Ehmke’s TPY-4 Antenna Array Travel Cover

Customer Profile

Lockheed Martin Corporation – RMS (LMCO) is a global security company that specializes in the research, customized design and development, manufacturing and integration of advanced technology specifically in sensing and electronic warfare capabilities. LMCO products are integral in early warning and threat detection, target tracking and situational awareness.

The Air Force (USAF) Command operates the AN/TPY-4 radar, a next-generation ground-based air surveillance radar designed to give military forces long-range detection, tracking, and identification of airborne threats. The sophisticated mobile array system is often transported into a harsh contested environment to execute its mission.

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Challenge

To ensure operational availability, the USAF must protect the TPY-4 from environmental conditions that may affect its readiness. The tracked vehicle that transports the array often travels across harsh and contested terrain exposed to dust, dirt, vibration, rain, sleet, hail and high winds. Any damage to the array’s sensors, technology or hardware minimizes its effectiveness putting U.S. military assets and personnel at risk.

The cost of Foreign Object Debris (FOD) damage to the array can run into millions of dollars.

LMCO called on our company as a sole-source provider to engineer, fabricate and install an original protection system to protect all horizontal surfaces from over-the-road impact and environmental threats to the TPY-4 Antenna Array. The customer required an engineered solution capable of performing in extreme temperatures, providing high abrasion resistance, and deflecting environmental threats. Performance specifications included deployment of the protection system by four individuals in two hours or less, without the use of overhead cranes. Our company was tasked with developing a unique solution that had never before been fielded.

Solution

The TPY-4 Antenna Array Travel Cover needed to be quickly deployable, resistant to extreme temperatures, portable, easily storable, and capable of consistently withstanding road FOD debris. The criteria required waterproof, weather-resistant fabric, cushioning, webbing, fastener tape, and hardware resilient enough to perform in extreme conditions. The fabric could not tear against the antenna or damage any sensitive sensors. All hardware needed to be recessed and protected to prevent contact with the array face. Universal cutouts and contours were also required to accommodate the array vehicle’s numerous antennas, access doors, and complex angles. The proprietary multi-layer solution required extensive testing.

Ehmke’s unique “AWAY TEAM” concept provided engineering support to the customer and helped tailor a customized solution.

Results

Our company delivered a successful solution on time and under budget. Our “Away Team” spent two weeks onsite tailoring and custom-fitting multi-layer panels to the unique external features of the array vehicle. The successful completion of the project led to a production contract to outfit the TPY-4 Antenna Array inventory.

References

Project Manager: Greg Nichols – Ehmke Manufacturing Company, Inc

Engineering: Daniel Nguyen – Ehmke Manufacturing Company, Inc.

Manufacturing Engineer(s): Glenn Aust – Ehmke Manufacturing Company, Inc.

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