Weapon-Borne Micro Air Vehicle Developed for Bomb Damage Indication (BDI) Flight Test Demonstration

A team lead by System Dynamics is currently under Government contract to develop a weapon-borne micro air vehicle (MAV) to provide a BDI capability for large conventional air-launched weapons. The dispenser-housed MAV is ejected from the weapon tail kit several seconds prior to weapon impact.

Like most small UAVs, the MAV developed for the weapon-borne BDI flight test demonstration can be hand-launched from the ground in an auto-takeoff mode. However, due to the MAV's unique weapon-borne requirements, it has been specifically designed to accommodate deployment from an air-launched munition to perform the BDI mission. Some unique features of the MAV, which is equipped with a Procerus Kestrel v2.2 autopilot and a U-Blox LEA5H GPS receiver, include:

1. Autopilot software customized for airborne deployment
2. Wings fold to fit within 5" diameter dispenser
3. Umbilical cable enables serial communication with weapon flight computer and provides MAV power up/down capability
4. RF transmissions (video & telemetry) suppressed until MAV exits dispenser
5. NTSC video transmitted on Rover III-compatible L-Band (1840 MHz) -- CCD camera
6. MAV components heated for high-altitude delivery

Pictured below are the MAV and the tactical dispenser that have been developed for the weapon-borne MAV BDI program.

Dispenser Ejection and MAV Release Ground Tests

The tactical dispenser is designed to be ejected from a BDI canister mounted in the weapon tail kit. The MAV is then released after the parachute-equipped dispenser decelerates to a safe terminal velocity. A series of ground tests was conducted to ensure that: (1) the dispenser reliably exits the canister, (2) the parachute properly ejects, and (3) the MAV safely exits the dispenser.

Tactical Dispenser Ejection from Tail Kit Canister (2000 frames/sec) Ejected via BKNO3 propellant charge Borerider switch extends to enable arming of dispenser pyros and trigger timing circuit Real Time (154 KB) Slow Motion (1029 KB)
Parachute Ejection Test (2000 frames/sec) Chute pack for Low-Q flight tests Real Time (162 KB) Slow Motion (717 KB)
MAV Release from Tactical Dispenser (1000 frames/sec) Cable-cutter pyro initiated to open dispenser MAV wing unfurls Dispenser-to-MAV umbilical cleanly separates Real Time (84 KB) Slow Motion (886 KB)

Flight Worthiness Tests

The MAV and dispenser have undergone extensive environmental tests to verify their flight worthiness. The components have been cold-soaked at -40o C for one hour, heat-soaked at +70o C for one-hour, and exposed to a one-hour pressure chamber test to simulate extreme altitude (50,000 ft; 1.605 psi). Both the MAV and the dispenser performed as designed after exposure to these environmental conditions. Vibration and shock tests were then conducted with the dispenser/MAV installed in the BDI canister and tested per MIL-STD-810. The canister was secured to a mount that was attached to a Unholtz-Dickie shaker table.

MIL-STD-810 Vibration and Shock Tests 10.3 grms vibration along x, y, and z axes for one hour each Six, 20 g, 6-9 ms pulses along x, y, and z axes Vibration Test (1123 KB)

Live Deployment Test from Surrogate Tailkit (Low Altitude)

Low altitude deployment tests were conducted at Ft. Devens, MA to validate system hardware, software, and the critical sequencing of events in a moderate-dynamic environment. The dispenser (with MAV installed) was inserted into the BDI canister. The BDI canister and the dispenser ejection system hardware were then mounted in the tail kit of an inert MK-20. The MK-20 was carried aloft by a leased helicopter. When the MK-20 was released, two lanyards were severed to initiate an on-board timer mounted in the tail kit. After a programmed delay of a few seconds, the ejection system properly ejected the MAV dispenser. After ejection, the three dispenser events were performed as designed: (1) two parachutes (secondary and main) were immediately deployed, (2) the MAV was powered-up and (3) the dispenser opened and the MAV was released. Following release, the MAV wings immediately unfurled and the MAV autonomously stabilized and entered a CCW holding pattern to search for GPS satellites.

MK-20 released from helicopter Dispenser Ejected from MK-20 tail kit MAV released from dispenser and autonomously achieves stable flight Flight Test (3014 KB)

High Altitude Deployment Test

Following the low altitude tests, high altitude tests were conducted at the Naval Air Weapons Station at China Lake, CA. The inert MK-20 was released from a SK-35 Draken fighter aircraft at high altitude. The dispenser ejected from the MK-20 approximately 35 seconds after release, with the MK-20 descending at near sonic velocity. The dispenser parachute system deployed to decelerate the dispenser and the MAV was then released. The MAV immediately stabilized and acquired GPS satellites. It then autonomously flew over three miles to the programmed waypoint coordinates and executed the prescribed holding pattern about the coordinates. MAV telemetry data and streaming video were recorded throughout the flight.

Draken fighter releases MK-20 Dispenser Ejects from MK-20 tail kit MAV released and autonomously achieves stable flight MAV flies to programmed waypoint and executes prescribed holding pattern High Altitude Test (8311 KB)

Flyovers at Government Test Range

MAV flight tests were conducted over two designated sites at a Government test range. The objective of the flights was to gather MAVCam video data and record the video on the L-Band Rover III receiver. For the flights, the MAV was hand-launched in the auto-takeoff mode and programmed to fly to, and enter a holding pattern about, the site coordinates. The holding pattern was programmed to be a counter-clockwise circular loiter at a prescribed offset radius from the coordinates. After completing several revolutions of the site, the MAV was then commanded (via the ground station) to autonomously return to the launch site. In the vicinity of the launch site, the ground pilot took control of the MAV to safely land the air vehicle.

MAV hand-launched in auto-takeoff mode MAV quickly climbs to programmed altitude at desired airspeed Video recorded on Rover III receiver MAV Camera (8311 KB)

Automated Catapult-Launch MAV Flyovers following Live Weapons Tests

MAV automated catapult-launch missions have also been conducted at a Government test range. The intent of the missions is to catapult-launch the MAV in the vicinity of the impact site (within a few hundred meters) immediately after weapon impact. Following weapon impact, a wireless trigger signal is manually sent from the Control Center to an instrumentation van near the MAV launcher. A hard-wire activation signal is then routed from the van to the launcher and through the MAV umbilical cable to power-up the MAV autopilot. After the MAV acquires GPS satellites, the autopilot activates the throttle and sends a signal through the umbilical to the launcher electronics to launch the MAV. For all of these tests, the MAV has quickly achieved stable flight and successfully performed its pre-programmed BDI mission above the target site coordinates at three different viewing altitudes.

Automated Catapult Launch MAV climbs into clouds at intermediate waypoint MAV proceeds to impact coordinates transmitting BDI video Automated Catapult Launch (5900 KB)

For more information, contact Kevin Shortelle.