DEPARTMENT OF DEFENSE

Transcription

1 DEPRTMENT OF DEFENSE JOINT ORDNNCE TEST PROCEDURE (JOTP) GUIDELINE FOR QULIFICTION OF FUZES, SFE ND RM (S&) DEVICES, ND IGNITION SFETY DEVICES (ISD) DoD Fuze Engineering Standardization Working Group (FESWG) DISTRIBUTION STTEMENT. pproved for public release; distribution is unlimited. 1

2 FOREWORD 1. Beneficial comments (recommendation, additions, and deletions) and any pertinent data which may be of use in improving this document shall be addressed to: Chairman DoD Fuze Engineering Standardization Working Group U.S. rmy rmament Research, Development and Engineering Center TTN: rmy Fuze Management Office (RDR-EIF) Picatinny rsenal, NJ DoD, Guideline for Qualification of Fuzes, Safe and rm Devices (S&), and Ignition Safety Devices (ISD), dated, supersedes DoD FESWG Document , Guideline for Qualification of Fuzes, Safe and rm Devices (S&), and Ignition Safety Devices (ISD), dated 07 October

3 1. SCOPE This guideline provides guidance on qualification test plan definition of fuzes, S&s and ISDs. The primary purpose of the qualification guideline is to standardize a minimally acceptable test series, addressing safety and basic suitability for service use. It is expected that other tests and test items would be added, as required, based on unique program specifications and munition lifecycle to further support suitability for service use. This guideline applies to fuzes, S&s and ISDs. Exclusions include nuclear weapons systems and trainers, flares and signals dispensed by hand-held devices and pyrotechnic countermeasure devices. These tests do not replace the basic munition safety tests of MIL-STD This guideline has been developed by the DoD Fuze Engineering Standardization Working Group (DoD FESWG) for use by the rmy Fuze Safety Review Board (FSRB), the rmy Ignition System Safety Review Board (ISSRB), the ir Force Nonnuclear Munitions Safety Board (NNMSB), and the Navy Fuze and Initiation System Technical Review Panel (FISTRP). These Service Safety Review uthorities will review fuze, S& and ISD qualification test plans for compliance with this guideline. 2. PPLICBLE DOCUMENTS MIL-STD-331 MIL-STD-461 MIL-STD-464 MIL-STD-810 MIL-STD-1316 MIL-HDBK-1512 MIL-STD-1901 MIL-STD-1911 Fuze and Fuze Components, Environmental and Performance Tests for Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment Electromagnetic Environmental Effects Requirements for Systems Environmental Engineering Considerations and Laboratory Tests Fuze Design, Safety Criteria for Electroexplosive Subsystems, Electroexplosive Subsystems, Electrically Initiated, Design Requirements and Test Methods Munition Rocket and Missile Motor Ignition System Design, Safety Criteria for Hand-Emplaced Ordnance Design, Safety Criteria for 3

4 MIL-STD-2169 High ltitude Electromagnetic Pulse (HEMP) Environment (Copies of these documents are available online at or from the Standardization Document Order Desk, 700 Robbins venue, Building 4D, Philadelphia, P ) 3. REQUIREMENTS 3.1 General. s part of qualification, all fuzes, S&s and ISDs shall be subjected to Sequential Environment (Waterfall) Testing, Miscellaneous Tests, Performance Tests, and Electromagnetic Environmental Effects (E3) Tests. These requirements do not constitute an entire qualification program. Rather, they must be included as part of the qualification program. 3.2 Test Basis. In general, MIL-STD-331 should be used as the test basis for qualification of fuzes, S&s and ISDs. In the case where the Stockpile to Target Sequence (STS) environments are greater than those of MIL-STD-331, the STS environments must be employed. Tests from other standards (i.e., MIL-STD-810) or Test Operations Procedures (TOP) may be employed when there is no similar MIL- STD-331 test or such standards pose more severe test parameters. 3.3 Sequential Environment Testing Sequential environment testing representative of fuze, S& or ISD life cycle will consist of Transportation Vibration (Trans Vib), Temperature and Humidity (T&H), Extreme Temperature (ET), Thermal Shock (TS) and Tactical Vibration (Tac Vib) as a minimum. Non-operating environments should occur prior to operating environments in test series There are two methods for conducting Sequential Environment Testing. One of the two test methods shall be employed as part of a fuze, S& or ISD qualification program. minimum of thirty test items are required to be subject to all environments in prescribed sequence for either Method Method I. Method I is intended to be the baseline test series and includes full duration tests outlined in Figure 1a depicts the environmental test sequence for Method I. Figure 1b depicts an expanded notional example of the sequential test flow for Method I Method II. Method II requires the same sequential environment tests as in Method I, but allows for lesser T&H and ET test duration in the sequential path. However, additional, full duration T&H and ET tests must be conducted in parallel to the sequential tests. This allows for a reduced test schedule, but an increase in test items in comparison to Method I. Figures 2a and 2b depict the environmental test sequence 4

5 for Method II. Figure 2c depicts an expanded notional example of the test flow for Method II. minimum of three test items are required for each full duration ET and T&H tests conducted in parallel with the sequential environment tests in Method II Sequence of Environments. The sequence of environments for Test Methods I & II depicted in Figures 1a, 1b, 2a, 2b and 2c is the preferred sequence. Deviations from this should be considered on a case by case basis. 3.4 Miscellaneous Tests s part of the qualification program for fuzes, S&s and ISDs, the following safety tests shall be conducted on the fuze, S& or ISD: Primary Explosive Component Safety/Out-of-Line, Jolt, Jumble One-and-a-half Meter (5 foot) Drop, Transportation Handling, Transportation Vibration and Twelve Meter (Forty Foot) Drop. (One-and-ahalf Meter Drop test not required here if conducted as part of Sequential Environment Tests.) Miscellaneous Tests shall be conducted as described in Figure dditional Miscellaneous Tests shall be conducted as described in Figure 4. 5

6 TRNSPORTTION VIBRTION MIL-STD-331C Test B1.1 TEMPERTURE & HUMIDITY MIL-STD-331C Test C1 EXTREME TEMPERTURE MIL-STD-331C Test C6 THERML SHOCK MIL-STD-331C Test C7 TCTICL VIBRTION 6,7 MIL-STD-331C Test B3 C Sequential Environment Tests Method I 1,2,3,5,8,9 n start C C B C B C B C B B n final 30 Notes: 1. Does not include other unique environments that may be required by the weapon system program, i.e., acoustics, altitude, rapid decompression, mechanical (launch, dispense, other), shock, salt fog, etc. 2. Sequential environmental testing should be representative of item/munition life cycle. Non-operating environments should occur prior to operating environments in test series. 3. Total number of test items sequentially exposed to all environments should be no less than 30. More than 30 items total may be required. mbient temperature testing is not mandatory. Test items should be split between hot and cold test tracks. Navy requires some test assets be alternated between hot and cold test tracks. Coordinate with appropriate Service Safety uthority. (Unique to Program) C B B (Safe, rm, Fire/Intended Output Performance) C Visual Inspection, X-Ray, 4 4. No mechanical arming and re-safing, (clearing of potential/growing failure mode). 5. Temperature pre-conditioning of test items does not apply to T&H, Extreme Temp and Thermal Shock tests. 6. This test only required when applicable. For example, in general, this applies to missiles and rockets, but not necessarily mortars. 7. Testing on items in both safe and arm modes required as applicable. 8. Service Safety Review uthority should be consulted on need for 1.5m (5ft) drop testing to be conducted as part of the Sequential Environment al Test Series. 9. Dashed events are optional. n start = total number of test items at beginning of test series (= n final + S test B items) n final = total number of items subject to all sequential environments at end of testing Figure 1a. Sequential Environment Testing Method I 6

7 Start (n start ) Transportation Vibration (MIL-STD-331C, Test B1.1) HOT COLD Temperature & Humidity (MIL-STD-331C, Test C1) Extreme Temperature (MIL-STD-331C, Test C6) HOT COLD Thermal Shock (MIL-STD-331C, Test C7) Tactical Vibration (MIL-STD-331C, Test B3) HOT COLD End (n final ) KEY: Required Step Optional Step Figure 1b. Method I Test Flow Expanded 7

8 TRNSPORTTION VIBRTION MIL-STD-331C Test B1.1 TEMPERTURE & HUMIDITY 6 MIL-STD-331C Test C1 (modified) EXTREME TEMPERTURE 6 MIL-STD-331C Test C6 (modified) THERML SHOCK MIL-STD-331C Test C7 TCTICL VIBRTION 7,9 MIL-STD-331C Test B3 C Sequential Environment Tests Method II 1,2,3,5,10,11, * n start C C B TEMPERTURE & HUMIDITY 8,12 MIL-STD-331C Test C1 3 Units D C B MIL-STD-331C Test C6 3 Units EXTREME TEMPERTURE (HOT) 8,12 D C B MIL-STD-331C Test C6 3 Units EXTREME TEMPERTURE (COLD) 8,12 D C B B n final 30 n start = total number of test items at beginning of test series (= n final + S test B items) n final = total number of items subject to all sequential environments at end of testing * See next page for notes and intermediate test steps Figure 2a. Sequential Environment Testing Method II 8

9 (Unique to Program) C B B (Safe, rm, Fire/Intended Output Performance) C Visual Inspection, X-Ray, 4 D Visual Inspection, X-Ray (Safe, rm, Fire/Intended Output Performance) Sequential Environment Tests Method II Notes Notes: 1. Does not include other unique environments that may be required by the weapon system program, i.e., acoustics, altitude, rapid decompression, mechanical (launch, dispense, other), shock, salt fog, etc. 2. Sequential environmental testing should be representative of item/munition life cycle. Non-operating environments should occur prior to operating environments in test series. 3. Total number of test items sequentially exposed to all environments should be no less than 30. More than 30 items total for sequential testing may be required. Similarly, more than three test units each for full duration T&H and Temperature Extreme testing may be required. mbient temperature testing is not mandatory. Test items should be split between hot and cold test tracks. Navy requires some test assets be alternated between hot and cold test tracks. Coordinate with appropriate Service Safety uthority. 4. No mechanical arming and re-safing, (clearing of potential/growing failure mode). 5. Temperature pre-conditioning of test items does not apply to T&H, Extreme Temp and Thermal Shock tests. 6. These tests can be of decreased duration (14 day duration each test, each test temperature). 7. This test only required when applicable. For example, in general, this applies to missiles and rockets, but not necessarily mortars. 8. Full 28-day duration tests. 9. Testing on items in both safe and arm modes required as applicable. 10. Service Safety Review uthority should be consulted on need for 1.5m (5ft) drop testing to be conducted as part of the Sequential Environment al Test Series. 11. Dashed events are optional. 12. Test quantities for these parallel tests should be no less than three for each test. ** Figure 2b. Sequential Environment Testing Method II Notes 9

10 Start (n start ) Start (n TH ) Temperature & Humidity (MIL-STD-331C, Test C1) Visual Inspection, X-ray Transportation Vibration (MIL-STD-331C, Test B1.1) HOT COLD Fire) End (n TH ) Temperature & Humidity (Modified MIL-STD-331C, Test C1) Start (n ETH ) Extreme Temperature (Hot) (MIL-STD-331C, Test C6) Visual Inspection, X-ray Extreme Temperature (Modified MIL-STD-331C, Test C6) HOT COLD Fire) End (n ETH ) Thermal Shock (MIL-STD-331C, Test C7) Start (n ETC ) Extreme Temperature (Cold) (MIL-STD-331C, Test C6) Tactical Vibration (MIL-STD-331C, Test B3) HOT COLD Visual Inspection, X-ray Fire) End (n ETC ) KEY: Required Step End (n final ) Optional Step Figure 2c. Method II Test Flow Expanded 10

11 Miscellaneous Tests PRIMRY EXPLOSIVE COMPONENT SFETY/OUT-OF-LINE 1 MIL-STD-331C Test D1 Electrical Stress Tests as per Service Safety Review uthority 3 Units JOLT 2 MIL-STD-331C Test 1 3 Units JUMBLE 3 MIL-STD-331C Test Units 1.5M(5FT) DROP 4 MIL-STD-331C Test 4.1 Notes: 1. Primary Explosive Component Safety/Out-of-Line tests not required for in-line items. 2. rmy requires Jolt for out-of-line items. Navy requires it for all items. ir Force does not require it. 3. rmy requires Jumble for out-of-line items. ir Force requires it for all items. Navy does not require it. 4. Service Safety Review uthority should be consulted regarding need for 1.5m (5ft) drop testing to be conducted as part of the Sequential Environmental Test Series. Figure 3. Miscellaneous Tests 11

12 dditional Miscellaneous Tests TRNSPORTTION HNDLING 1 MIL-STD-331C Test 5 PROJECTILE FUZE RMING DISTNCE 3 MIL-STD-331C Test D1 TRNSPORTTION VIBRTION MIL-STD-331C Test B1.1 12M/40FT DROP 2 MIL-STD-331C Test 3 RM, LL-FIRE, NO-FIRE TCTICL PERFORMNCE 4 MIL-DTL Firing Properties Notes: 1. Test 5 meant to be conducted in conjunction with Transportation Vibration (B1.1). This test applies to items packaged for Level, maximum military protection, IW R Conducted on bare item or packaged configuration (warhead or inert-warhead assembly, cartridge, etc.). n inspection of the fuze/isd safety features shall be made after the test. 3. rming distance for munitions other than projectiles shall be verified by suitable means. 4. For inline fuzes. Figure 4. dditional Miscellaneous Tests 12

13 3.5 Performance Tests s part of the qualification program for fuzes, S&s and ISDs, the following performance tests shall be conducted: Progressive rm, Subverted Jolt (two configurations), Subverted Jumble (two configurations), Subverted 1.5m (5 ft) Drop (two configurations) and rm, ll-fire, No-fire Tactical Performance The subverted Jolt, Jumble and 1.5m Drop tests require two configurations to be tested. One configuration has the first safety feature intact, with the second safety feature subverted. The other configuration has the second safety feature intact with the first safety feature subverted. Each of these tests will be conducted with the required quantities of each configuration Performance Tests shall be conducted as described in Figure Electromagnetic Environmental Effects (E3) Tests The following E3 tests shall be conducted as part of the qualification program for fuzes, S&s and ISDs: Personnel-Borne Electrostatic Discharge (ESD), Helicopter-Borne ESD, Power Supply Transients, Lightning Effects, Electromagnetic Radiation (EMR), Electromagnetic Pulse (EMP) and Electromagnetic Interference (EMI) E3 Tests shall be conducted as described in Figure 6. 13

14 Performance Tests PROGRESSIVE RM 2,3 MIL-STD-331C Test D8 (SUBVERTED I) 1.5M/5FT DROP 1 MIL-STD-331C Test Units (SUBVERTED II) 1.5M/5FT DROP 1 MIL-STD-331C Test Units (SUBVERTED I) JOLT 1 (SUBVERTED I) JUMBLE 1 MIL-STD-331C Test 1 3 Units MIL-STD-331C Test Units (SUBVERTED II) JOLT 1 (SUBVERTED II) JUMBLE 1 MIL-STD-331C Test 1 3 Units MIL-STD-331C Test Units Notes: 1. Subverted Safety test unit configuration (inert or live) should be coordinated with the appropriate Service Safety uthority. 2. Progressive rm tests not required for in-line items. 3. Progressive rm test not applicable to zip/snap/non-progressive arm items unless used for purposes of gathering statistics for out-of-line safety. Figure 5. Performance Tests 14

15 Electromagnetic Environmental Effects (E3) Tests 4 PERSONNEL-BORNE ESD 1 HELICOPTER-BORNE ESD 1,3 MIL-STD-331C Test F1.1/2 F MIL-STD-331C Test F1.1/2 F POWER SUPPLY TRNSIENTS (PST) LIGHTNING EFFECTS (LE) see Misc Safety Tests Electrical StressTests MIL-STD-1316, 1901 & 1911 MIL-STD-464 ELECTROMGNETIC RDITION (EMR) 5 MIL-STD-1316 & 1911 MIL-HDBK-1512 & MIL-STD-464 MIL-STD-1901 MIL-STD-464 MIL-STD-331C Tests F3.1, F4.1 ELECTROMGNETIC PULSE (EMP) 2 MIL-STD-1316 & 1911 MIL-STD-2169 MIL-STD-1901 MIL-STD-464 MIL-STD-331C Test F2.1 ELECTROMGNETIC INTERFERENCE (EMI) MIL-STD-1316 & 1911 MIL-STD-461 MIL-STD-1901 MIL-STD-464 Notes: 1. Items shall be tested in all expected electrostatically-significant handling configurations, i.e., with and without caps, covers, protective devices, etc. Rationale for proposed exclusion of energetics must be made. 2. MIL-STD-464 refers to MIL-STD-2169 (classified) for EMP. This test should be conducted only as applicable to program. 3. This testing is typically conducted at a system level. HESD testing at the bare item level may be required. 4. E3 test item quantities to be coordinated with the appropriate Service SMEs. 5. EMR testing includes appropriate Hazards of Electromagnetic Radiation to Ordnance (HERO) test(s). Figure 6. Electromagnetic Environmental Effects Tests 15

16 4. CRONYMS FSRB DoD E3 EMI EMP EMR ESD ET FESWG FISTRP HEMP HERO HESD ISD ISSRB JOTP LE NNMSB PESD PST S& SME STS T&H Tac Vib TOP Trans Vib TS U.S. rmy Fuze Safety Review Board Department of Defense electromagnetic environmental effects electromagnetic interference electromagnetic pulse electromagnetic radiation electrostatic discharge extreme temperature DoD Fuze Engineering Standardization Working Group U.S. Navy Fuze and Initiation System Technical Review Panel high altitude electromagnetic pulse hazards of electromagnetic radiation to ordnance helicopter-borne electrostatic discharge ignition safety device U.S. rmy Ignition System Safety Review Board Joint Ordnance Test Publication lightning effects U.S. ir Force Nonnuclear Munitions Safety Board personnel-borne electrostatic discharge power supply transients safe and arm subject matter expert stockpile to target sequence temperature & humidity tactical vibration test operation procedure transportation vibration thermal shock 16