicle
platforms. As a part of the
Army test community, the SABL
lab has an open communication
and collaboration policy with
ARL, ATEC and other Army
laboratories to share data in an
effort to improve the material
that shields Soldiers from harm
in the field. It’s this mission —
saving warfighters’ lives — that
is the most fulfilling part of the
SABL’s work. “One of the things
I’m most proud of is that one
customer we did testing for
came back a few months later
and said the work that we did
saved some lives,” remarked Sass.
“I like direct feedback like that.”

Chris Williams is a Writer/Editor

with BRTRC and provides contract
support to TARDEC’s Strategic
Communications team. He has a
S p ecia l 2010 E d it io n

B.A. in communication from Wayne

State University in Detroit, MI, and
has previously written for The Source
newspaper in Shelby Township, MI,
TARDEC Engineer Terry Avery customizes a launch package for firing prior to testing. The and The Macomb Daily and C & G
SABL customizes each package fired to adjust for desired velocity, allowing for customized and Newspapers in Macomb County, MI.
consistent results. (U.S. Army TARDEC photo by Ted Beaupre.) 89
 Innovative Materials Bridge
Partnership Between TARDEC
and Lawrence Tech
Matthew Sablan

T
he Army’s vehicles endure harsh environments in the field
every day. In Afghanistan, for instance, extreme heat and
cold are both possible, and the country has some of the driest
regions in the world, not to mention some of the most rugged
mountainous terrain in the region. Continued operations in this
environment stress material and systems components, and the
U.S. Army Tank Automotive Research, Development and Engineering
Center (TARDEC) continues to find ways to ensure that the Army’s
vehicles withstand these diverse elements. As part of TARDEC’s
ongoing research and development (R&D) initiatives, it entered into a
partnership with Lawrence Technological University in October 2008
to develop, install and operate an environmental/loading chamber.
This chamber is part of Lawrence Tech’s Center for Innovative
Materials Research (CIMR), and its scientists and engineers assist
TARDEC with environmental testing of advanced materials for vehicle
armor and structural components.

A gunner checks his weapon while working through a sandstorm near Camp Victory, Iraq. The
harsh conditions in Iraq and Afghanistan can be recreated at CIMR to allow TARDEC to test
vehicles and components to ensure they will withstand the elements in the theater of operations.
(Multi-National Corps Iraq Public Affairs photo.)
S peci a l 2010 E d it io n

90
Establishing the CIMR
With dedication of the CIMR
building in early 2008, the Army
has been able to capitalize on
Lawrence Tech’s groundbreaking
research and testing in the areas of
infrastructure, military fabrics and
other sustainable materials.
“Lawrence Tech has built expertise
for a number of years,” declared
Dr. Nabil Grace, Lawrence Tech
Professor of Civil Engineering and
CIMR Director. “We have a good
track record with simulation and
new materials.”
For TARDEC, the CIMR is helping
to create vehicle armor that weighs
less than 100 pounds per square
foot. “We plan to use the CIMR to
look at new materials that can be
incorporated into Army vehicles’
S p ecia l 2010 E d it io n
armor and structures,” TARDEC
Engineer Scott Hodges commented.
Research Capabilities
The CIMR has a broad range
91

Lawrence Tech’s Dr. Nabil Grace stands in front of the environmental chamber at Lawrence Tech's
CIMR. The environmental chamber became operational in December 2009 and will be able to test
vehicle components in various conditions, furthering TARDEC’s, ARL's and Lawrence Tech’s R&D
initiatives. (Photo courtesy of Lawrence Tech.)
of capabilities, so its research
covers a wide range of topics.
Built to military standards, the
CIMR’s fire/loading chamber can
test objects up to 22 feet long,
including military vehicles such as
the High Mobility Multipurpose
Wheeled Vehicle. The facility also
is able to test impacts up to
one million pounds of
force in static, repeating or
impact measurements.
The facility is equipped with
hydraulic pressure pumps capable
of 160 gallons a minute and can
produce flames and other effects.
The fire/loading chamber can
become hot enough to simulate
the effects of Sept. 11, 2001,
with temperatures up to 2,300
degrees Fahrenheit. The weather
S peci a l 2010 E d it io n
simulations can mimic up to
40 mile per hour winds, rains
“We plan to use the CIMR to look at new materials. These materials
can be incorporated into Army vehicles’ armor and structures.”
92
and 100-percent humidity. The
environmental loading chamber
is built to Military 310 Global
Climatic Data for Developing
Military Product standards.
No other facility in the United
States can provide full-scale
environmental testing such
as the CIMR.
The CIMR’s environmental
chamber measures 3,600 cubic
feet — approximately 12’ wide x
21’ 6” deep x 14’ high — and is
built from insulated blocks. The
floor can withstand 150 pounds
per square inch in a cyclic load
condition while undergoing
temperature transitions from
-85 degrees to 185 degrees
Fahrenheit. The chamber has a
liquid temperature conditioning
system that allows the chamber to
prepare for American Society for
Testing and Materials freeze/thaw
testing and rain preconditioning.
After explaining these capabilities,
Grace noted, “The CIMR is a
comprehensive test facility.”
TARDEC Engineer Donald
Ostberg explained that the CIMR
also would assist TARDEC in
researching armor components.
TARDEC has Lawrence Tech
test for specific properties and
materials. “The work done at
Lawrence Tech will let us model
the materials more appropriately,”
Ostberg remarked. “TARDEC lets
them know, for example, what
temperature range to test at. We
help them make sure they’re not
going in the wrong direction.”
“Lawrence Tech has built
expertise for a number of years.
We have a good track record
with simulation and
new materials.”
The facility’s tests will allow
engineers to design vehicles that
are safer and capable of saving
more lives. These capabilities
also will allow TARDEC to
reduce life cycle costs, since more
tests can be performed in the
same area, reducing travel and
scheduling challenges.
Ongoing Technology
Development
“Lawrence Tech has conducted
significant work,” Grace
stated. “Several graduate and
undergraduate students are
working around the clock.” On
top of student work, professors
and other engineers have access to
the facility. The Federal Highway
Commission, National Science
Foundation and Michigan
Department of Transportation
have successfully engaged in
research with Lawrence Tech.
 GROUND SYSTEMS SURVIVABILITY
Lawrence Tech’s CIMR is capable of various military scale tests. Here, a line of burners are active. These burners can reach temperatures up to 2,300
degrees Fahrenheit and will be used to test a vehicle’s heat thresholds and tolerances. (Photo courtesy of Lawrence Tech.)

Additionally, some of the research A new environmental chamber to real-world engineering

conducted at the CIMR is being
looked at internationally. Ostberg
also cited the work Lawrence
Tech finished with ductile hybrid
fabrics, a hybrid between glass
and graphite fibers. Furthermore,
Lawrence Tech created a grid
system for use with the Army’s
ceramic armor tiles.
became fully operational in
December 2009, and provided
the CIMR even more capabilities.
“This is a unique facility — we can
provide any test and evaluation
required,” Grace continued. “Our
students benefit from this as well,
as Lawrence Tech produces well-
rounded engineers with exposure
problems and solutions.”
The new environmental chamber
will allow vehicle armor to
undergo full- and partial-scale
vehicle and composite armor
testing. The facility’s capabilities
will allow the armor to be tested
under salt spray, humidity,
solar and ultraviolet light along
with freezing and thawing
environments. Vehicles can be
put through their paces, ensuring
their ability to deal with the
harsh climates the Army typically
operates in worldwide. Lawrence
Tech’s CIMR also is investigating
advanced carbon fiber materials
to improve military vehicle and
body armor performance while
also reducing total vehicle and
equipment weight.
S p ecia l 2010 E d it io n

Matthew Sablan is a Writer/Editor

with BRTRC and provides contract
support to TARDEC’s Strategic Com-
The interior of the CIMR after a demonstration. The central surface combustion chamber munications team. He has a B.A. in
can determine if component parts or vehicle systems can withstand the heat up to more than English and history from Marymount
2,000 degrees Fahrenheit and various amounts of force. The beams in the foreground are about
to undergo testing in the CIMR, with the environmental chamber in the background. (Photo University in Arlington, VA.
courtesy of Lawrence Tech.) 93
 Testing Capabilities Help

O
n the battlefield, Soldiers are faced with many explosive threats.
Weapons such as mines or improvised explosive devices (IEDs)
can cause great damage and harm to Soldiers and their vehicles.
Finding a way to mitigate this is a high priority for the U.S. Army
Tank Automotive Research, Development and Engineering Center
(TARDEC) in Warren, MI. Through extensive research and devel-
opment, engineers and scientists are working on methodologies that will
help prevent extensive damage from these heinous explosive weapons.
S peci a l 2010 E d it io n

A High Mobility Multipurpose Wheeled Vehicle (HMMWV) mounted with countermine equipment
plows through a testing course at Yuma Proving Ground (YPG) in Yuma, AZ. Results from these tests
are used by TARDEC researchers to design optimal countermine equipment to help provide Soldiers
with better vehicle protection when driving on potentially mine-strewn battlefields. (U.S. Army photo
courtesy of YPG Public Affairs Office (PAO).)
94
Mitigate Explosive Damage
Surrogate Instrumented Mine
(SIM) Capability
To develop tools that defeat
explosive devices, TARDEC has
the SIM, an engineering tool used
to optimize, verify and character-
ize countermine and IED neu-
tralization equipment. The SIM
system is comprised of specialized
instrumentation devices and soft-
ware. It was developed to evaluate
countermine roller performance
Patrick Pinter
as it relates to mine neutralization
capability. This specialized tool
can be used to conduct anti-tank
mine vehicular overpass analysis
in a dynamic environment.
The SIM, which provides real-world
data not previously available, has
proven to be cost-effective and has
the ability to provide valuable in-
sight into countermine and coun-
ter-IED equipment performance.
“We have a couple of different
versions of the same sensor, and by
sensor I mean look-alike for a land
mine. The imitation mine has mul-
tiple sensors inside that allow us to
tell what is going on with the pres-
S p ecia l 2010 E d it io n
sure plate at any particular moment
in time,” explained Chris Newell,
Countermine Science and Technol-
ogy Lead on TARDEC’s Mechanical
Countermine Team. “We can take
that capability and make it work
95
 An up-armored HMMWV mounted with SPARK rollers fore and aft runs through a testing course littered with
TARDEC-developed SIMs. Information and data gathered from these tests allows engineers and researchers to
develop better blast mitigation tools. (U.S. Army photo courtesy of YPG PAO.)
with a laptop, a wireless repeater
and the mine. We literally have
just three pieces of equipment
we need to send.”
“We don’t have a facility, per
se. We have the sensors, and
wherever we need to take
them, we go with them.”
TARDEC developed the SIM
as an effectiveness evaluation
tool to assist in developing
countermine and counter-IED
neutralization equipment. The
SIM’s mission is to provide
S peci a l 2010 E d it io n
consistent and accurate informa-
tion regarding a targeted threat’s
neutralization. Another objective
for the SIM is to reduce equip-
ment development time and
testing costs.
96
A SIM is an engineering tool to optimize,
verify and characterize countermine
equipment performance. The SIM system is
comprised of specialized instrumentation
devices and software to evaluate countermine
roller performance as it relates to mine
neutralization capability. (U.S. Army photo
courtesy of YPG PAO.)
The SIM contains no explosive
charge so testing can be per-
formed anywhere without explo-
sive ordnance disposal support.
Its purpose is to provide data
regarding how an explosive
hazard would react to the me-
chanical countermine equipment
that it encountered. This data
then provides engineers with
the information they need to
make any necessary changes to
the countermine or IED defeat
equipment so that the desired
result is achieved.
Additionally, the Mechanical
Countermine Team has support
equipment that is often used with
the SIM. The Mobile Data Acqui-
sition trailer is used to support an
isolated test site. “The capability
we have in the trailer is not just a
SIM support trailer. It supports
the entire team function, which
can be strain gauging, instrumen-
tation and acquiring global posi-
tioning data,” commented Newell.
“We have the ability to monitor
testing and some tools in there,
like a drill press, that allow us to The SIM, buried during testing, serves as an effective evaluation tool to assist in developing
do on-the-fly repairs or modifica- countermine equipment. The tool also provides consistent and accurate information
regarding a targeted threat’s neutralization. (U.S. Army photo courtesy of YPG PAO.)
tions during testing.”

GROUND SYSTEMS SURVIVABILITY

Countermine Testing Facility
The Countermine Testing Com-
plex is a dedicated area at Aber-
deen Proving Ground (APG) in
Aberdeen, MD. This testing facil-
ity allows engineers to establish a
countermine system’s capability
to reliably clear a minefield seeded
with pressure-fused, tilt-rod actu-
ated, seismic, magnetic influence
and acoustic mines. The facility
includes mine lanes, a magnetic
countermine test area, static blast
test area, shop and equipment
storage facilities, and fully func-
tional office space to support
testing. “We frequently have the
SIM at APG and YPG. Our sensor
is getting pretty advanced at this
point. We don’t have a facility, per
se. We have the sensors, and wher-
ever we need to take them, we go
with them. This is a wonderful
capability to have,” Newell voiced.
“We have many different
“It is challenging to design equipment to negate a threat like this,
but we are learning more and more about mines, collectively as the
Mechanical Countermine Team and TARDEC.”
organizations we have worked
with in regards to the SIM.
They have used our devices
extensively to characterize per-
formance of equipment that is
going into theater.”
Continuing to Find Solutions
As a result of TARDEC’s SIM ca-
pability, significant advancements
have been made in researching
and developing countermine
and counter-IED neutraliza-
tion equipment, such as the Self
Protection Adaptive Roller Kit
(SPARK). Despite the devel-
opments in countermine and
counter-IED defeat tools,
TARDEC and Product Manager
IED Defeat/Protect Force must
continually evolve because of the
enemy’s ever-changing tactics. “It
is challenging to design equip-
ment to negate a threat like this,
but we are learning more and
more about mines, collectively
as the Mechanical Countermine
Team and TARDEC,” remarked
Newell. “There are a lot of com-
plicated devices out there. We
continue to try to find solutions.
Overall, having these SIMs and
having the ability to take them
to the facility and countermine
equipment manufacturers for
testing has been a major benefit.”
S p ecia l 2010 E d it io n

Patrick Pinter is a Writer/Editor with

BRTRC and provides contract support
to TARDEC’s Strategic Communica-
A Mine Resistant Ambush Protected vehicle equipped with SPARK
rollers is run through countermine testing at YPG. Mines continue tions team. He has a B.A. in journalism
to be the most prevalent battlefield threat in Iraq and Afghanistan. and political science from Western
TARDEC engineers are developing solutions to counter this threat Michigan University.
and save Soldiers’ lives. (U.S. Army TARDEC photo by Scott Merritts.)
97
 Laser Protection Research
and Integration Laboratory
— Protecting Soldiers’ Eyes
and Optical Sensors
Michael D. Kaplun

N
ew cutting-edge tools and instruments are improving Soldier
vision. Through the U.S. Army Tank Automotive Research,
Development and Engineering Center’s (TARDEC’s) Laser
Protection Research and Integration Laboratory, these tech-
nological enhancements protect Soldiers’ eyes and day-vision
cameras used for fire control or antisensor laser weapons. The
laboratory provides Soldiers with equipment to combat laser threats
and other battlefield or environmental hazards.

TARDEC Associate John Vala performs a sensor vulnerability

test with a laser at the Laser Protection Research and Integra-
tion Laboratory. Through enhancements in laser technology,
Soldiers will have better protection against laser threats and
hazards. (U.S. Army TARDEC photo.)
S peci a l 2010 E d it io n

At right, the Omni-Directional Inspection System (ODIS) was originally

developed by TARDEC to help Soldiers screen vehicle undercarriages for
explosive devices, contraband and other suspicious materials at security
checkpoints in Iraq and Afghanistan. ODIS is teleoperated by Soldiers
who remain at safe standoff distances. Laser Protection Research and
Integration Laboratory scientists and engineers continue to overcome
daunting operational challenges to harden and enhance optical vison
and surveillance devices being used by Soldiers in Iraq and Afghanistan.
98 (U.S. Army TARDEC photo by John Vala.)
Soldiers from the 101st Airborne Division (Air Assault) train with
advanced combat training gear, including the Digital Infrared
Timing Simulator (DITS). DITS adds realism and authenticity in
this newest form of nonlethal, force-on-force training equipment
that employs lasers and blank cartridges to simulate actual battle.
(U.S. Army photo by SPC Joe Padula.)

Paratroopers with the 82nd Airborne Division (Advise and Assist

Brigade) train using infrared lasers and night vision optics at Camp
Ramadi, Iraq, Oct. 26. The paratroopers train constantly to maintain
their fighting edge while standing ready to provide assistance to Iraqi
security forces. (U.S. Army photo by SPC Mike MacLeod.)

Located in a Class 100,000 clean
room, the TARDEC facility seeks
to preserve Soldiers’ sight, which
increases survivability and mis-
sion completion probability,
while creating and developing
materials that limit the amount
of light that can filter through
to a sensor or human eye. Ad-
ditionally, the facility develops
techniques that harden and
enhance combat vehicle surveil-
lance vision devices. Laboratory
devices are fabricated, integrat-
ing the materials and designs.
“The laboratory will be used to
investigate sensor vulnerability
to lasers and possible protection
solutions,” explained TARDEC
Associate Robert Goedert. “Lasers
are becoming ubiquitous in the
Army and will only increase their
presence on the future battlefield.”
Various tests are conducted at the
TARDEC laboratory on optical
nonlinear optical materials and
novel optical designs are increas-
ing the laboratory’s capabilities
and creating indispensible new
tools for the Future Force. “The
TARDEC lab has evolved into a
great asset for assessing poten-
tial problems relating to future
laser devices and investigating
potential protection techniques,”
Goedert concluded.
S p ecia l 2010 E d it io n

equipment includes laser sources,
detection devices, spectromet-
ric instrumentation, optical test
benches, laser beam profiling
systems, optical microscopes and
computer support facilities. New
performance. By using vision
devices with the laser protec-
tion filters, engineers are able to
determine the amount of damage
a given laser attack may have on
the human eye. These tests on
Michael D. Kaplun is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He holds a B.A. in
English and media and society from
Hobart and William Smith Colleges.
99
MODELING AND SIMULATION (M&S)
 Total Immersion in
Leads to Engineering
Patrick Pinter

W
hen Soldiers need an immediate vehicle solution on the
battlefield, there is no time to waste in the design process.
Design and development phases cannot take months or
even weeks — engineers must find viable solutions that
can materialize in a matter of days. When this type of
request comes in from the field, engineers at the U.S. Army
Tank Automotive Research, Development and Engineering Center
(TARDEC) use every tool possible to deliver vehicle solutions
quickly to Soldiers on the front lines.

A Stryker mechanized unit from the 2nd Stryker Cavalry Regiment performs tactical maneuvers
in a training exercise during Joint Task Force – East in the Novo Selo Training Area in Bulgaria.
The CAVE has been used for Stryker vehicles and components to simplify and expedite vehicle
design, development and platform enhancement. (U.S. Army photo by MSG Cecilio Ricardo.)
20 10 EEd
S peci a l 2010 ioonn
d iti ti

102
Virtual Environments
Innovation
One such tool is the Cave
Automatic Virtual Environment
(CAVE). The CAVE is an immersive,
virtual reality environment where
projectors are directed toward a
number of walls in a room-sized
cube. Users stand inside the CAVE
wearing special glasses to view the
3-dimensional (3-D) graphics that
are generated. With these glasses,
objects appear to be suspended
in space, and viewers can walk
around them for a fully immersive
view showing the object’s various
sides and components. The CAVE
gives designers and engineers the
ability to see how components fit
and operate on a vehicle before
any manufacturing is completed,
providing enhanced design
reviews that lead to more rapid
development of vehicles and vehicle
components. “We use the CAVE for
many things, such as simulation,
design reviews and development of
new vehicles,” explained TARDEC
Engineer Jon Petrosky.
The ability to walk around a
3-D model is made possible by
electromagnetic sensors. When a
S p ecia l 2010 E d it io n
person moves around in the CAVE
with a pair of special glasses on, his
or her movements are tracked with
these sensors, and the video
adjusts accordingly.
103

Eleven Soldiers from the 82nd Airborne Division visited the Detroit Arsenal in July 2009 to view
the work done by TARDEC researchers and engineers. TARDEC Mechanical Engineer Allen Rubel
explains a Stryker vehicle virtual environment to Soldiers during a visit to the CAVE. The special
glasses make images inside the CAVE appear to float in space with users able to virtually walk
around them. (U.S. Army TARDEC photo by Ted Beaupre.)
Depending on the vehicle model’s
complexity, or fidelity, designs
can be ready for viewing in the
CAVE in a matter of days. If the
model and the engineers’ plans
are fairly simple, the design can
be loaded into the CAVE quickly.
“The process typically starts when
we get contacted by someone
who asks to see their vehicle in
the CAVE,” commented Petrosky.
“They give me their computer-
aided design (CAD) data. We have
a converter that converts almost
any CAD format to the CAVE’s
format. The length of time to
import a vehicle into the CAVE
really depends on the model. If
the model is very detailed with
every last nut and bolt, it takes
longer. But if it is simple, it can be
S peci a l 2010 E d it io n
ready to go in only a few days.”
The CAVE also has a connecting
desktop version so that the
projected images can be viewed
as needed on any computer. With
104
the desktop version, “when you
leave here, the process is not over,”
TARDEC Engineer Brian Brumm
stated. “The data you see here in
this immersive 3-D environment,
you can bring back to your desk
in a miniature version that will
help you remember what
you saw.”
Soldier Feedback
Helps Design Engineers
Deliver Solutions
Feedback from Soldiers who
have used the CAVE has
been extremely helpful for a
product’s development phase
by providing designers with
a perfect opportunity to get
comments from the people who
have been and will be out in the
field using these vehicles. “Most
of the people who have been in
the CAVE say they really like it.
Most have never been in anything
like this. With something like the
CAVE, where the design is right
there in front of them, people feel
like they can reach out and almost
touch it,” noted Petrosky. “Most
Soldiers who come in here think
this tool is very helpful. It gives
them the ability to tell us what
will work and what won’t work.”
“Most Soldiers who come
in here think this tool is very
helpful. It gives them the
ability to tell us what will
work and what won’t work.”
The CAVE’s primary benefit is
that it is easy to use for everyone
involved. Users do not have
to be CAD or engineering
experts to use the CAVE. Any
customer, engineer or Soldier
who walks in and picks up a pair
of glasses can see the design.
“When we get Soldiers or other
people in here without CAD or
engineering knowledge, they have
the ability to easily understand
and comment on designs or
modifications without any formal
training,” Petrosky remarked.
Brumm also added, “What the
CAVE is really good for is a
nontechnical person. It helps
them in understanding what is
going on rather than looking at
a normal CAD design. This tool
can be used to explain ideas to
other people rather than just
engineers or designers. During
your standard design reviews,
PowerPoint slides with design
specifications are usually only
presented. In most cases, that is
hard for a person to visualize. The
CAVE takes the design review to
the next level.”
“The TARDEC CAVE was one of
the design review locations for the
Stryker model,” Brumm remarked.
“That was a project that was given
an aggressive timeline for comple-
tion, and the CAVE played a big
 MODELING AND SIMULATION
CW3 Jason Greegor looks at a Family of Medium Tactical Vehicles in the CAVE virtual reality environment. His first time in the setting, Greegor tries
to reach out and “touch” the image. (U.S. Army TARDEC photo by Bill Dowell.)

role in meeting that timeline. The

vehicle was quickly and complete-
ly understood by all participants
because they were able to see the
vehicle without having to visualize
it in their heads. Here you are able
to visualize a vehicle in complete
detail. There are not many places
within the Army where you can
do this type of thing.”

TARDEC also has the capability to

bring the CAVE to customers out-
side the TARDEC facility through
the Reconfigurable Automatic
Virtual Environment (RAVE).
Similar to the CAVE, the RAVE
is a transportable, multiperson,
high-resolution, 3-D video/audio Visitors to the CAVE are amazed by the virtual reality’s authenticity and capabilities. (U.S.
environment. The system has Army TARDEC photo by Bill Dowell.)
three rear-projected screens and a
front-projected floor, and it can be Overall, the CAVE has simplified system is better prepared to meet
set up in various configurations. vehicle design and development battlefield demands.
so that it is not just engineers
“Here you are able to visualize making all the tough decisions
a vehicle in complete detail. — Soldiers and other customers
S p ecia l 2010 E d it io n

can be involved in the process Patrick Pinter is a Writer/Editor with

There are not many places
within the Army where you
can do this type of thing.”
and provide suggestions. This
type of feedback is particularly
valuable from Soldiers so that
when vehicles like the Stryker
hit the road, the vehicle/Soldier
BRTRC and provides contract support
to TARDEC’s Strategic Communica-
tions team. He has a B.A. in journalism
and political science from Western
Michigan University.
105
 A Virtual Environment
Gets Soldiers Ready
for Action
Patrick Pinter

The crew station screen gives the operator a simulated

view of what he or she would see on the battlefield.
The platform provides a number of stimuli to give test
subjects the feeling that they are really on the battlefield.

C
omputing systems and their abilities to recreate battlefield scenarios
play an important role in training Soldiers and testing vehicle equip-
ment operation. The virtual experience allows for significant train-
ing and testing time, as well as a safe training environment. At the
U.S. Army Tank Automotive Research, Development and Engineering
Center (TARDEC), this capability is used extensively to ensure Soldiers
and equipment are ready for real-world battlefield experiences.
S peci a l 2010 E d it io n

TARDEC Engineer Jonathan Joyce works with the Embedded Simulation crew station. Through tools
like this, TARDEC has the ability to create a virtual battlefield environment that replicates real-world
battlefield conditions for Soldiers getting ready to deploy to the theater of operations. (U.S. Army
TARDEC photos by Bill Dowell.)

106

Joyce operates the ES crew station. Tools like this give Soldiers an opportunity to test equipment
that could possibly be used on the battlefield.
With its Embedded Simulation
(ES) Laboratory, TARDEC can
develop component or system
models. The lab’s ES system sup-
ports local and long-haul distrib-
uted simulation in both classified
and unclassified environments.
“The lab is more like a set of
tools,” explained Scott Lohrer,
Embedded/Distributed Simula-
tion Team. “With the ES system,
we can provide a simulation
environment to promote the
development of crew station
technology. We provide the
stimulus to the Soldier and, by
creating the virtual battlefield, we
tie in other tools, like a com-
puter-generated force, and that
tool basically will augment and
fill out the battlefield.”
“We provide a lot of
the stimuli to give the
test subjects a feel that
they are in some kind of
battlefield environment.”
The ability to create a virtual
battlefield environment that
replicates real-world battlefield
conditions for Soldiers, or any
other test subject, is one of the
ES system’s primary benefits. “We
provide a lot of the stimuli to give
the test subjects a feel that they are
in some kind of battlefield envi-
ronment,” remarked Lohrer. “One
example that we have worked with
is to measure workload for a com-
mander. We would simulate the
tasks a commander would experi-
ence in a real-world mission.”
Another system benefit is the
ability to replicate a weapon’s fir-
ing without actually firing a live
round. “The crew stations that
Intelligent Ground Systems build
can be set up in a lab environment
or moved inside a vehicle so our
software can go with the crew in-
side,” explained Lohrer. “Without
the ability of live firing indoors,
we can provide a live virtual envi-
ronment where you can replicate
a live firing.”
The lab houses primarily off-
the-shelf computing systems
capable of running either Linux or
Windows operating systems that
are used to evaluate component or
system models. The lab supports
both high-level architecture and
distributed interactive simulation
protocols. “With the ES system,
we can also work in a distributive
environment,” commented Lohrer.
“If there are other labs that are
MODELING AND SIMULATION
focusing on sensor modeling, we
can run their high-fidelity models,
for example, and create a coopera-
tive modeling environment.”
The high-tech simulation work
being done with the ES system is
helping provide valuable infor-
mation and feedback, which is
promoting the development of
crew station technology. This
development is a key component
in delivering to Soldiers the user
interface and vehicle solutions
they need to meet current battle-
field threats.
The foot pedals on the crew station represent
the gas and brake pedals that are located in
combat vehicles, contributing to the simula-
tor’s realism. The ES team tries to replicate
the same environment and conditions that
Soldiers will face on the battlefield.
S p ecia l 2010 E d it io n
Patrick Pinter is a Writer/Editor with
BRTRC and provides contract support
to TARDEC’s Strategic Communica-
tions team. He has a B.A. in journalism
and political science from Western
Michigan University.
107
 Ground Vehicle Simulation
Laboratories Simulate Real-
World Testing and Analytics
Patrick Pinter and Matthew Sablan

An MRAP and Interim High Mobility Engineering Excavator are

shown on the RNPS where the posts, or fixtures, are easy to set up
and can accommodate vehicles with gross vehicle weight (GVW)
up to 80,000 pounds. Computer- and servo-controlled hydraulic
actuators provide the forcing function into the test specimen. The
actuator duty cycle can originate from proving ground, computer-
based or swept sine sources. (U.S. Army TARDEC photo.)
S peci a l 2010 E d it io n

108
E
xperimentation has been
the heart of scientific
methodology for centuries
and is often time-consum-
ing and expensive, but it
is necessary to advance
relevant technology and scientific
research. The U.S. Army Tank
Automotive Research, Develop-
ment and Engineering Center’s
(TARDEC’s) Ground Vehicle
Simulation Laboratories (GVSL)
have been leveraged by various
program managers (PMs) and
internal TARDEC engineers and
scientists since 1985 to assist
with reducing costs and time by
simulating natural phenomena
and environments. These actions
have led to expanding experimen-
tation capabilities and a wealth of
usable data.
The U.S. Army develops some
of the most highly technical
ground vehicles in the world.
Before these vehicles reach the
battlefield, hundreds, sometimes
thousands, of hours of testing
and research go into develop-
ing them and making sure they
meet Soldier requirements.
TARDEC has tools that facilitate
this research and development
to ensure these vehicles are ready
when they hit the battlefield.
The GVSL uses modern technol-
ogy to simulate the effects of
real-world testing in a controlled
environment. These facilities allow
TARDEC to complete more tests
on its premises, which, in turn,
reduces travel and centralizes
assets and test data accessibility.
The lab’s simulators include the
Load Handling System Simulator
(LHSS), Reconfigurable N-Post
Simulator (RNPS), Pintle Motion
Base Simulator (PMBS), Vehicle
Inertial Properties Evaluation
Rig (VIPER), component test fix-
tures and tire test machines.
The LHSS is a motion platform
designed to test the payload
of Heavy Expanded Mobility
Tactical Truck (HEMTT) and
Palletized Load System vehicles.
The RNPS features vertical
tire and track-coupled fixtures
generally used for chassis and
body/payload fatigue studies
capable of characterizing or
testing wheeled vehicles with
two to five axles. The PMBS
uses servo-hydraulic actuators
S p ecia l 2010 E d it io n
109
 to reproduce real-world and
proving ground terrain.
Vehicles can undergo preliminary
testing at TARDEC, allowing
engineers to find and solve
design problems before embark-
ing on expensive real-world
tests at the Army’s various test
centers. The simulators can
provide durability evaluations
and characterizations of systems,
subsystems and components.
“The GVSL’s various simulators
provide engineering support
services to the Army ground
vehicle platform managers,” re-
marked TARDEC Acting Associ-
ate Director for the Hardware
and Man-in-the-Loop Simula-
tion Group Dr. Mark Brudnak.
“We can support laboratory
testing, vehicle characterization,
system and component durabil-
ity, and hardware/man-in-the-
loop simulation. Along with the
other tools available, the GVSL
provides test and analysis sup-
port to a variety of customers.”
TARDEC also has two simula-
tors that help researchers solve
vehicle problems and familiarize
Soldiers with new and upcoming
vehicles. Those tools are the Ride
Motion Simulator (RMS) and
the Crew Station/Turret Motion
Base Simulator (CS/TMBS).
TARDEC’s Dr. Mark Brudnak keeps a close
eye on data recorded during RMS testing.
Brudnak and his team use the RMS test
data to help engineers and designers better
understand the decision-making process
Soldiers use on the battlefield. (U.S. Army
TARDEC photo by Elizabeth Carnegie.)
S peci a l 2010 E d it io n
110
An MRAP is being tested on the VIPER, which is used
to accurately measure a vehicle’s center of gravity and
inertial characteristics. (U.S. Army TARDEC photo.)
Soldiers Inside Simulators
The RMS is a 6-degrees-of-free-
dom motion simulator designed
for crew station and Soldier-in-
the-loop experimentation. It is
capable of reproducing the ride of
automotive, combat, tactical and
nearly any other type of ground
vehicle with high precision. It
has integrated motion, audio and
visual systems for high-fidelity
simulations. “The RMS consists
of hydraulic actuators, which
move the simulator. It houses
one occupant and has a recon-
figurable cab, which you can bolt
different components to, such
as seats, displays and controls to
simulate a vehicle cab,” explained
Motion Base Technologies Team
Leader Harry Zywiol. “It can be
configured as a wheeled vehicle,
a combat vehicle or any land ve-
hicle. This permits us to simulate
the mobility or ground motion
of the vehicle on cross-country,
secondary road or, really, any ter-
rain surface.”
The ability to create various sce-
narios in many environments is a
unique RMS benefit. The simula-
tor can replicate environments
that Soldiers will face on the
battlefield in Iraq or Afghanistan
or at any proving ground. “Many
of the real Army proving grounds
— we can simulate those and
more,” commented Zywiol.
“Environments in Afghanistan
or Iraq can be simulated using
this motion base. The drive in
Iraq is more of a flat ride and
less rough. In Afghanistan, the
terrain is really rough and hilly.
We can also simulate the visual
sense, what you would see as you
are driving. We can simulate hills,
valleys, buildings, lakes, streams
and the movement and actions
of friendly, enemy and civilian
forces using computer-generated
imagery and models.”
“We can support laboratory
testing, vehicle characterization,
system and component
durability, and hardware/man-
in-the-loop simulation.”
With the RMS, TARDEC engi-
neers address two challenges —
quick solutions to vehicle prob-
lems and understanding Soldiers’
cognitive processes. “What we do
with this simulator are two kinds
of work. The first is helping to
solve the problems currently in
vehicles in Afghanistan and Iraq.
Those problems could be seat-
ing and restraint issues or con-
trol positions that affect Soldier
performance, fatigue and com-
fort — basically, rapid solution
 “We can simulate hills, valleys,
buildings, lakes, streams and
the movement and actions of
friendly, enemy and civilian
forces using computer-generated
imagery and models.”
testing,” explained Zywiol. “The
second thing we do with this is
heavily research focused. We are
beginning to look at the Soldiers’
cognitive abilities, in particular
the way Soldiers think and their
thought processes to, ultimately,
design significantly better vehicle
crew stations. The whole idea is
that we have a good handle on
how people respond to motion
when they are in vehicles, but we
don’t have a good handle on their
cognitive processes, what causes
them to make the decisions they
are making and what are the in-
fluences on those decisions. That
is what we are trying to research.”
“Using simulation is
advantageous because you
can identify potential problems
and then quickly apply
engineering solutions.”
The CS/TMBS also is capable
of reproducing dynamic condi-
tions encountered by combat or
tactical vehicle. However, this
simulator can be configured as
either a full crew station simula-
tor or as a gun turret system.
There are six hydraulic actuators
below that support a table capable
of having vehicle subsystems
mounted on top of it. “The idea
here is that everything is recon-
figurable to fit any customer. For
example, we can make this crew
station cab into a High Mobility
Multipurpose Wheeled Vehicle
(HMMWV) or a Mine Resistant
Ambush Protected (MRAP) idea of how Soldiers would drive
vehicle for whatever we have to and fight in these vehicles with
do,” explained Zywiol. “This is a the simulator. We can now have
Soldier-based simulator that can measurements on how the driver
MODELING AND SIMULATION
fit multiple people in it.” is using all the power and energy
A close-up shot of what the simulator looks like while being tested. Personnel, seated in
the RMS, train in similar conditions that Soldiers face on the battlefield. The feedback that
TARDEC researchers and scientists receive helps in developing solutions for vehicle-related
challenges Soldiers are facing in the theater of operations. (U.S. Army TARDEC photo by
Elizabeth Carnegie.)
The CS/TMBS is a popular testing on board. This information helps
tool with Soldiers. The experience TARDEC engineers learn how
Soldiers have in the simulator the Soldiers are going to use the
enables them to provide good vehicle,” Zywiol continued.
feedback, which leads to mak-
ing vehicles better. The simulator VIPER
also allows Soldiers to test new The VIPER is used to accurately
vehicles that have not yet reached measure a system's center of grav-
the field. “There is a lot of feed- ity and the inertial characteristics
back from users. Soldiers really of trucks, trailers and turrets.
like it because they are deeply Most vehicles can be evaluated
engaged in the scenarios, and they without modification or disas-
think it is realistic. However, they sembly. “On this equipment, we
also point out that it is not per- test for the center of gravity and
fect. They let us know what key the moments of inertia. When the
pieces we are missing so we can vehicle comes to an abrupt stop,
make it better,” Zywiol noted. “We there is a tendency for an object
often use this simulator to come to resist changes. The VIPER is
S p ecia l 2010 E d it io n
up with what we call a duty cycle, able to calculate it,” said Physi-
which is synonymous with vehicle cal Simulation Lab Operations
use history of new or upcoming Team Leader Terry Hoist. “There
vehicle designs. Vehicles on the is interest to use it for Army or
drawing board don’t have a lot of Joint Vehicle Programs, as well
use history, but we can get a good as private businesses.” The data
111
 generated by the VIPER are used
by the Concepts, Analysis, Sys-
tem Simulation and Integration
(CASSI) group to model vehicle
dynamics to help mitigate vehicle
rollover hazards as well as im-
prove handling performance and
ride quality.
The VIPER consists of four
in-ground scales, a configurable
platform and the software
necessary to post-process the
results. “We have also done
work with the Department
of Transportation,” remarked
Hoist. “Overall, we characterize
vehicles approximately 40-50
times per year. The VIPER has
become especially useful for the
characterization of MRAPs.”
RNPS
The reconfigurable motion base
simulators feature vertical tire
The CS/TMBS simulator allows Soldiers to test
new vehicles that have not yet reached the field.
The experience that Soldiers have in the CS/
TMBS enables them to provide good feedback,
which leads to better engineered vehicles. (U.S.
Army TARDEC photo by Elizabeth Carnegie.)
S peci a l 2010 E d it io n
112
“The value here is that we have
Soldiers right in the simulation
with the same ride they get in
the theater, and we are using the
same equipment they would be
using in the field.”
and track-coupled fixtures that
are generally used for chassis and
body/payload fatigue studies.
These posts, or fixtures, are easy
to set up and can accommodate
GVWs up to 80,000 pounds.
“With the RNPS, we test the
vehicle’s suspension, chassis and
integrated subsystems to verify
whether or not it can endure
proving ground and real-world
terrains. The ability to do the
suspension testing here in
the lab is a big advantage,”
commented Hoist. “Using
simulation is advantageous
because you can identify potential
problems and then quickly apply
engineering solutions.”
Computer- and servo-controlled
hydraulic actuators provide the
forcing function into the test
specimen. The actuator duty
cycle can originate from proving
ground, computer-based or swept
sine (analysis used for measure-
ments involving high dynamic
range or wide frequency inter-
vals) sources. “We have ways to
record information and moni-
tor the vehicle while it is on the
N-Post. We have strain gauges on
the axles to make sure we are not
bending them. We also mount ac-
celerometers at various locations,”
remarked Hoist. “We not only
test the vehicles to see if they are
durable, we also provide the data
to our modelers and analytical
people so they can modify and
improve their designs.”
Having testing equipment like
the N-Post Simulator onsite at
TARDEC gives engineers the abil-
ity to test a vehicle’s durability
before it is sent to a proving
ground. “When you take the
vehicle to the field, you are going
to have much higher confidence
since it has been through signifi-
cant testing,” said Hoist. “That is
the big selling point: to start here
in our laboratory rather than at
a proving ground. We perform
simulations here to improve the
vehicle’s chance of success before
it is sent to a proving ground.”
The RNPS has proven itself to be
a very useful tool in developing,
studying and designing ground
vehicles. It is constantly being used
to develop vehicle solutions for to-
day’s Soldiers. “This piece of equip-
ment is very busy,” commented
Hoist. “We have performed many
HMMWV tests here. Now, with
the focus shift to MRAPs, we test a
lot more of those.”
TARDEC’s simulations allow
a repeatable, controllable
environment and process
to compare different
technologies and solutions
on the same vehicle while
reducing or eliminating
questionable variables.
PMBS
The PMBS is a hydraulically
powered physical motion-base
simulator designed to test light-
to medium-weight lunette, or
hitch, trailers with GVWs of up
to 20,000 pounds. “Right now it is
mostly used for testing with light
tactical trailers,” said Hoist.
The HEMTT is a transport truck with a payload capacity of more than 10 tons. To ensure this
vehicle fleet remains at maximum operational capability, TARDEC’s LHSS tests HEMTT payload
capabilities to find any engineering problems that need addressing. (U.S. Army TARDEC photo.)
This simulator can impart mo-
tion to a trailer’s lunette in three
directions — vertical, lateral and
longitudinal — to emulate the
forces imparted by the prime
mover. In addition, the PMBS
can move each trailer wheel ver-
tically, like the RNPS.
Continuing to Provide
Soldiers with Rides
TARDEC’s simulations allow a
repeatable, controllable environ-
ment and process to compare
different technologies and solu-
tions on the same vehicle while
reducing or eliminating ques-
tionable variables. Simulations
ensure that when enhancements
are made to a vehicle, its struc-
tural integrity is not compro-
mised, reducing the total number
of tests. “In short, the physical
simulation labs assist PM deci-
sion making and provide pro-
gram risk reduction, saving time
and money,” Brudnak noted.
“The value here is that we have
Soldiers right in the simulation
with the same ride they get in
the theater, and we are using the
MODELING AND SIMULATION
same equipment they would be
using in the field,” remarked
Zywiol. “Having this capability
here highlights TARDEC’s labs.”
TARDEC’s simulation tools
are helping to deliver rapid
solutions on new and future
vehicle platform designs.
These simulators are providing
invaluable information and
feedback that are being used
to help today’s Soldiers remain
lethal, mobile, survivable and
sustainable on a very complex
and evolving battlefield.
Patrick Pinter is a Writer/Editor with
BRTRC and provides contract support
to TARDEC’s Strategic Communica-
tions team. He has a B.A. in journalism
and political science from Western
Michigan University.
S p ecia l 2010 E d it io n
Matthew Sablan is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He has a B.A. in
English and history from Marymount
University in Arlington, VA.
113
 Assessing Material and
Microstructural Failures —
Metallurgical and Failure
Analysis Laboratory Provides
Critical Analysis
Michael D. Kaplun
S peci a l 2010 E d it io n

TARDEC’s Demetrios Tzelepis displays samples of tested

objects in TARDEC’s Metallurgical and Failure Analysis
Laboratory. An EBG Materials and Environmental
Team member, he orchestrates the laboratory’s analysis
capabilities and metallurgical manufacturing processes.
(U.S. Army TARDEC photos by Bill Dowell.)
114
S
eeking to ensure Soldiers
have safe, high-quality
equipment to execute their
operations, the U.S. Army

MODELING AND SIMULATION

Tank Automotive Research,
Development and
Engineering Center’s (TARDEC’s)
Metallurgical and Failure
Analysis Laboratory specializes
in providing objective, cost-
effective analyses of component
failures. The lab, located in the
Prototype Integration Facility,
utilizes the experience of highly
skilled and trained technicians
and engineers to provide material
evaluation and identification,
microstructural evaluation,
hardness testing and fracture
analysis to assess component
failures on all vehicle and Veteran Associate Midge Krueger studies test samples under a microscope in TARDEC’s Metallur-
gical and Failure Analysis Laboratory. Analyses performed in the facility range from nuts and bolts
weapons systems.
to HMMWV doors and MRAP vehicle hulls.

Analyses performed in the

laboratory range from nuts
and bolts, track components,
wheel rims, weldments and
steering arms, to High Mobility
Multipurpose Wheeled Vehicle
(HMMWV) doors and Mine
Resistant Ambush Protected
(MRAP) vehicle hulls.
Nondestructive testing, including
dye penetrant, magnetic particle
inspection and radiography, are
available to inspect suspect parts.
TARDEC’s Metallurgical and
Failure Analysis Laboratory
supports the Physical
Prototyping Team, while also
performing work for program
managers, program executive
offices, the Army Criminal
Investigation Division, U.S.
Navy, Naval Criminal Division
and fielded units. The lab is
equipped with a scanning
of minute inclusions in the
material. The laboratory also has
a spectrographic analyzer, which
enables chemical analyses
of most metals, including alloy
steels, stainless (nickel-based)
steels, titanium, copper and
aluminum alloys.
The lab utilizes the experience
of highly skilled and trained
technicians and engineers to
provide material evaluation and
identification, microstructural
evaluation, hardness testing
and fracture analysis to assess
component failures on all vehicle
and weapons systems.
the accident or if the accident
caused the failure,” Krueger
remarked. She also emphasized
that TARDEC’s efforts are
progressing to increase the
laboratory’s use, which can be
seen by the Engineering Business
Group (EBG) Materials and
Environmental Team’s recent
addition of Demetrios Tzelepis,
a materials engineer specializing
in metallurgy. “His knowledge
and understanding of the
laboratory’s capability, as well as
the metallurgical manufacturing
processes, will enable us to
better assess and fix component
problems,” affirmed Krueger.
S p ecia l 2010 E d it io n

electron microscope (SEM) and
electron dispersive spectrometer
(EDS). The SEM can magnify a
fracture face up to 10,000 times
its size, and the EDS can do a
qualitative chemical analysis
Serving as the laboratory’s
senior technician is TARDEC
Associate Midge Krueger. “I have
been asked to analyze parts that
have caused fatal accidents to
determine if the failure caused
Michael D. Kaplun is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He holds a B.A. in
English and media and society from
Hobart and William Smith Colleges.
115
 Conducting M1A2
Software Maintenance and
Enhancement — M1A2 System
Integration Laboratory
Michael D. Kaplun

Armor crew members from Company C, 1st Battalion, 66th Armor

Regiment, 1st Brigade Combat Team, 4th Infantry Division, fire the
main gun of their M1A2 Abrams Main Battle Tank during a tank
screening at Range 8b, Camp Buehring, Kuwait. The Soldiers’ training is
in support of Multi-National Division – Baghdad and Operation Iraqi
ioonn

Freedom. (U.S. Army photo by SGT David Hodge.)

d iti ti
20 10 EEd
S peci a l 2010

116
T
he M1A2 System Integration Laboratory (SIL) provides the
These new capabilities enable
hardware, operating system, network and software infrastruc-
ture that enables the Software Engineering Center (SEC) to SEC engineers to fully develop
conduct software maintenance and enhancement projects for
the M1A2 Abrams Main Battle Tank System Enhancement Pack- and test their software before it
age (SEP). The M1A2 SIL is an integral part of the U.S. Army is installed on a vehicle, while
Tank Automotive Research, Development and Engineering Center’s
(TARDEC’s) SEC under Associate Director Mark Slominski. The allowing software and test
facility includes line-replaceable unit and system benches, develop-
engineers to resolve a variety
ment servers, emulators, tank software, Force XXI Battle Command
Brigade and Below support, automated test software and various of field problems and system
simulators. “The M1A2 SIL has proven to be an indispensible tool in
sustaining the software for the Abrams tank to a high-quality level,” trouble reports.
remarked Slominski.

Software Engineer John Konopik reads through auxiliary power unit emergency shutdown proce-
dures for the driver’s integrated display station prior to simulation tests in the M1A2 SIL. (U.S. Army
TARDEC photo by Bill Dowell.)
Managed by TARDEC Engineer
Keith Shockley with support
from fellow TARDEC associ-
ates Aaron Micyus, Matt Brief,
Patrick Delehanty, Jim Gengler
and Rhonda Paprocki, the SIL
was developed in the mid-1990s
and has continually added new
capabilities. These new capabili-
ties enable SEC engineers to fully
develop and test their software
before it is installed on a vehicle,
while allowing software and test
engineers to resolve a variety
of field problems and system
example of the SIL’s adaptable
nature is the recently added
simulation software that enabled
SEC engineers to quickly develop
and test software that integrated
an experimental auxiliary power
unit into the SEP system.
The laboratory shares its assets
and supports other organiza-
tions within TARDEC, includ-
ing Mobility, Survivability and
Project Manager Heavy Brigade
Combat Team training devices.
The SIL’s staff also validates
Software Engineer Scott Pletz tests the auxiliary
power unit tank software interface in the M1A2 SIL,
part of TARDEC’s SEC. The laboratory provides the
hardware, operating system, network and software
infrastructure that enables the SEC to conduct
software maintenance and enhancement projects for
the M1A2 Abrams Main Battle Tank SEP. (U.S. Army
TARDEC photo by Bill Dowell.)
TARDEC’s M1A2 SIL provides
a multitude of systems integra-
tion capabilities. The laboratory’s
operations are integral in help-
ing TARDEC achieve its chief
mission — enhance warfighter
readiness and protection.
S p ecia l 2010 E d it io n

trouble reports by implementing trouble reports and software

changes to the SEP display; diag-
nostic; and Command, Control,
Communications, Computers,
Intelligence, Surveillance and
Reconnaissance software. An
update testing on the M1A2
SEP v2, while supporting Mine
Resistant Ambush Protected
vehicle development and Stryker
SIL acquisition.
Michael D. Kaplun is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He holds a B.A. in
English and media and society from
Hobart and William Smith Colleges.
117
 DREN Provides TARDEC’s
Computing Power
Michael D. Kaplun

T
he Defense Research Engineering Network (DREN) is a
nationwide, robust, high-capacity, low-latency computer
network created in the late 1980s to further crucial military
research and development (R&D) projects. Operated by the
Department of Defense (DOD) High Performance Computing
Modernization Office (HPCMO), DREN supports DOD- and
Army-wide R&D initiatives while providing digital, imaging, video and
audio data transfer services between defined service delivery points.
S peci a l 2010 E d it io n

TARDEC Associate Jonathan Bence manages the network from a console workstation, TARDEC’s
heart to DREN connectivity. (U.S. Army TARDEC photos by Bill Dowell.)
118
 “DREN is a technology enabler. It provides a viable conduit to the
Army for collaboration among the research, hardware and software
development, engineering and testing communities.”
TARDEC Associate Jonathon Smereka checks network server connections. DREN connectivity is
TARDEC’s conduit for high-speed DOD technology transfer.
DREN was originally used to
connect Defense Supercomputing
Research Centers (DSRCs) and
17 other smaller distributed
computer centers. Today, there are
four Defense Research Centers —
two for the Army (Army Research
Laboratory and Engineer Research
and Development Center), one for
the Air Force (Air Force Research
Laboratory) and one for the Navy
(Naval Oceanographic Office).
Several distributed centers have
been removed from the DOD
HPCMO, but many, such as
TARDEC, have maintained their
DREN connectivity to interact
with DSRCs and other partners.
“DREN is a technology enabler,”
remarked TARDEC Team
Leader Ted Currier. “It provides
a viable conduit to the Army
for collaboration among the
research, hardware and software
development, engineering and
testing communities.” As the
backbone of TARDEC’s laboratory
environment, DREN enables
high-performance computing
(HPC), embedded simulation
labs, ground vehicle simulation
labs, advanced collaborative
environments and systems
integration labs to establish and
connect simulation and test
environments. This connection
allows for real-time modeling
and simulation experiments, as
well as high-end computational
analyses supporting DOD- and
Army-wide strategic initiatives.
Through DREN, TARDEC is
able to partner and collaborate
with other U.S. Army Research,
Development and Engineering
Command laboratories linked
together by the network. “Much
of TARDEC’s broadband efforts
would not be possible without the
interconnection fabric of DREN,”
Currier affirmed. “This is why
the network was created and
has flourished.”
Today, there are many other
laboratories, agencies and
testing facilities with DREN
connectivity to perform research,
development and testing (RDT).
TARDEC’s DREN operation
hosts approximately 150–200
workstations throughout the
center and several larger systems,
such as supercomputers and HPC
systems. These supercomputing
systems and other DREN systems
are accessible to anyone working
MODELING AND SIMULATION
within Army RDT and evaluation
programs, in accordance with
standard DOD computer
use policies.
Through DREN’s active
technological engagement,
TARDEC is on the forefront
of leading-edge connectivity
and technology transfers across
DOD. The center’s position
ensures enhanced technological
capabilities exist in and out of
the network.
TARDEC Associates Jonathan Bence (stand-
ing) and Dan Kedziorek verify proper con-
nections in a station network rack. Proper
connections are vital to DREN operability.
Here, Kedziorek traces Ethernet wire connec-
tions in a network rack. Ethernet wires are
plugged in for each line to connect computers
to the network server.
S p ecia l 2010 E d it io n
Michael D. Kaplun is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He holds a B.A. in
English and media and society from
Hobart and William Smith Colleges.
119
 Two TARDEC engineers monitor
the work being done in the HPC.
The HPC runs simulations in a
variety of areas but mostly focuses
on vehicle dynamic analysis, CFD
and CSM. (U.S. Army TARDEC
photos by Todd Solgat.)

High-Performance Computing
Center Delivers Proven
Vehicle Solutions
Patrick Pinter

W
hen Soldiers enter the crew compartment of a tactical vehicle, they’re putting a lot of trust in
the vehicle’s ability to meet the highest standards of mechanical performance, survivability and
rigorous battlefield demands. One reason Army vehicles are able to meet and surpass these high
demands results from the work being done by the highly skilled scientists and engineers using
the U.S. Army Tank Automotive Research, Development and Engineering Center’s (TARDEC’s)
High-Performance Computing (HPC) Center.

What’s Going on at the HPC?
TARDEC’s HPC houses more
than 1,000 processors spread
across two systems. These
systems are used for analyzing
various physics problems re-
lated to ground vehicle systems.
“TARDEC, being the ground
vehicle integrator, has the ca-
pability to evaluate the vehicle
performance manufacturers
are claiming against all of the
design parameters,” remarked
HPC Team Leader Ted Currier.
“TARDEC transforms vehicle
characteristics from the vendors
into electronic models, and the
scientists and engineers run an
array of analytical simulations.
Without this capability, it would
S peci a l 2010 E d it io n
Researchers and developers
from TARDEC and enterprise
partners from the U.S. Army
TACOM Life Cycle Management
Command use the HPC to run
numerous simulations in the
areas of vehicle dynamic analy-
sis, computational fluid dynam-
ics (CFD) and computational
structural mechanics (CSM).
These complex physics-based
analyses help solve potential ve-
hicle problems before they ever
reach Soldiers.
“Vehicle dynamic analysis is
where the mathematical model
of a specific vehicle is run over
a real-terrain database that is
represented mathematically in
of modifications to current ve-
hicles,” commented Currier. “An-
other focus area is CFD, which
mainly focuses on analyzing
fluid flow. Here at TARDEC, our
primary CFD focus is on inter-
nal engine combustion and ther-
mal and signature modeling. We
also do a lot of analytical simu-
lations in CSM to evaluate kit
designs and material strength.
This is one of TARDEC’s core
analysis capabilities. Basically,
CSM is determining the stresses
and strains on the vehicle and
how the vehicle is going to react
in certain environments. In this
case, environments are defined
as force-loading scenarios based
on vehicle operational events.”

be impossible to evaluate the a supercomputer. This type of The HPC systems include sub-
complex vehicle systems that are simulation helps us assess vehi- stantial online and offline storage
being developed and fielded.” cle performance and the effects and high-speed, high-bandwidth
fiberoptic networking for HPC-
“CSM is determining the stresses and strains on the vehicle and based computation and visualiza-
tion throughout TARDEC. The
120
how the vehicle is going to react in certain environments.”

Pictured are some of the computing equipment in the HPC. The HPC can resolve potential physics
problems that appear in ground vehicle designs provided by the manufacturer.
TARDEC HPC Center was estab-
lished in 1988 and designated as
a Department of Defense (DOD)
HPC Distributed Center from
1996–2002 and is still prominent
today in the Army and DOD
HPC communities.
“TARDEC scientists and
engineers have the ability
to look at fatigue, corrosion,
stress fracture and
thermal breakdown, crew
survivability and a variety of
other failure modes.”
“Back in the 1980s, the govern-
ment and the Army were looking
into scientific computation as
a means to deal with the ever-
increasing complexities in vehicle
design and performance. Super-
computing was becoming a new
field, and the Army decided it
needed some sort of supercom-
puting capability,” remarked Cur-
rier. “Around that time is when
TARDEC received this capability.
Today we have a world-class com-
puting center, supporting a large
user base of vehicle engineers,
consisting of a team of 16 people.”
In addition to specific modeling
and simulation in the focus areas
of vehicle dynamics, CSM and
CFD for developmental vehicle
platforms and systems, the HPC
is used to develop solutions for
fielded vehicle systems. “We do
other less complex tasks, too,
which are not so glamorous —
something is in the field and
isn’t working, a component or
structure is failing but is within
design specifications, things
like that where we have to find
a solution. It is smaller stuff but
very valuable,” explained Currier.
“TARDEC and TACOM receive
requests from fielded units, and
TARDEC scientists and engineers
using HPC can model and per-
form physics-based analyses to
solve the issue fairly quickly.”
Pushing to Develop Quicker
Solutions in the Future
Despite the great work being
done in the HPC, Currier knows
that vehicle solutions need to be
provided more quickly to better
serve today’s Soldiers. The HPC
Center is working with TARDEC
researchers and developers to
provide a more rapid response
for full-vehicle platform analyses
and decision making. “TARDEC
MODELING AND SIMULATION
scientists and engineers have the
ability to look at fatigue, corro-
sion, stress fracture and thermal
breakdown, crew survivability
and a variety of other failure
modes. The HPC Center super-
computers here are being used
to expand simultaneous, multi-
discipline analysis capabilities,”
Currier concluded.
With the work being done using
the HPC, proven ground vehicle
solutions are being delivered to
American Soldiers. HPC research
and analysis validates ground
vehicle designs and models. This
validation is imperative in deliv-
ering strong, proven designs to
Soldiers who require vehicles that
meet rugged battlefield conditions.
An engineer tests HPC equipment to ensure
it is running optimally. The HPC computers
perform complex analyses on vehicle models.
These analyses attempt to determine whether
models measure up to the manufactures’
promised specifications.
S p ecia l 2010 E d it io n
Patrick Pinter is a Writer/Editor with
BRTRC and provides contract support
to TARDEC’s Strategic Communica-
tions team. He has a B.A. in journalism
and political science from Western
Michigan University.
121
 Hydraulic cylinders hanging from the transoms above push through load cells onto the
load feet, or whiffles, to test this segment of bridging. Various loads can be applied to
the Armored Vehicle Launch Bridge (AVLB). By testing bridging technology under
various conditions, TARDEC engineers can certify the military’s bridges for operational
deployment. (U.S. Army TARDEC photos by James Stankewitz.)

Dynamic Structural Load

Simulator Laboratory (DSLSL)
Bridges Capability Gaps
Matthew Sablan

E
stablished with the Bridge
Engineering Team in the
1960s, the DSLSL began at
Fort Belvoir, VA, former
home of the U.S. Army En-
gineer School. It continued
operating there until 1993, when
the mission and equipment were
transferred to the U.S. Army Tank
Automotive Research, Develop-
ment and Engineering Center
(TARDEC) in Warren, MI. By the
late 1990s, the DSLSL was operat-
ing at Michigan’s Selfridge Air
National Guard Base.
Securing the Army’s Bridges
S peci a l 2010 E d it io n
ultimate loads in accordance with
the Trilateral Design and Test
Code for Military Bridging and
Gap-Crossing Equipment agree-
ment among the U.S., United
Kingdom and Germany. The facil-
ity is equipped to accomplish this
mission with an overhead gantry,
10 computer-controlled hydraulic
load actuators on five moveable
transoms, tool crib, parts crib
and fabrication area. “We test and
certify a wide range of mobile
bridges. Some are mounted on
tank or truck chassis,” noted
Suzanne Culkin, TARDEC Bridge
Engineering Team Leader.

Housed inside an airplane hangar

leased from the Air Force, the
DSLSL tests and certifies the safe
load capacity of mobile military
bridges, including verifying their
working loads, overloads and
122
The DSLSL addresses the bridges’
structural capacity. These bridges
are often modular, with vary-
ing requirements, depending on
the environments where they

“We certify the military’s
bridges will safely support
their crossing vehicles before
the bridges are released to
Soldiers in the field.”
will be deployed. To fulfill this
mission, the facility is equipped
with a reconfigurable load gantry
with a one-million-pound load
capacity. The gantry can apply
a load that adheres to the North
Atlantic Treaty Organization’s
Standardization Agreements for
Military Load Class vehicles. The
gantry applies the load to a bridge
with a width of up to 30 feet and
a length of up to 165 feet. The
DSLSL also has 100,000-pound
load cells with National Institute
of Standards and Technology-
traceable and calibrated recording
systems, which allow for high-
precision load measurement and
recording. While testing bridges
The DSLSL uses spare bridge modules to support the bridge ramps during a
test. This represents the abutments’ or bank slope’s condition the laboratory
wants to examine.
and materials, researchers use
a 120-channel data acquisition
system and custom load-feedback
control system to help gather infor-
mation for review. “We certify the
military’s bridges will safely sup-
port their crossing vehicles before
the bridges are released to Soldiers
in the field,” Culkin summarized.
External Applications
In addition to the Bridging Team,
other organizations use the facil-
ity to conduct analysis, evaluate
equipment and otherwise support
the Current and Future Forces.
The DSLSL’s drop tower simulates
the impact of a mine blast, and
TARDEC has used the tower in
testing. “TARDEC recently used
the DSLSL to conduct engine tests
in a joint effort with a contractor,”
Culkin explained.
TARDEC Bridging Systems Proj-
ect Engineer James Stankewitz
explained another organization’s
use of the facility, stating, “The
National Aeronautics and Space
Administration (NASA) used the
facility to test a system that is
part of a prelaunch check for
ice formation.”
MODELING AND SIMULATION
Stankewitz added that the DSLSL
“is also reclassifying bridges for
the growing up-armored ve-
hicles.” As the vehicles grow in
weight to meet emerging threats,
the Bridging Team must evaluate
improvements to bridging tech-
nology to accommodate the extra
weight the up-armored vehicles
place on the bridge.
An AVLB is tested at the DSLSL. In addition
to testing bridges, TARDEC’s DSLSL has
been used by other organizations, such as
NASA, for testing. The laboratory uses test
equipment to ensure the launch bridge meets
various usage requirements.
The Bridging Facility provides
invaluable support to Soldiers in
the field by ensuring their bridges
are capable of transporting sup-
plies and vehicles across numer-
ous obstacles and waterways.
Logistics issues are increasingly
important in the current conflicts
in Afghanistan and Iraq, and the
Bridging Team’s tests are pivotal in
ensuring that the Army’s vehicles
are able to meet the mobility
demands and challenges they are
currently facing in Southwest Asia
and around the world.
S p ecia l 2010 E d it io n
Matthew Sablan is a Writer/Editor
with BRTRC and provides contract
support to TARDEC’s Strategic Com-
munications team. He has a B.A. in
English and history from Marymount
University in Arlington, VA.
123
 TARDEC Chief Scientist Helps
Develop Army Ground Systems
Technology Focus
Michael I. Roddin and Chris Williams

A
s U.S. Soldiers face evolving challenges on the battlefield, Dr.
David Gorsich, Chief Scientist for the U.S. Army Research,
Development and Engineering Command (RDECOM) Tank
Automotive Research, Development and Engineering Center
(TARDEC), must evaluate and make recommendations re-
garding TARDEC’s science and technology (S&T) portfolio to
properly equip warfighters for today’s challenges, while strengthening
technology for tomorrow’s battles.
S peci a l 2010 E d it io n

Dr. David Gorsich began his position as TARDEC’s Chief Scientist in January 2009. A project
under development in the laboratory he previously oversaw is the crew station/turret motion-
based simulator, which is shown here testing a prototype turret. (U.S. Army TARDEC photo by
Bill Dowell.)

124
With the number of challenges
facing TARDEC’s S&T community,
collaboration is crucial. Gorsich,
who has nearly two decades’ experi-
ence as an Army researcher and
earned a Ph.D. from the Massa-
chusetts Institute of Technology,
depends on TARDEC’s senior
technical experts (STEs) to dive
deep into their areas. “I have a huge
challenge on my shoulders in that I
have a lot of ground to cover,” stated
Gorsich, who began his new posi-
tion in January 2009. “I can’t do this
on my own.”
As TARDEC’s top scientist, Gor-
sich must ensure that TARDEC
associates conduct the neces-
sary research and development
(R&D) to meet emerging and
future ground system battlefield
requirements. To keep the orga-
nization focused on the Army’s
S&T strategy and in sync with
the U.S. Army TACOM Life Cycle
Management Command (LCMC)
Annual Operating Cycle, Gorsich
collaborates closely with TARDEC
and RDECOM executives. “I focus
on the STEs and the technology
directorates,” Gorsich explained.
“Because I reach out across the
ground systems enterprise, I look
to them for help because they are
an entry point into their organi-
zations and help me understand
the S&T challenges in those
groups. They also help me reach
out to and develop the junior
technical staff and our universi-
ties and other research partners.”
Portfolio Management Process
Gorsich believes proper portfolio
management is essential to ensur-
ing that TARDEC’s work benefits
the entire TACOM LCMC and all
its enterprise partners. Properly
managing the ground system’s S&T
portfolio affects nearly every aspect
of the organization, including long-
term investments in human capital
and facility planning. “My interest
is making sure that TARDEC has
a well-defined, rigorous portfo-
lio management process that we
then use to balance our technol-
ogy portfolio,” he stated. “The
overall way in which we manage a
portfolio is very important to me.
It’s probably the most important
thing I’ve been watching since
becoming chief scientist. My role
is to ensure that we get it estab-
lished correctly and that the tech-
nology reviews we do at TARDEC
feed that portfolio management
process. It’s a big task that several
people are involved with, and it’s
very important to us in terms
of transitioning technology and
coordinating all of our different
efforts and business processes.”
Proper portfolio management is
particularly important given the
current economy and changes
coming to weapon systems
procurement. In May 2009, U.S.
Secretary of Defense Robert
Gates announced that cuts in the
Department of Defense’s (DOD’s)
budget would affect the Army’s
Future Combat Systems (FCS)
— now Program Executive Office
Integration — and ground vehicle
programs. Gorsich said proper
portfolio management will be
required for TARDEC scientists
and engineers to develop solu-
tions that are able to protect
Soldiers from current threats,
while also ensuring that research-
ers are anticipating and develop-
ing solutions for potential future
needs. “The former FCS program
had been looking to spin out its
technologies as much as possible
earlier-on in current platforms,”
Gorsich remarked. “We see this as
a greater opportunity to develop
technologies for the current fleet
of vehicles, because wherever
you see us doing future systems-
related work, you see applications
of that work being integrated into
current tactical vehicle systems.”
Predicting Future Needs
Predicting Soldiers’ future needs has
always been a challenge. In addition
to the complexities and
unpredictability involved in
anticipating what may arise,
the majority of TARDEC’s S&T
budget is focused on meeting
current requirements. Only a
small amount has been dedicated
to predicting and preparing for
future needs. “Most of what
TARDEC does is driven by custom-
er needs today,” Gorsich clarified.
“A small amount of funding is
actually addressing tomorrow’s
customer needs. We cannot have
half our budget dedicated to
tasks that customers aren’t asking
for — you just can’t do that in
this current environment. It’s a
challenge for us because we have
a really small budget to work with
to predict what’s coming down
the path and invest in some key
technology areas and initiatives to
drive that discovery process.”
One future need that TARDEC is
focusing on is developing, imple-
menting and executing alternative
fuel and energy programs. To im-
prove the Nation’s energy security
and decrease its dependence on
foreign oil supplies, the Army must
find new ways of powering ve-
hicles and bases through biofuels,
hybrid-electric (HE) technology
or alternative energy sources. As
the Army’s and DOD’s lead for
fuels and lubricants, TARDEC
bears the responsibility for devel-
oping these resources and ensur-
ing that life cycle management is
properly integrated into all new
and existing ground vehicle pro-
grams. Gorsich works regularly
with officials in various power
S p ecia l 2010 E d it io n
and energy groups to stay up-to-
date on alternative power devel-
opments. “We’ve been having a
series of small strategy sessions
to define what we need to do in
the area of fuels,” he explained.
125

This Utility Variant Vehicle is equipped with a remote weapons system, night-vision capability,
ballistic glass, video cameras, touch-screen controls and a diesel-electric hybrid engine. Future
tactical vehicles will have extremely large auxiliary power demands. Hybrid vehicles are an
important P&E thrust area for TARDEC’s energy research program. (U.S. Army photo.)
“We’ve looked at fuels, and we
know that there’s a requirement
to eventually have a single fuel
and lubricant on the battlefield.
The question we are dealing with
now is, ‘How do we address that
given our current vehicle fleet?’
We’re also looking at jet propel-
lant 8 and biofuels and how they
behave in internal combustion
engines — how do they affect the
performance and reliability of
those platforms?”
Gorsich said there are a number of
key areas that TARDEC researchers
are focusing on — one such focus
area is the use of new innovative
materials. As the Army Research
Laboratory (ARL) develops new
materials and composites that are
lightweight, strong, durable and
survivable, TARDEC associates will
be responsible for developing and
integrating them into the Army’s
ground vehicle fleet to meet mobil-
ity, payload and survivability needs.
“There is the problem of technolo-
gy integration area of new types of
materials, ceramics and composites
S peci a l 2010 E d it io n
with multiple properties that we
haven’t necessarily seen before,”
he explained. “The challenge is
integrating those materials into the
vehicle’s structure without de-
grading current capabilities.”
126
Gorsich also plans to help
TARDEC associates make strides
in researching and developing
other technologies throughout
the coming years. “We’re looking
at advancements in transmissions
to get higher efficiencies out of
powertrains and higher densities
out of batteries,” he stated. “We’re
working hard to mature technol-
ogy in intelligent ground systems
(IGS) such that we can make
autonomous ground systems that
are practical, safe and effective on
the battlefield. There’s still a lot of
progress that needs to be made to
create a fully autonomous system.”
Additionally, there is a new
TARDEC Chief Scientist Dr. David Gorsich (left) and a TARDEC associate speak with Michigan
Technological University student Timothy Rossetto about his experience working in TARDEC’s
Summer Hire Program. (U.S. Army TARDEC photo by Ted Beaupre.)
emphasis on neuroscience and
cognitive systems. “We’re hoping
that we can take into account a
Soldier’s cognitive processes and
link those into a platform to make
the Soldier-machine interface
more effective,” Gorsich remarked.
Additionally, Gorsich hopes that
TARDEC’s Technology Integration
and Assessment Process, which
was used to develop the Mine Re-
sistant Ambush Protected (MRAP)
Vehicle Expedient Armor Program
and deal with weight issues in the
early days of operations in Iraq,
will continue to mature. “This
is a process by which we look
at technologies, their readiness
levels and their size, weight and
power to assess whether there may
be a good solution for a specific
requirement,” he related. “Then we
look at all the ‘-ilities’ of the system
— survivability, transportability,
mobility, etc. — and match those
signatures. We’ve found we can as-
sess the impacts of many technolo-
gies on a system.”
Partnering with Academia
Gorsich leverages TARDEC’s
partnerships with academia, serv-
ing on a number of university
review boards and assisting in
developing curriculum that may
produce next-generation Army
scientists. “What’s important to
us is having students that have an
interdisciplinary perspective on
life,” he stated. “They’re not just
trained in mechanical engineer-
ing, mathematics or electrical
engineering. We want them to
have a broader perspective when
they walk in the door. When they
come to TARDEC, we want them
to take a more systems engineer-
ing approach and understand our
overall acquisition process.”
As TARDEC continues its rela-
tionships with those in academia
through joint research projects,
Gorsich believes it’s important
to involve more students with
TARDEC engineers and scientists.
“We must be involved personally
with the graduate students who
are on the university projects we’re
funding,” he expressed. “As we do
that, we have a better opportunity
of bringing them onboard to
TARDEC and also getting more
from them in terms of transitioning
the research and technology they
do at the university for TARDEC.”
Each summer, several students
and faculty members from various
universities work at the TARDEC
campus in Warren, MI. Gorsich
said it is imperative that TARDEC
engineers work closely with the
faculty to facilitate mutually ben-
eficial relationships. “We need to
work with faculty to understand
what the fundamental gaps in
knowledge are and provide them
with an understanding of various
programmatic needs and tech-
nology issues that our engineers
and scientists face in emerging
technology programs,” he stated.
“The faculty should understand
what types of research to propose
to us and what types of students to
recruit who would be interested in
TARDEC’s research requirements.
That type of collaboration is very
A platform Hybrid-Electric Reconfigurable Moveable Integration Test Bed (HERMIT), developed
by TARDEC, is designed to evaluate ground combat vehicle components. Platforms such as the
HERMIT will allow TARDEC to address HE needs and assist in future ground vehicle systems
development. (U.S. Army TARDEC photo.)
important, and it has to happen
face-to-face for it to work.”
Rewarding Innovation
In a time when the enemy is highly
agile and adaptable, capable of
exploiting available technologies,
the Army remains steadfast in
staying ahead of emerging threats
to our Soldiers and their vehicle
systems. TARDEC continually
works toward this goal by fostering
innovation and “out-of-the-box”
thinking. Gorsich and other
TARDEC senior scientists and
technical staff have established the
TARDEC Innovation Grant to cre-
ate a flood of new technology ideas.
By enabling associates to translate
novel ideas into new in-house
capabilities, along with technolo-
gies and processes, the TARDEC
Innovation Grant gives the orga-
nization an essential leading edge
in technology R&D. The goal for
the grant is to acquire and manage
knowledge so all technology proj-
ects, whether successful or unsuc-
cessful, always benefit TARDEC.
The grant’s output will be reviewed
by a board for patentability and
business development potential.
Typical grant amounts will range
from $25,000 to $200,000. In ad-
dition, according to Army Regula-
tion 27-60 – Intellectual Property,
intellectual property owners can
receive up to 10 percent of its
profits, as well as additional funds
for the laboratory. All innovation
funds are good for one year.
The first TARDEC Innovation
Grants were awarded to: Dr. Matt
Castanier and Dr. David Lamb to
develop an analytical tool to im-
prove predictions of durability and
reliability of vehicle fleets; Dustin
Gascho, Michael Baker and Daniel
Rowell to develop a restraint
system for military vehicles; Jason
Hefter, Bernard Sia and Randy
Cassner to design a high-strength,
low-weight footbridge; Jeremy
Gray to develop a prototype for a
door opening mechanism for the
Small Robotic Toolkit; William
Norton and Steve Caito to design
a new type of rocket propelled
grenade defeat mechanism; and
Dr. Thomas Meitzler and Dr. Elena
Bankowski to develop an experi-
mental prototype of nanometer-
sized spintronic devices that can
be attached to armor to detect
microwave radiation for anti-radar
and communications applications.
Energizing the Technical
Workforce
As chief scientist, Gorsich
serves as TARDEC Director Dr.
S p ecia l 2010 E d it io n
Grace M. Bochenek’s principal
scientific advisor and is respon-
sible for developing TARDEC’s
technical staff and its reputation
as a nationally recognized center
of technical excellence. During a
127

During the recently completed Convoy Active Safety Technologies testing, Soldiers wore a
neuroergonomic cap to record brain waves related to their reactions to driving autonomously.
Gorsich hopes to use neuroscience research to take Soldiers’ cognitive functions into account
when developing this and other IGS technology. (U.S. Army TARDEC photo by Paul Tremblay.)
meeting with TARDEC associates
on Oct. 7, 2009, Gorsich highlight-
ed the organization’s renewed com-
mitment to research and the role
of newly created positions within
the Army’s S&T community. “It is
very important that even though
we get caught up in all the current
activities we do in war, and all of
the things we do for our custom-
ers, we must spend the time to keep
updated and active in technologies
related to automotive research,”
explained Gorsich.
To further support Gorsich and
TARDEC’s scientific community,
STE positions have been created
across TARDEC’s six technical fo-
cus areas. The STEs work alongside
TARDEC’s associate directors and
are responsible for technical devel-
opment in their selected areas. STEs
will play a crucial role in develop-
ing and evaluating TARDEC’s S&T
portfolios. “As I’m concerned about
the development of the technical
staff in the entire organization, the
“Ultimately, we have to continue to
focus part of the Army’s
S peci a l 2010 E d it io n
S&T portfolio on improving
ground systems viability and
performance, even with the
128
unpredictable economy.”
STEs are concerned about the tech-
nical staff in their specific organiza-
tions. We have very similar objec-
tives, and they mirror each other,”
Gorsich explained. “If we only have
one transmission expert in all of
TARDEC out of 1,500 people and
yet we manage approximately 2,000
systems across the command, that’s
a problem. I rely on those STEs and
meet with them on a regular basis,
and we come up with strategies on
how to address and build up the
right skills in the organization.”
Dr. Peter Schihl has been named
STE for TARDEC’s Power and
Energy Team, and Dr. Jim Over-
holt has been named STE for
TARDEC’s IGS. As of press time,
STE positions were still being
filled in the areas of Surviv-
ability, Force Projection, Vehicle
Electronics and Architecture,
and Concepts, Analysis, System
Simulation and Integration.
Another program, TARDEC’s
Factor IV Program, helps define
TARDEC’s technical career track.
Factor IV provides opportunities
for researchers to eventually move
into higher positions, such as
those of STEs. Gorsich emphasiz-
es the importance of publications,
patents, society memberships and
other factors in moving TARDEC
associates forward in their careers
and having the correct skill sets
needed by customers.
Looking Forward
Despite the economic challenges
ahead, Gorsich maintains that
TARDEC will continue to play
an essential role in developing
new technologies that will benefit
Soldiers. “We know that transporta-
tion and the need to have protected
mobility will always be crucial,”
he offered. “We know that there
will be a focus on having robust,
mobile, safe systems that are reli-
able — that is a given. Ultimately,
we have to continue to focus part
of the Army’s S&T portfolio on
improving ground systems viability
and performance, even with the
unpredictable economy. Because of
this and because the Nation cannot
afford to lose its automotive indus-
try and manufacturing base, we
are strengthening our partnerships
with industry. We cannot lose this
organic capability — it’s too tied in
to national defense and embedded
with so many different businesses
and jobs in the United States, so we
will address this issue over time.”
Michael I. Roddin is the TARDEC
Strategic Communications Director and
accelerate Editor-in-Chief. He holds B.S.
degrees in English and journalism from
the University of Maine and an M.S.
in marketing from the University of
Southern California. Roddin is a former
Army Advertising Program Manager
and 3-time Army Keith L. Ware Journal-
ism Award recipient. In 2005, he was
selected by the Secretary of the Army
for Editor-of-the-Year honors.
Chris Williams is a Writer/Editor with
BRTRC and provides contract support
to TARDEC’s Strategic Communica-
tions team. He has a B.A. in communi-
cation from Wayne State University in
Detroit, MI, and has previously written
for The Source newspaper in Shelby
Township, MI, and The Macomb Daily
and C & G Newspapers in Macomb
County, MI.
 TARDEC Ground Vehicle Integration Center Director Dr. Bruce Brendle
highlights Prototype Integration Facility (PIF) projects currently in
production at TARDEC facilities. Pictured from left: Brendle; Acting
PIF Associate Director Luis Hinojosa; Chiarelli; Mathes; Bochenek; and
Executive Director of Engineering Magid Athnasios.

Vice Chief of Staff of the Army (VCSA) GEN Peter W. Chiarelli

toured the U.S. Army Tank Automotive Research, Development and
Engineering Center (TARDEC) in Warren, MI, on Nov. 24, 2009.
During the visit, TARDEC Engineer Dr. Mark Brudnak (right)
showcased several test lab capabilities in TARDEC’s Ground Vehicle
Simulation Laboratory. From left: Chiarelli; TARDEC Director Dr.
Grace M. Bochenek; TARDEC Executive Director of Development
Thom Mathes; and TARDEC Military Deputy COL Eric Fletcher.
(U.S. Army TARDEC photos by Elizabeth Carnegie.)

Energy Storage Team Leader Sonya Zanardelli (right)

explains to Chiarelli TARDEC’s Power and Energy (P&E)
initiatives in developing advanced Lithium-ion (Li-ion)
batteries that improve energy storage capabilities.
TARDEC is shouldering numerous alternative energy/
energy storage challenges through its advanced P&E
initiatives, including developing advanced Li-ion batteries
that improve energy storage capabilities and researching
electric, hybrid and fuel cell technologies. The strategies TARDEC Engineer Harry Zywiol discusses the Ride Motion Simulator’s capabilities for
TARDEC is developing have the potential to change how total Soldier training immersion in this laboratory’s unique simulated environment.
the military uses fuel and energy over time. From left: Fletcher; Special Assistant to the VCSA in Science and Technology Dr. Kathleen
Quinkert; Bochenek; Chiarelli; and Zywiol.