Technology ISSN : 0971-4413 BULLETIN OF DEFENCE RESEARCH AND DEVELOPMENT ORGANISATION Vol. 18 No. 4 August 2010 TECHNOLOGIES FOR SONAR SYSTEMS Sonar systems have undergone evolutionary changes from unitary systems to composite systems where fusion of data from multiple sensors makes sonar displays highly user-friendly. Over the last three decades, DRDO has designed, developed and inducted several sonar systems for the warships and submarines of the Indian Navy to enhance its capabilities. S onar is basically a remote sensing technique that uses sound waves to detect, locate and identify objects in water. The term sonar is an acronym for Sound Navigation and Ranging. Sonars are the eyes and ears of ships or submarines in water and are mainly used for underwater navigation and surveillance. Civilian uses of sonar include determination of water depth, mapping the ocean floor, locating various objects in the ocean, determining the characteristics of ocean bottom, and even fish finding. Sonar system consists of underwater transducers, front-end signal conditioning units, signal processors, and displays. Sonar transducers transmit acoustic power and pick up the echo returns or merely listen to the underwater sounds, process the signal and provide information about targets on the display units. High Bandwidth Real-time Sensor Data Real-time Information and Control Data Raw Data Bus FE Front-end Hardware Gigabit Ethernet Transducers Display Data Bus Signal Processing and Post Processing Sub-systems Gigabit Ethernet Raw Data Processed Data Data Recorder Functional Layout of a typical Sonar System Display MESSAGE SONAR systems still remain the primary surveillance technique for ships and submarines in naval warfare. In the case of submarines, SONARs are the eyes and ears underwater. Ocean going platforms being relatively slow moving, airborne surveillance SONARs play a key role in early warning. Naval Physical and Oceanographic Laboratory has been the pioneering R&D establishment in the country responsible for near-total self-reliance in airborne, surface ship-mounted as well as submarine-borne SONAR systems of the Indian Navy. The technologies associated with SONAR systems, viz., signal processing, power amplifiers, transducers, handling gears, hydrodynamics, oceanographic, etc., are complex and multidisciplinary. This issue of Technology Focus lucidly brings out the cutting-edge accomplishments of DRDO, in various enabling technologies that makeup the three-dimensional world class SONARs. I am sure this effort would go a long way in providing the readers, a quick awareness in this specialised area. Dr J Narayana Das OS & Chief Controller R&D (NS, M & HR) MESSAGE Vol. 18 No. 4 August 2010 02 The SONAR systems being the only sensor system that has the capability to overcome the limitations of the underwater environment, it provides the capability for surveillance of undersea situation by naval platforms and ultimately provides inputs for launch of weapons to neutralise opposing forces. It also enables safe navigation, obstacle avoidance and underwater communication. Considering its strategic utility for the underwater vessels, availability of indigenously developed technology in SONAR systems is critical to our Navy. It is a matter of great pride that various SONAR systems developed by DRDO have been inducted into Naval platforms and their operational utility has provided impetus for further improvement/upgradation and development of new configurations of underwater systems in tune with global standards. Some of the recent developments of DRDO pertaining to this technology have been summarised in this Special Issue of Technology Focus. These will augur excellence in indigenous developments in this area and further optimise the configuration of the systems. Commodore PK Mishra Director Naval R&D and Member Editorial Board Technology Focus From the Desk of Special Editor For an emerging economic power like India with 7600 km long coastline, 12 major and 184 minor ports, and 90 per cent of its international trade through sea routes, the importance of defending its coastline against threats through superior underwater surveillance capability needs no emphasis. Over the last three decades, DRDO has designed, developed and inducted several sonar systems for the warships and submarines of the Indian Navy to enhance this capability. Surface ship sonars like APSOH, HUMSA, and HUMSA NG, submarine sonars like PANCHENDRIYA and USHUS, TADPOLE sonobuoys for airborne applications are some of the major systems delivered by DRDO and exploited by Navy. Several technologies for the towed array sonar and airborne dunking sonar have also been developed by DRDO during this period. DRDO has been working very closely with PSUs, private sector industries, and academic institutions for the design, development, production, and induction of sonar systems. With the increasing requirement for sonar systems for the new platforms being acquired by the Indian Navy, the industry has evinced keen interest in absorbing the complex sonar technologies. Moreover, the sonar systems have undergone evolutionary changes from unitary systems to composite systems where fusion of data from multiple sensors makes sonar displays highly user-friendly. Riding on the revolutionary changes offered by the computation and communication technologies, and the indigenously developed models for prediction and interpretation of sonar performance in Indian waters, user has gained more confidence in exploitation of these sonar systems. The large number of unique testing facilities established under DRDO for evaluation of sonars have been gainfully utilised by both Navy and industry alike. This issue of Technology Focus gives a summary of various technologies that are at work in the development and induction of sonar systems. New sonar technologies are under development in DRDO in consonance with the advances in commercial technologies and increasing demands on performance and reliability of sonar systems. induction of advanced sonar systems. S Anantha Narayanan OS & Director Naval Physical & Oceanographic Laboratory (NPOL), Kochi Vol. 18 No. 4 August 2010 03 We are confident that these will further strengthen the surveillance capability of our naval forces through Sonar for naval applications broadly falls into two categories: active and passive. Active sonar emits pulses of sound waves that travel through the water and processes the received target echo to estimate the range, bearing, and Doppler of the target. Passive sonar involves processing the sound signal generated by the target for estimating the bearing and target characteristics through spectrum analysis. The information gathered by the sonar is fed to the Fire Control Systems to compute other target parameters like speed, course, and range. Intercept sonars are early warning systems aiding classification of targets by processing the transmitted signals of other platforms. Obstacle-avoidance sonars are high frequency active sonars for submarines to aid safe surfacing operations. Underwater communication systems permit communication between platforms through acoustic means in different modes including voice, telegraph, and data. For submarines, the sonar is also the navigation equipment. Sonar systems can also be used to realign inertial navigation systems by identifying known ocean floor features. The performance of a sonar system is strongly influenced by the ocean environment, which is highly unpredictable, thereby making the development of a sonar system a challenging task. Continued ocean studies for better understanding of Algorithm To offset the adverse effects on detection by the bathymetric profile of the ocean and self-noise of the platform, the deployment mechanisms of sonar transducers have undergone changes to maximise the detection range. Though the hull-mounted and bowmounted transducers are the most common approaches, the variabledepth towed array sonars also help in detection of targets and torpedoes below the surface-sound channel. Dunk bodies housing transducers and associated electronics are dipped from helicopters for ASW Oceanography Design Vol. 18 No. 4 August 2010 04 the ocean are being pursued and better acoustic propagation models are being developed for accurate estimation of predicted ranges. Modelling & Simulation MMI/Display Materials Transducers Signal Processing Signal Conditioning Sensor Structures/Handling Systems Advanced Sonar Systems Technologies DRDO has been striving to meet the aspirations of the Indian Navy on sonar systems through the technologies and systems developed by the Naval Physical and Oceanographic Laboratory (NPOL) at Kochi. During the last four decades DRDO has delivered various types of sonar systems for ships, submarines, and airborne platforms of Indian Navy, and thereby NPOL has matured as a System Laboratory of DRDO. Keeping in view the growing strategic requirements of the Indian Navy, the Laboratory is focusing on developing advanced sonar systems technologies. Over the years, Advanced Sonar Systems technologies being developed by NPOL have made an impressive growth in the research and development in all the above areas. This special issue of Technology Focus highlights the technologies developed and implemented into various subsystems and the technologies transferred to production agencies for realising the sonar systems inducted in various Naval platforms. Sonar systems rely on acoustics and a suitable transduction of the acoustic energy to electrical energy. NPOL has pioneered the designing of transducer using finite element analysis. The designs have been prototyped and engineered for use in ship, submarine, and helicopterborne sonar systems. Their detailed acceptance tests and characterisation have also been done using the unique test facilities available at NPOL. Usually these acoustic transducers are made of piezoelectric materials; their working principle is based on piezoelectric effect. Acoustic transducers are mainly of two types—projector for underwater transmission and hydrophone for reception. The piezoelectric ceramics used in these transducers are indigenously manufactured at a cost that is comparable to that of imported Single Stave components but meet tighter tolerances. The technology for manufacturing the transducers has been transferred to production agencies. There are mainly four different types of designs for underwater projectors. Tonpilz (German for “singing mushroom”) transducers are used in active sonar systems to radiate high levels of directional acoustic pressure. The echo is received through a hydrophone array and processed to detect, track, and classify targets. Members of this family of transducers have been used in active submarine sonar, active ship sonar, underwater communication, and obstacle-avoidance systems. Several Tonpilz transducers have been designed and developed with a high transmitting voltage response, a 3 dB bandwidth of more than one octave, and a power-to-weight ratio much higher than that achieved Circular Array Vol. 18 No. 4 August 2010 05 detection of sub-surface targets. These requirements have posed new challenges in sonar technology development related to winches and towed bodies. Development and characterisation of exotic materials for sonar systems in various areas like composite materials, nanomaterials, baffles, encapsulants, etc., are important for improved reliability and enhanced life of transducers and interconnect materials. earlier. Transducers, in this family, with resonance frequencies ranging from 1.5 kHz to 25 kHz are individually encapsulated, are capable of operating at a depth of 300 m for more than 10 years, and have been extensively tested and characterised. Tests with specially tuned transducers and indigenous power amplifiers have demonstrated very high source level over reasonably large bandwidth. Vol. 18 No. 4 August 2010 06 Most of these transducers are also used as hydrophones to receive the echo. In addition, these are also used in passive sonar operations where the usable bandwidth is much higher as the receiving sensitivity has a rolloff below resonance and, therefore, reduces the high and low frequency ambient noise. The flextensional transducer has a shell that is driven by piezoelectric ceramic stacks. The extensional vibration of the electrically-excited stack causes the shell to flex, giving the transducer its name. These transducers are well suited for low frequency sonar applications because these are omni-directional. These have better power handling capacity, and power-to-weight and power-to-size ratios much higher than those of Tonpilz transducers. The shape of the shell determines the class of the transducer. A family of class IV transducers has been designed using finite element analysis. These transducers have elliptical cylindrical shells, made of transducers have been indigenously developed. The technology for manufacturing these transducers has been transferred to industrial partners. Flextensional Transducer aluminium, that are excited by stacks of piezoelectric ceramics. Flextensional transducers with low resonant frequencies have been designed and developed for use in helicopter-borne dunking sonar systems and ship-borne towed sonar systems. The arrays have been pressure tested to operate at depths up to 300 m. Efforts are on to further achieve lower frequencies. Piezoceramics used in these Hydrophones are broadband receivers used in passive surveillance, intercept, and towed array sonars with very good free-field receiving sensitivity and effective acceleration compensation. These devices are designed for deep water applications with long operational life for submarine sonar systems. Hydrophones have omnidirectional response in the radial direction in desired frequency range. Mainly there are three different kinds of acceleration-balanced hydrophones: Passive Surveillance Array (PSA) hydrophones; Medium Frequency (MF) intercept hydrophones; and towed array hydrophones. The PSA hydrophone is one of the broadband hydrophones operating in the frequency range up to 10 kHz without any baffles. The hydrophone is capable of operating up to a depth of 600 m and has an operational life of more than 7 years. It has omnidirectional response in radial direction up to 10 kHz within 1dB. Its specially designed mounts at the ends, with central spacer design, provide low acceleration sensitivity. Low Frequency Flextensional Transducer Array The MF intercept hydrophone is a wideband hydrophone used in the PSA Hydrophone frequency above 10 kHz. This is capable of operating up to a depth of 450 m. Two piezoelectric ceramic tubes have been assembled with passive components and encapsulated using PV bonding technology. DRDO has excelled in developing different types of towed array hydrophones with a wide operational frequency range. These hydrophones are small in size and moulded with oil-compatible rubber encapsulant. The technology has been transferred to production agency for the bulk fabrication of the hydrophones. Intercept Hydrophone for MF Band Electro-acoustic reference transducers of two different types have been designed for underwater acoustic measurements and calibration to work over different Reference Transducers: NP 20 and NP 30 (top) Towed Array Hydrophone operating bands. These transducers work as a projector as well as a hydrophone. As a projector, it operates over a wide frequency band and is capable of providing high acoustic source level. As hydrophones, these provide flat frequency response. The transducer technology has been transferred to production agency. DRDO has designed and developed high frequency transducers using 1-3 piezocomposites. Specifications: Reference Transducers NP 30 NP 20 Resonance frequency 30 + 1 kHz 21 + 1 kHz Usable frequency frequency range range Usable 3-60 kHz kHz 3-60 1-50 kHz kHz 1-50 Beam pattern Omni (horizontal) Toroid (vertical @ 12 kHz) Omni (horizontal) Toroid (vertical @ 10 kHz) Operating depth 0-300 m with + 1.5 dB variation 0-300 m with + 1.5 dB variation Input power 400 W 400 W Cable length 30 m 30 m Vol. 18 No. 4 August 2010 07 Parameters The design is basically different from that of conventional low frequency transducer arrays. An array of 1-3 piezocomposite was first fabricated and the individual transducer elements were defined later by applying patterned electrodes on the major surfaces. A few prototypes of 150 kHz transducer arrays have been eva lua ted under wa ter . The se transducers are useful for high resolution underwater imaging applications such as Mine Hunting Sonar and Diver Detection Sonar. Vol. 18 No. 4 August 2010 08 Transducers with Micro-ElectroMechanical Systems (MEMS) technology are being developed at NPOL for miniature sensor array system especially for thin-line towed arrays (TLTA). MEMS are miniature devices or systems that combine electrical and mechanical components fabricated using IC batch processing technology. In MEMS, sensors and actuators are monolithically integrated with signal conditioning, interface circuits and 1-3 Piezocomposite Transducer Arrays Receiver. Inset: Projector electronics to generate intelligent microsystems that perform superbly at a reduced cost. MEMS hydrophone is one of the devices developed by DRDO. It comprises an extended gate MOSFET (Metal-Oxide-Semiconductor FieldEffect Transistor) and a piezoelectric sensor. The piezoelectric material senses the acoustic pressure fluctuation and an on-chip N–type depletion mode MOSFET amplifies the signal. It also acts as an impedance matching device. Five-element TLTA using MEMS Hydrophone Silicon MOSFET was fabricated using MOS process technology. MOSFET hydrophone has been mounted on a PCB (21mm x 14 mm) with a pre-amplifier. These hydrophones are encapsulated in acoustically transparent potting material. Dimension of individual hydrophone after encapsulation is 35 mm x 25 mm x 5 mm. These miniature sensors find applications in TLTA for submarines, surface ships, and Unmanned Surface Vessels (USV). Power Amplifier (PA) is an integral part of active sonar systems, and amplifies the sonar signal to the Switched Mode Power Amplifier Linear Power Amplifier Type levels required by the transducer element. NPOL has developed compact and energy-efficient power amplifier plug-in modules of different power handling capacities Technology in both linear and switched modes for use in several sonar systems. Major types of power amplifiers designed by the Laboratory are: Application (a) Quad wideband linear power amplifier MOSFET-based linear class AB Mine hunting sonar, obstacle avoidance sonar, echo sounder and side-scan sonar multichannel wideband ac source and fishing sonar (b) Wideband high power linear amplifier Power BJT-based linear class AB PA for broadband active sonar and broadband underwater communication systems and wideband ac source and audio power amplifier (c ) Energy efficient class S digital power amplifier Power MOSFETbased class S Diver deterrence sonar and low frequency echo sounder (d) IGBT-based class D high power amplifier Power IGBTbased class D Low frequency active sonar (e) MOSFET-based class D high power amplifier Power MOSFETbased class D Low frequency active sonar Quad Wideband Linear Power Amplifier (NP-LAQ-HF-0050) Configuration Power output/Amplifier Duty cycle Distortion at full load Frequency band Load impedance Dimensions (W x H x D) Weight : : : : : : : : Quad, linear class AB 50 W rms 10 % < 0.5 % 10 kHz to 100 kHz 500 Ω; Cane tailored to any load 21TE x 3U x 235mm < 4 kg Wideband High Power Linear Amplifier NP-LAS-WB-1000) Specifications Configuration Power output : : Linear class AB, bridge 1000 W rms Vol. 18 No. 4 August 2010 09 Specifications Duty cycle Distortion at full load Frequency band Load impedance Dimensions (W x H x D) Weight : : : : : : 10 % <2% 1 kHz to 12 kHz 125Ω; can be tailored to any load 21TE x 3 x 235 mm < 5 kg Energy Efficient Class S Digital Power Amplifier (NP-SAS-LF-3000) Specifications Type Configuration Power output Duty cycle Power control Operating frequency Load impedance Dimensions (W x H x D) Efficiency : : : : : : : : : Plug in, Blind mate type Full bridge class S switching 3000 W rms 10 % 0 to -9 dB in 3 steps 1 kHz to 10 kHz 100 - 400 Ω 10 % 21TE x 3U x 220 mm > 90 % IGBT-based Class D High Power Amplifier (NP-SAS-LF-5000) Specifications Configuration Switching technique Input Power output Duty cycle Power control Operating frequency Load impedance Efficiency Dimensions (W x H x D) : : : : : : : : : : IGBT full bridge PWM, class D Pulse width modulated signal 5000 W rms (max.) 10 % 0 to -6 dB in two steps 2.5 kHz to 6.5 kHz 200 Ω + 10 % >80 % 135 mm x 6U x 230 m MOSFET-based Class D High Power Amplifier (NP-SAD-LF-2000) Vol. 18 No. 4 August 2010 10 Specifications Configuration Switching technique Input Power output Duty cycle Power control Distortion at full load Operating frequency Load impedance Efficiency Dimensions (W x H x D) : : : : : : : : : : : Power MOSFET full bridge Uni-polar PWM, class D Pulse width modulated signal 2000 W rms (max.) 10 % duty cycle 0 to -42 dB (linear) < 0.5 % 2.5 kHz to 6.0 kHz 200 Ω + 10 % > 90 % 21TE x 3U x 220 mm Towed Array Electronics Specifications: Towed Array Data Acquisition System Output Acoustic sensors Serial data rate Power Dimension Length Outer diameter : : : : 2 x 160 channel/12 bit 96 + 128 24 Mbps + 24 Mbps 1 A at 300 V dc : : 200 m 80 mm transmission through a serial fibreoptic link is a challenging task. Fibre-optic data telemetry system has been developed for use in towed array sonar. The towed array electronics is a distributed multichannel real-time digital data acquisition system. The major challenges involved in it are: simultaneous acquisition of data from multiple channels, transmission of the data over tow cable of over 1 km length, and synchronisation of transmitter with the onboard receiver for accurate reconstruction. The acoustic and environmental sensors operate at different amplitude levels and frequency bands with analog and digital outputs in serial/parallel format. Acquisition of information from these varying sources distributed in an elongated towed body (which can be up to 1 km long) and combining these into a common interface for The realisation of the multichannel signal conditioning and data telemetry function has been achieved in a compact hardware form (housed in a polyurethane tube) for operations in high pressure and harsh dynamic conditions. The realisation of data in digital form has distinct advantages over analog systems. The entire hardware has been realised in multiple modules interfaced with water-blocked electromechanical connectors to enable easy repair and maintenance. This technology has been successfully demonstrated and used in towed array sonars. Coastal Surveillance Systems are essential to counter the asymmetric threats posed by hostile submarines, boats, and divers. DRDO has developed two core technologies̶ Seabed Arrays Technology and Diver Deterrence System—as part of a coastal surveillance system. Seabed arrays are off-board passive sonars, which can be deployed on the seabed for monitoring strategic locations at sea on a continuous basis to assess the threats from submarines and submersibles . A seabed system with capability to detect multiple targets around 360 without any left/right ambiguity and end-fire anomaly, has been developed and proven for performance. Multiple-arrays deployed with appropriate spatial separation will facilitate the passive range estimation of the target too. The system consists of multiple linear hydrophone arrays with a data acquisition system. The data can be transferred to a processing station at the coast. Vol. 18 No. 4 August 2010 11 Towed arrays are one of the well sought out technologies meant for getting better immunity from own ship noise because of towing the array far behind the towing ship. Also, the large aperture possible with large number of sensors assembled at relatively larger l/2, promises better range. Towed array combines a host of technologies, viz., packaging large number of sensors into a proper deployable casing, deployment from a moving platform, and digitisation and telemetry of acoustic and non-acoustic sensor data. Solid Linear Acoustic Sensor (SOLASE) array is the latest addition to the family of underwater acoustic surveillance arrays for seabed applications. It is designed and developed to alleviate the inherent problems of puncture damages and oil leakages associated with the manufacture and operation of the oil-filled version. SOLASE is a polymer-based monolithic flexible solid structure that embeds the sensors and allied electronics. It is a multi-channel linear passive acoustic receiver array and offers improved underwater surveillance capability through a new design of premoulded hydrophones, preamplifier PCB, and power supply unit,which are assembled on a Kevlar strength member that runs through the entire length of the array in a closed loop. Solid Linear Acoustic Sensor sonobuoys. RF communication devices using commercial-of-theshelf (COTS) components with duplex communication have been developed and used in sonar systems. programmable gain amplifier, and a digitally programmable anti-aliasing filter. The system can accept either single-ended or differential inputs. The PCB accommodating the design also supports two RS-422/485 serial ports. The time division multiplexed data is sent through a 100 Base TEthernet. In addition, there is a provision to send this TDM data over a fibre-optic link. A 32-channel data acquisition system with a facility to programme various functions has been developed. It incorporates a digitally Notable features of the design are the excellent phase matching and commendable high isolation between the channels. The data acquisition system is housed in a watertight unit making it readily deployable for underwater applications. A long-range singlemode fibre-optic communication over 100 km distance for the transfer of serial data has been designed and developed with COTS components. Alternately, RF communication of 10 km with COTS components with Duplex communication has been DRDO has developed a Diver Deterrence system, which can be deployed around high value assets and at harbor mouths. On activation under Command Control, the system emits high decibel acoustic pulses to deter the divers from executing their mission. Vol. 18 No. 4 August 2010 12 32-channel Data Acquisition Module Specifications: 32-channel Data Acquisition System Several technologies have been developed to handle low level signals picked up by multichannel sonar arrays, and to condition these signals in amplitude and signal bandwidth to digitise the signals for data telemetry, either through copper or fibre-optic medium. VHF receivers have been developed to receive the data transmitted from Number of analog input channels PGA : : Anti-aliasing filter : ADC Sampling frequency Output : : : 32 max. Digitally programmable 1 per channel Digitally programmable up to 10 kHz SAR type, 12 bits resolution Programmable Ethernet 100 baseT and fibre optic Ethernet link designed and developed. The wireless channel utilises IEEE 802.11g standard at a frequency of 2.4 GHz, capable of providing a data rate up to 54 Mbps. The transmitter uses 1 W (30 dBm) power through a 3-sector antenna with gain of 14 dB. The systems are extensively used for transferring both acoustic and telemetry data. from an inline aerial array by comparing the outputs from a phasesensitive detector alternatively driven by each element. The signals from the left/right and fore/aft aerials are sampled to provide a continuous indication of the buoy's position. This system is designed for operation in helicopters for homing on to sonobuoys. The left/right position of the sonobuoy, with respect to the aircraft, is derived from a phase comparison of the signals received from two-directional aerials designed to operate in the VHF frequency range. The VHF receiver, onboard ASW aircraft, is the communication link between the sonobuoy and the processor. The sonobuoy picks up the acoustic noises in the desired frequency band and modulates the carrier frequency (FM) of a VHF transmitter in any one of the 99 VHF channels. The receiver is capable of receiving eight sonobuoy channels simultaneously. The processed data go to the Signal Processor for LOFAR and DEMON processing and displaying. The fore/aft position of the buoy with respect to the aircraft is derived Specifications: 32-channel Sensor Data Recorder Number of analog input Signal bandwidth Dynamic range Gain control Sampling frequency ADC resolution Output data format : : : : : : : 32 max 100 Hz to 12 kHz 80 dB Programmable 31.25 kHz 12 bits 100 Mbps Ethernet VHF Receiver The sonar signal processing and display system extracts information from the data sensed by the sensors. The information extracted includes direction of arrival, speed of the contact, the bearing rate, dominant tonal frequencies, shaft rpm, and the number of blades. For this, the data coming from the various sensors is subjected to a variety of signal processing techniques. The processing is done using high performance Digital Signal Processors (DSP) and PowerPC-based boards. The information is subsequently presented to the operator through suitable human- machine interfaces. To meet the requirement of processing a large number of channels of data simultaneously to provide all-round surveillance, sonar systems use a high-speed signal processing strategy. Adaptive sonar signal processing techniques, which form the core of the processing, require enormous amount of Vol. 18 No. 4 August 2010 13 Homing Receiver System The recorder unit is used for recording the acoustic data directly from sensors for monitoring and storing for further analysis. This unit receives 32-channel sensor data, conditions it in both amplitude and frequency, digitises it and converts it to Ethernet format. It incorporates pre-amplifiers, programmable gain amplifiers, and different types of filters and data converters. computational capability along with the capacity to handle high input data rates. The resulting signal processing functions have been implemented using high-speed digital signal processor boards based on open standards using TigerSHARC processors. The processor board is designed in 6U form factor plugging on a VXS back plane. The TigerSHARC processor-based DSP board combines 24GFlops of raw computing power along with a variety of high-speed interfaces for efficient data transfer. The design combines a cluster of eight such high performance processors along with a separate communication engine based on a dual-core BlackFIN processor. Vol. 18 No. 4 August 2010 14 The communication engine connects to two Ethernet ports, each operating at 1Gbps, and VME and USB ports over the PCI bus. This completely takes care of all data interfaces and leaves the high performance core unhindered to do all core signal processing functions. The board also has two audio ports, a PMC site for PCI mezzanine boards as well as JTAG ports for debugging. The high computational power provided by the design makes the cherished dream of single-board sonar closer to reality. The NP-TS201-24 is complete with a user-friendly development support system, facilitating the utilisation of the hardware resources, most effectively. The design supports software development in C language, utilising an extensive collection of routines developed for signal processing applications and runs on a personal computer. Utility software communicates with NP-TS201-24 for downloading the compiled code, monitoring, and debugging the program during execution. Together with the available software support, the NP-TS201-24 offers significant advantages in hardware reduction and easy system integration. The board is being used in the latest series of sonar systems and was developed with the help of reliable industrial partners. For control, networking, and information and display data processing, a high-end Single Board Computer (SBC) is essential. Adapting open standards, an SBC in 6U VME form factor based on PowerPC MPC7448 processor operating at 1 GHz has been designed and developed in close collaboration with industrial partners. The board combines high processing power and IO bandwidth, and low power dissipation. The PowerPC has become the most widely used new generation Reduced Instruction Set Computer (RISC) processor because of its superscalar architecture, extended temperature options, instruction set compatibility across the entire product line, multiprocessing capabilities, long-term growth path, and the wide selection of development tools. A 128-bit implementation of "AltiVec" SIMD (Single Instruction, Multiple Data) engine accelerates typical networking and information processing functions. The NP-PPC7488 SBC has 512 MB DDRII SDRAM, 256 MB Flash, and two Gigabit Ethernet ports. Real-time Clock (RTC), high resolution timers, and watchdog timer are also available. The board is ported with U-Boot and Linux kernel. The SBC provides two PMC expansion slots for extended flexibility and integration of additional I/Os to the board. Configuration of NP-TS 201-24 NP-TS 201-24 Board Processing engine Internal memory Onboard memory External interface : : : : Communication engine Software support : : Eight TigerSHARC processor @ 500 MH z 24 Mb/processor 128 MB SDRAM; 16 MB Flash Gigabit Ethernet; VME; Link and Serial ports Black FIN processor VDSP IDE; TigerSHARC communicator; Signal processing library Configuration of NP-PPC7448 Single Board Computer Processor Memory : : PMC sites Network USB Backplane Firmware : : : : : Power PC 7448 @ 1GHz 512 MB DDR II SD RAM; 256 MB Flash; L2 1 MB Cache Slot 1(64 bit/66 MHz); Slot 2 (32 bit /33 MH z) 2 channel Gigabit Ethernet 2 USB 2.0 ports VME 64 x with 2eSST U-Boot 1.2.0 and Linux 2.6.16 BSP NP-PPC7448 Single Board Computer Application Program Services Utilities Middleware Linux OS The middleware mainly provides services for communication and multi-thread management. It presents the application program a protocol and hardware transparent communication interface to handle different interfaces like Ethernet, VME, serial port, and SDLC, channel, etc. For achieving protocol and hardware transparency, a common communication packet structure has been defined and modules for communicating data using different Communication Management TCP Ethernet UDP VME Hardware Communication Interface Multithread Management Serial Threads SDLC Queues interfaces have been provided in the middleware. It provides a generic method to communicate the data through different interfaces. Using these services, the application programmer is insulated from the complexities of low-level communication. As part of the architectural framework, the middleware provides a set of threads with specific functions. These include: receive thread (for receiving data), transmit thread (for transmitting data), process thread (processing of received data), health thread (for periodic health monitoring), and simulation thread (for simulating data). In addition to the major services described above, middleware also provides several utility services like handling of sub-system health, maintenance of system log, etc. The middleware was designed using OOD principles and is organised as different layers of project-independent common, project-specific common, and subsystem-specific common along with core functional logic required in the core domain. This also promotes reuse of software to a large extent Vol. 18 No. 4 August 2010 15 Common architectural framework for applications software for information processors of sonar systems was achieved by developing a middleware in-house. This, along with the use of open standard interfaces between sonar subsystems, helped in developing highly maintainable, reusable software in a short time span with lesser manpower. The middleware functions as a layer between the application and the Linux operating system. The bottom hardware layer could be the NP-PPC7448 SBC with necessary communication interfaces. Linux OS comes on top of the hardware. The middleware layer is sandwiched between the Linux and the application program. This layer provides a set of services, which can be accessed by the application program through well-defined interfaces. and reduces time period required for software development . The Human Machine Interface (HMI) of the sonar allows the operator to configure different sonar functions and present the processed information in an easily comprehensible manner. From the conventional approach of using custom devices, the new generation sonar HMI uses industry standard devices such as high resolution LCD displays, keyboards, and tracker balls shared through KVM switches. Vol. 18 No. 4 August 2010 16 The data is presented in composite pages in a Windows-like environment. The HMI pages have all the advanced graphics widgets like pop-up menus, combo boxes, command buttons, etc. Unlike conventional sonar systems display, where controls are selected through a nested series of soft key operations, in the new generation display, the required controls are available in the information page directly through the above widgets. In addition, the operator commands can be given through the touch panels. The HMI has been developed using object oriented methodology using C++/Qt over Linux operating system on indigenously developed NP-PPC7448 SBC with Graphics PMC. The graphics toolkit Qt, running on X window system, provides a lot of flexibilities in terms of the fonts and colours. Compared to the conventional sonar HMIs, which used to run on dedicated hardware with limited graphics support, the clientserver architecture of the new generation sonar HMIs provide much more flexibility to meet many requirements. A typical sonar display is broadly divided into video and annotations/ control areas. The video area contains graphs and cursors, which presents information from various sonar sensors. The information is presented as the amplitude and waterfall graphs. The amplitude graph provides the instantaneous signal amplitude, whereas the waterfall graph provides the history information in the form of signal intensities over time to the operator. The annotation area provides all necessary controls and status information. DRDO has acquired sufficient expertise in phased array signal processing, which forms core of the sonar signal processing. Spatial processing incorporating conventional and adaptive techniques are being used extensively in all the sonar designs. These include MVDR, MUSIC, ESPIRIT and STAP algorithms, which have been perfected to make these implementable on the signal Triplet Sensor for L/R Array processing hardware. The standard techniques of detection, tracking, background normalisation, and spectral analysis used in sonar signal processing have also been extensively refined to give better performance of both active and passive sonar systems. NPOL has expertise to detect transient signals, which are of short duration. Robust techniques have been developed for providing automatic transient alert using both cylindrical and linear arrays. The Laboratory has established its credibility in resolving the left/right ambiguity—a bane for a towed array sonar system. The left/right ambiguity resolution is achieved using a three-element linear sensor assembly, supported by powerful signal processing algorithms. Automatic Target Recognition (ATR) provides early warning so as to give sufficient reaction time for taking counter-measures. To this end, ATR extracts features of each of the tracked targets. A number of discriminatory features to distinguish different types of targets with very low miss-classification error have been successfully identified and established. All algorithms of signal processing have been subjected to elaborate Monte Carlo simulations for finalising the parameters involved. The 3-G Underwater Wireless Acoustic Communication System (3G UWACS) is the third generation product in underwater communi- cation from NPOL succeeding the stand-alone Underwater Telephone (UWT) and the integrated Underwater Telephone System used in submarines. The product has been developed in collaboration with an industrial partner. In modern network-centric warfare enabled operational scenarios, seamless connectivity between underwater platforms and surface vessels is of prime importance. This calls for an advanced wireless communication system with ability to cater to a variety of operational modes like multiband voice and robust data transfer. The 3-G UWACS has been developed with such an operational framework in view. It is a state-of-the-art system based on Software Defined Radio (SDR) Architecture. The 3-G UWACS has several new features in comparison with the earlier underwater communication products. This system incorporates advanced modulation and coding techniques in addition to data recording and analysis features. It offers the user enormous flexibility in materials without compromising strength and safety. The above subsystems have been designed and developed with the state-of-the-art technology in collaboration with industrial partners and inducted in several sonar systems used by the Navy. Air Transport Rack (ATR) is a ruggedised enclosure used for packaging of electronics and electrical items onboard airborne platforms. The ATR is designed as per military standards MIL-STD-810F for environmental testing , MIL - STD 461E for EMI/EMC compliance, MILSTD-704D for qualification of brick The various sub-components in a sonar system are sensor arrays, winch and handling systems, system electronics, and display units. The packaging of system electronics is done in compact enclosures with efficient thermal management and with EMI/EMC compatibility. In towed sonar systems the deployment and retrieval of sensor arrays with very long cables and separate transmitter bodies are handled by complex winch and handling systems. Winches for airborne applications are designed using lightweight Display Processor ATR Card Cage Assembly Salient Features: Air Transport Rack Backplane Heat load Cooling method Cooling fans Power supply unit I/O connection : : : : : : 12 slots, 6U-VME64x 300 W Forced convection using ambient air Two ebm-NADI axial fans 115 V ; 400 Hz- brick type, integrated MIL-C-38999 connector on frontal panel Vol. 18 No. 4 August 2010 17 3-G Underwater Communication System operation, easier maintenance, and a host of additional features through a comprehensive GUI. Besides, it supports remote operation and monitoring through standard networking technologies critical for platform-level integration. The system has been designed with a view to make it backward compatible with the earlier versions of UWT to facilitate operational requirements with platforms equipped with the earlier product. The system can be utililsed in stand-alone or integrated mode of operation. side panels. The temperature throughout the cabinet is maintained to be within limits. type power supply unit, and IEEE standard 6U VME card cages. The rack developed is a display processor card cage assembly of standard one ATR long dimensions and fabricated using airworthy aluminium alloy. DRDO has designed and developed a winch (ASW 4001) for lowering and hoisting the dipping sonar dome into the sea for underwater surveillance operations. The winch has been installed on platforms after obtaining flight clearance certification. It has the facility to display cable paid out length, cable angle and has automatic speed control with respect to sonar dome position while lowering as well as hoisting. The winch has been fabricated using aluminium alloy based on an optimum design for strength and safety, and has got a cable spooling mechanism. The unit is fully integrated and has successfully completed all the environmental tests as per the specifications. Heat generated by PCBs is removed by forced convection of air. The cooling design is such that it maintains a positive pressure in the enclosure to keep dust ingression to minimal. The unit is mounted on an ARINC tray for easy maintenance and installation, and provided with shock mounts (Barry controls) for isolating the ATR from the shock and vibration of the platform. Display-cum-Processor Cabinet Vol. 18 No. 4 August 2010 18 Display-cum-Processor cabinet is intended to integrate display processing and signal processing functions of a sonar system. The cabinet comprises five levels where each level is a standard subrack stacked one over the other. IEEE standard 6U form factor subracks along with VME backplane have been incorporated in this cabinet. In addition, VME standard plug-in units such as PCB and power supply including injector and extractor handles have also been used. The cooling design of the cabinet is a combination of series and parallel flow types. Cooling is achieved by lateral entry of fresh air at each level through a double-walled duct at the The winch is driven by a main hydraulic motor capable of developing 10 HP at 4000 rpm. Its speed is controlled by an electrical servo valve and a hydraulic circuit. It also has an auxiliary electrical back up motor and a manual cranking device for redundancy, and a pyrocutting device for emergency. The winch is software-driven in the lines of latest state-of- the- art technology . Salient Features: DCP Cabinet Backplane Packaging capacity Heat load Cooling method Cooling fans No. of displays Keyboard EMI/EMC protection : : : : : : : : 18 slots, 6U-VME64x 90 PCBs and 5 power supply units 1200 W Forced convection using ambient air Two centrifugal fans Two Foldable Using EMI fingers and honeycomb ASW 4001 Salient Features: Airborne Hydraulic Motor : : : : : : : : : Axial piston Fixed Bend axis 30o 6 + 0.1 cc/rev MIL-H-5606 or its equivalent 2 kg (max.) 9 with fixed strokes 38.5 + 0.1 lpm : : : 207 bar (continuous) 210 bar 6400 + 100 rpm (at 38.5 lpm) Low frequency dipping sonar, deployed from a helicopter to detect underwater targets in the sea has been developed. The dipping sonar utilises a dunk body (NP-DB-214) lowered from the helicopter for ASW operations. The body consists of an electronic unit, drive assembly, active and passive transducer array assembly, and non-acoustic sensors unit. The dunk body is connected to the winch by means of an Dunk Body Dome with extended arms electromechanical (EM) connector using high strength multi-core EM cable. It has a high-power active transducer array to transmit sound signals underwater to detect longrange targets. The drive assembly comprises mechanism for the foldable and unfoldable passive transducers array fixed in vertical staves and is actuated by an actuator. The array fold and unfold mechanism can be remotely operated from the platform during sonar deployment. The complete control of the dunk body deployment along with winch operation can be carried out from the operator console unit installed in the platform. The dunk body has been designed keeping in view the hydrodynamic aspects during the deployment. All the mechanical components have been manufactured using airborne quality aluminium alloy and GFRP. The components that will be exposed to seawater during deployment have been anodized to withstand corrosion. Vol. 18 No. 4 August 2010 19 Type Displacement Axis of rotation Bend angle Displacement volume Fluid Weight No. of cylinders Theor tical flow rate at max. continuous speed Pressure rating Maximum pressure Max. continuous speed Hydraulic Ship-borne Sonar Winches NPOL has developed ship-borne winches (SSW 5 H and SSW 7 H) for onboard installation on Naval platforms. Winches have proven seaworthiness by undergoing several sea trials, and are been used for deployment, retrieval, spooling, and stowage of the wet-end sonar systems. Vol. 18 No. 4 August 2010 20 The systems are electrohydraulic with stand-alone power packs and are controlled by microprocessors. Dedicated sensors and ergonomic displays help in online monitoring of critical system parameters like cable paid out length, cable tension, speed of operation, etc. Safety interlocks (software and hardware controlled) have been integrated into the system for safeguarding the system as well as the operator. These winches are driven by hydraulic motors through SSW 5 H compact planetary gearboxes with provision for redundant electric drive and manual drive for maintenance purposes. SSW 5 H can accommodate 500 m of tow cable, 30 m passive array, and is designed for 5 ton. SSW 7 H system is capable of handling 1300 m of tow cable and 200 m towed array, comprises a dedicated handling system for deployment and retrieval of underwater towed body and is designed for survival load of 7 ton. Electric Ship-borne Sonar Winch Electric Ship-borne Sonar Winch (SSW 5 E) is an electric winch developed to deploy, retrieve, and to store 1500 m of electromechanical optical cable and sensor array. The system consists of a drum with flanges on both sides over which the cable is wounded. The drum is driven by a 3-phase 25 hp induction motor controlled by Variable Frequency Drive (VFD) through a reduction gearbox. A constant-speed, 3-phase 5 hp electrical motor drives the drum at constant speed in redundant mode. Dog clutch mechanism has been provided for change of 'operation mode' to 'redundant mode'. Operational speed of SSW 5 E is between 0 and 25 rpm in VFD mode. Operator console has a joystick for speed control. The control console consists of a variable frequency drive and an overload trip device. The system is built-in with strain gauge and encoder assembly for online cable tension and the cable length pay out measurement. The system is also fitted with failsafe electrically operated thruster brakes. Overall size of the system is 2150 mm x 2100 mm x 2000 mm and the weight is approximately 5 ton. SSW 7 H cable (LTC) through flexible link. TTB handling system caters for the safe deployment and recovery of the towed body from a moving ship. A pair of hydraulically operated robotic arms facilitates the purpose. The mode of operation of the entire system is electrohydraulic. Underwater Electromechanical Connector The compact and lightweight connector provides mechanical as well as electrical connections between the different functional modules of a towed sensor array. The unique features of the connector include sealing against seawater, high axial load-bearing capacity, automatic polarisation, quick assembly/disassembly, and streamline shape. The connector is designed to withstand harsh The transducer is powered by a tuning coil unit, which is also housed inside the TTB. The sub-systems are integrated with titanium grade five fasteners. The bridle is connected to the pivot axis of the body using two fulcrum pins. The TTB fore-end is connected to the heavy tow cable using a U-shaped bridle assembly through an electrooptic mechanical interconnector. Salient Features: Strength Member A swivel hub, provided at the rear end of the TTB, connects light tow Material Cross-section (mm) Breaking Strength ( kN) Kevlar 13 x 2 21 Spectra 1000 13 x 3.5 40 Spectra 1000 dia: 10 13 21 A Towed Transmitter Body (TTB) and handling system has been developed by NPOL in collaboration with an industrial partner. TTB is a hydrodynamically shaped towed underwater body and has got an elliptical cross-section. The body is used to house flextensional transducer and serves as an acoustic source for towed array sonar system. The major sub-systems of TTB are: shell assembly, ballast, splitter plates, wing, bridle, and flextensional transducer. Towed Transmitter Body and Handling System Vol. 18 No. 4 August 2010 SSW 5 E operating conditions including dynamic towing loads and hydrostatic pressure. The connector is dry-mateable. Mating and demating is carried out using a portable assembly fixture. Electro-Opto-Mechanical Inter Connector It is a flexible pressure-balanced module of towed array system that performs the following functions in a field environment with dynamic tension: Electrical, optical and mechanical inter-connection between Heavy Tow Cable (HTC) and LTC. Mechanical engagement and electrical powering of TTB. Vol. 18 No. 4 August 2010 22 Transfer of towing loads from LTC to HTC. Electro-Opto-Mechanical Inter Connector (EOMIC) assembly is encapsulated with polyurethane (PU) hose and filled with gel under pressure to block water seepage into the assembly. It maintains a pressure difference of zero making it a pressure-balanced design. Enough slackness has been provided for tow cable core sheath, electric and fibreoptic lines to compensate relative elongation. A loop of strength member (SS wire rope) takes the dynamic load acting on EOMIC. It is designed to withstand a pressure of 30 bars and can take an axial load of 30 kN. The outer diameter of EOMIC assembly is 80 mm. Rubber-based encapsulants are used for protecting the electroacoustic transducers from the marine environment. The need for long shelf-life of rubber encapsulants has been addressed leading to development of new encapsulants. Adhesives have been used widely for development of underwater components meant for sonar systems. Underwater cable junction boxes are necessary especially for submarine sonar systems to route multichannel sensor array data to the electronic hardware kept inside a pressure hull compartment. Adhesive-free cold moulded PU underwater junction box and cable splicing technology have been used for realising the same. Encapsulants based on thermoplastic polyolefine elastomers have been developed. The encapsulants have shelf-life of 25–30 years and possess better electrical resistivity. Electro-Opto-Mechanical Inter Connector Transducers with Long-life Enhancement Colourants can be added to the encapsulants for enabling colour coding and easy traceability of encapsulated sensors. A new indigenous adhesive (NP 235) has been used for fabrication of molded Rubber Junction Boxes (RJBs), cable splicing, and transducers encapsulation . The adhesive is flexible with good peel strength, seawater compatibility, and insulation resistance. The adhesive bonds vulcanised rubber to either vulcanised rubber or primed metal substrates. It is well-suited for producing and bonding of transducer electrical components because of its better insulation properties and durability in underwater marine environments. Underwater cable junction boxes are used to connect multiple singlecore neoprene cables to a multi-core cable to be used in deep sea The sealing material employed is a two-part PU system having excellent bonding with varieties of substrates. Higher water impermeability, stability, and improved mechanical and electrical properties are additional advantages of the material employed. Ocean has a complex environment in which sonar system has to perform to the needs of the Navy, the end user. Since the sonar performance is largely influenced by the ocean behaviour, a proper understanding of the ocean environment is most imperative for optimum performance. Oceanographic studies are concentrated towards this end to know the environment and the acoustic propagation in a better way by modelling and validation of the model by data collection. comprehensive data available till today. The other model is a unique package, to simulate 3-D structure of temperature, salinity, current fields and to estimate the sound velocity structure off the west coast of India for any desired month, both on climatologically and daily scales, using a 3-D circulation model. A sonar performance modelling tool has been developed and implemented by DRDO. It is a generic model catering to the modelling requirements of a wide range of active and passive sonars. This is implemented as a PC-based menudriven program with user-friendly interface. It is being used extensively within the Laboratory for modelling the performance of various types of sonars during the design, development, and evaluation phases. Two other software packages have been developed to understand and visualise the ocean environment and to support the above modelling tool. Complete with a user-friendly interface, one model visualises the environment, i.e., temperature, salinity, and velocity up to the water column depth using the best 23 environment. Adhesive-free cold molded PU underwater junction box and cable splicing technology have been developed in collaboration with industrial partner. To obtain better mechanical strength and avoid contamination of soldering slag, connectorisation of the cables has been achieved by crimping with tinned copper tubes in place of soldering. The technology avoids the problems associated with fabrication at higher temperature, and hence can be extended to thermallysensitive cables and sensors. Cold Moulded Underwater PU Junction Boxes in situ Vol. 18 No. 4 August 2010 Spliced Cable using NP-235 airborne, and submarine applications. A large number of technologies as described above have found applications in the large number of sonar systems developed and delivered by DRDO and fitted on Naval platforms for ship-borne, The technology roadmap for futuristic sonar systems envisage development of high power and low frequency transducers, efficient compact power amplifiers, highspeed high-resolution multichannel data acquisition systems, high performance computing engine for gleaning out sonar information and fusion of data, thin-line towed array for submarine sonar applications, lightweight compact sonar winches, and more accurate sonar rangeprediction models. 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Editor-in-Chief Shashi Tyagi Editors B Nityanand Manoj Kumar ºÉà{ÉÉnBÉEÉÒªÉ ºÉcɪÉBÉE nÉÒÉÊ{iÉ +É®Éä®É Editorial Assistant Dipti Arora izh-izsl ºÉàÉx´ÉªÉBÉE AºÉ BÉäE iªÉÉMÉÉÒ Pre-press Coord. SK Tyagi MhvkjMhvks dh vksj ls funs’kd] MslhMkWd }kjk eqfnzr ,oa izdkf’kr Printed & published by Director, DESIDOC, on behalf of DRDO RNI No. 55787/93 àÉÖphÉ AºÉ BÉäE MÉÖ{iÉÉ cÆºÉ BÉÖEàÉÉ® Printing SK Gupta Hans Kumar ÉÊ´É{ÉhÉxÉ +ÉÉ® {ÉÉÒ ÉʺÉÆc Distribution RP Singh