Photo By Justin Eimers | Dr. Clinton Holder, an electronics engineer at Tobyhanna Army Depot, designed a test...... read more read more
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TOBYHANNA ARMY DEPOT, Pa. — An innovative engineering solution developed here will save the depot more than $12 million over the next three years, exceeding Tobyhanna’s Value Engineering (VE) savings goal while improving component-level reliability within various systems.
Dr. Clinton Holder, an electronics engineer in the depot’s Production Engineering Directorate, designed a test set that will evaluate the detector/cooler bench (DCB), a major component of the Long Range Advance Scout Surveillance System (LRAS3), for faults and failures. The second generation forward looking infrared (SGFLIR) B-kit DCB allows the system into which it is installed to generate a clear infrared image of the battlefield.
LRAS3 is a long-range multi-sensory system that provides real time ability to detect, recognize, identify, and geo-locate distant targets and improvised explosive devices.
Program Manager – Ground Systems (PM–GS), Fort Belvoir, Virginia, started an overhaul program for the LRAS3 and tasked Tobyhanna with replacing the DCB in all applicable assets due to poor reliability of a continuously operating mechanism. With each replacement unit at a cost of more than $33,000, Holder realized the need for an alternative.
“Rather than replace the whole DCB because of failing cryocooler subassemblies, I designed a test set which provided in-house testing capability to verify that all specifications are met while exposed to extreme differences in temperature,” said Holder, adding that this will allow engineers to replace certain components rather than the entire DCB. The fiscal 2016 program requires 138 assets needing DCB replacement at a total cost of $4.6 million. Cryocooler replacement and testing is just over $4,000 per unit, resulting in a savings of $3.9 million for all units this year.
Two test stations were constructed in Tobyhanna’s engineering lab to carry out two tests — environmental stress screening and final acceptance. The first test requires recording the voltage, current and temperature every minute for 12 hours. The second involves eight hours of exposure to extreme changes in temperature during which the DCB is turned on and off repeatedly. Measurements are taken every 10 seconds. In both tests, the automated test set has the ability to simultaneously pass or fail up to four DCBs.
Since its inception, more than 100 cooler benches have had their cryocoolers replaced, successfully tested and have been certified for use. The units are also major components of the Abrams M1A2 commander’s independent thermal viewer and Bradley Fighting Vehicle’s improved Bradley acquisition subsystem.
James Waters, electronics engineer in the Continuous Process Improvement Directorate, spoke highly of both the work done by Holder for the LRAS3 mission and Tobyhanna’s VE initiatives.
“I’ve been associated with value engineering for more than five years and Holder’s proposal is the second-highest cost avoidance total I’ve seen for a project,” he said. “Not only did Tobyhanna surpass its VE savings goal in excess of $7 million, but CECOM was able to meet their goal as a result of savings associated with this effort.” Waters is the depot’s VE study facilitator.
John Link, systems engineer assigned to the SGFLIR system at PM–GS, highlighted the impact of the test set on this and other missions.
“This has proven to be a positive effort since costs to inspect, repair and test are much less at Tobyhanna than if the original equipment manufacturer had performed them,” he said. “Abrams [tanks] and Bradley [fighting vehicles] are actively working towards the goal of full repair capability of FLIR systems.”
Waters explained the importance of using this solution as a benchmark for future efforts.
“The more things we do to save money, improve processes and make our products better, the more successful we will be in our mission to deliver readiness around the globe,” he said.
Tobyhanna Army Depot is a recognized leader in providing world-class logistics support for command, control, communications, computers, intelligence, surveillance and reconnaissance systems across the Department of Defense. Tobyhanna's Corporate Philosophy, dedicated work force and electronics expertise ensure the depot is the Joint C4ISR provider of choice for all branches of the Armed Forces and industry partners.
Tobyhanna's unparalleled capabilities include full-spectrum logistics support for sustainment, overhaul and repair, fabrication and manufacturing, engineering design and development, systems integration, post production software support, technology insertion, modification, foreign military sales and global field support to our Joint Warfighters.
About 3,200 personnel are employed at Tobyhanna, which is located in the Pocono Mountains of northeastern Pennsylvania. Tobyhanna Army Depot is part of the U.S. Army Communications-Electronics Command. Headquartered at Aberdeen Proving Ground, Maryland, the command’s mission is to research, develop, acquire, field and sustain communications, command, control computer, intelligence, electronic warfare and sensors capabilities for the Armed Forces.
| Date Taken: | 08.26.2016 |
| Date Posted: | 08.26.2016 14:57 |
| Story ID: | 208324 |
| Location: | TOBYHANNA ARMY DEPOT, PA, US |
| Web Views: | 80 |
| Downloads: | 0 |
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