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Development of the e-Zapper Mobile System for IED Neutralization

This project focuses on mobilizing the e-Zapper system designed for destroying IEDs. Key objectives include designing a platform for the e-Zapper and determining its power requirements. The work is divided into three teams focused on vehicle dynamics, power generation, and heat transfer. Key design specifications include trailer dimensions, ramp systems for loading and unloading, winch requirements, and the creation of a front-end support. This initiative aims to enhance the mobility and operational efficiency of the e-Zapper in combat situations.

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Development of the e-Zapper Mobile System for IED Neutralization

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  1. e-ZapperMobilized Support for destroying IED’s 1/C Emison, 1/C McHugh, 1/C Merrick, 1/C Schnappinger, 1/C Tang, 1/C White, 2/C Schwamberger Mentors: Prof. Nelson, Prof. Ziegler, CDR Hamilton, USN, CDR Nolan, USN, Steve Andrews of Technical Options and Mr. Delikat Funded by ONR/EOD NSWC-Indian Head (Scott Stewart)

  2. 2007 Project Objective • Mobilize the e-Zapper system • Design a platform on which the e-Zapper can be mounted. • Determine the Power Requirements to run the e-Zapper These objectives have been divided into three sub-teams • Vehicle Dynamics • Power Generation • Heat Transfer and Radiation

  3. Loading and unloading the e-Zapper unit onto a platform suitable for transporting the system Problem Statement

  4. The Trailer

  5. SPECIFICATIONS: Loading Height 17\" Attic Interior Height 32\" Riser Wall Height 45\" Sidewall Height 6\'3\" Lower Deck Box Length 35\'8\" GVWR 21,600# Payload Capacity 13,293# Axles 7200# Triple Rear Door Height 72\" Rear Door Width 87-1/2\" Rear Doors Ramp Platform Height 22\" Interior Width 8\'0\" Box Height/OA Height 8\'5\" Box Width/OA Width 8\'4\"/8\'6\" Interior Length 44\'0\" Overall Length 44\'6\" Pace American: SHADOW SCXG8544TTA5K

  6. Loading and Unloading the e-Zapper • Using a simple ramp and track system, the e-Zapper can be placed on the tracks and winched up and down the ramp.

  7. The Concerns • Weight distribution within the trailer • The weight of the e-Zapper on the ramp • The strength of the rollers used • Aligning the rollers with the track • The angle of approach and high centering • The winch requirements • Fabrication of a front end support for e-Zapper

  8. Trailer Layout 44.5ft

  9. The Ramp System

  10. The Ramp Selected • Landsport company • COMBO  40,000 lb. Capacity*, 16-foot Ramp Modular that doubles as 20,000 lb. Capacity Load Levelers (Plenty of strength to support e-Zapper) • 4 segments, 8 feet long, 20 inches wide • Price: $1995

  11. Swivel top roller dolly 5,000 lbs capacity each Steel 8 (length) x 6 (width) x 4.5 (height) in. $240.00 per roller 6 rollers needed The Rollers

  12. Angle of Approach 16’ ramp 6.58o 23” vertical to the trailer bed *Figure not to scale

  13. Break Over Angle 22” 42o Giving a maximum angle of approach 48o, without bottoming out on the interface of the ramp and the trailer bed.

  14. The Winch Requirements F_gravity F_sliding 16’ Ramp F_normal 6.58o F_gravity= 9,200 lbs F_normal= F_gravity*cos(6.58)= 9,139 lbs F_sliding= F_gravity*sin(6.58)= 1,054 lbs F_total= 1785 lbs (F_sliding + F_static) *F_total is the force needed to move the e-Zapper up the ramp

  15. The Winch • $490.00

  16. The Front End Support • The need to design and fabricate a support for the front end of the e-Zapper • Must be the same width as the rear supports in order for the rollers to align with the track. • Bending and compression stresses need to be taken into consideration.

  17. Existing Roller Attachment Location Front End Support Attachment Location

  18. Front End Support: Display of Deflection Front End Support: Display of Loads and Restraints Front End Support: Display of Safety Factor

  19. To Be Done • Front Support • Already engineered, needs fabrication • To hold front end of e-Zapper • Load Distribution • U-Track System • Necessary for alignment of e-Zapper during loading and unloading • Precision is vital (1/16” tolerance recommended)

  20. Experiment Results Max Current Drawn: 85 Amps

  21. Generator Requirements • Sound Enclosure • 208 Volts- 3 phase power • 60 Hertz • 100 Amps

  22. Generator Selection Generator Selection Choices Caterpillar Baldor Cummins Kohler

  23. Generator Selection Table

  24. Final Selection Baldor  IDLC30-JD Industrial Diesel Liquid CooledGenerators (IDLC)Standby / Prime Power Final Cost = appx. $10200 + shipping with sound enclosure

  25. Trailer Layout 44.5ft

  26. Basic e-Zapper Coolant System Schematic e-Zapper Sump / heat exchanger Centrifugal pump *drawing not to scale e-Zapper Coolant Medium Sump Coolant Medium Sump Heater

  27. Chiller Specifications CHILLER TEMPERATURE REQUIREMENT: 13.3 kW

  28. Ranking Factors for Chiller Selection For Chillers: 1=worst, 9=best For Factors: higher number=more important For Total: Higher number=best choice

  29. Selected Chiller • Cold Shot ACWC-60-E • $ 6465

  30. 1 in lead mrem Iron pipes Electronics Cabinet E-Zapper Concrete Beamstop ½ in lead Simulated Operator Position

  31. Deliverable Costs • Chiller-$7,000 • Ramp system- $3,000 • Rollers- $1,500 • Generator- $20,000 • Trailer- $30,000 • Radiation Shielding- TBD • Load Cells- $1,500 • Winch and Jack- $1,500 • All money comes from ONR/EOD-NSWC-IH budget

  32. Questions?

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