A

STATUS REPORT

SUBMIITTED TO

DRDO, R&DE (ENGINEERS), DIGHI, ALANDI ROAD,

PUNE-15
ON

“MINITURE TURBO GENERATOR FOR ELECTRONIC FUZE”

BY
ABHISHEK PRADIP GUDMETI

UNDER THE GUIDANCE OF

DR. SANDEEP WANKHADE

DEPARTMENT OF PRODUCTION ENGINEERING

ALL INDIA SHRI SHIVAJI MEMORIAL SOCIETY’S
COLLEGE OF ENGINEERING, PUNE – 01
(YEAR 2017-18)
 CONTENTS

Sr. No. Title Page no

Title sheet

Contents i

List of Figures iii

Abstract 1

1. FUZE 2

1.1 Introduction 2

1.2 Function of Fuze 3

1.3 Classification of Fuze 3

1.4 Main Component of Fuze 5

1.5 Various Power Source of Fuze 5

2. ELECTRONIC FUZE 8

2.1 Introduction 8

2.2 Basic Element of Electrical Fuze 8

2.3 Working Principle 8

2.4 Type of Electrical Fuze 9

2.5 Advantage of Electrical Fuze 9

AISSMS COE PUNE/Production Department/2016-2017 i

 MINITURE TURBO GENERATOR FOR
3. 10
ELECTRONIC FUZE

3.1 Introduction 10

3.2 Design Methodology 11

3.3 Rotational Turbine Speed/Torque on Turbine 11

3.4 Air Intake Valve 14

3.5 Rectifier & Firing Circuit 15

CONCLUSION 16

REFERENCES 17

BIBLIOGRAPHY 18

AISSMS COE PUNE/Production Department/2016-2017 ii

 LIST OF FIGURES

FIG. NO. TITLE PAGE NO.

1.1 Section view of Electronic Fuze 2

1.2 Different activation type in Fuze 3

3.1 Turbo Generator Assembly 10

3.2 Section View of Turbo Generator Assembly 11

3.3
Rotor, Starter Assembly, Shaft & Magnet 12
Assembly
3.4 Air Intake Valve Assembly 14

3.5 PCB For Rectification, Regulation & firing 15

AISSMS COE PUNE/Production Department/2016-2017 iii

Abstract
In this Project we deal with the Design & Analysis of “Miniature Turbo Generator For
Electronic Fuzes” used in missile. This is new technology in which power is generated within
the warhead fuze.

Early the research was carried out on turbo generator for electronic fuze. Where Traditionally
storage batteries were used as a power source for fuzes. To overcome their shortcomings like
short life, chemical leakages, unreliability etc.; a new technology was required. R&D was
carried out, which resulted in the development of wind driven turbo generator that could fit
inside the fuze body. The obvious advantages of such a power source were long life,
nonhazardous storage & greater reliability. So, it has become the most preferred choice for use
in artillery munitions etc.

In this paper we work on a design, development of Miniature Turbo-Generator. The Miniature

Turbo Generator will be useful in development of miniature electronic fuzes for various non-
spin projectile and missile.
.

AISSMS COE PUNE/Production Department/2016-2017 1

 CHAPTER 1

FUZE

Introduction :

 Beside, its requirement that when launched, the ammunition must fire at desired time
and/ or place in the enemy territory so that the intended purpose of infliction damage
on enemy target can be achieved with high precision and even selectively if required.
[5][6]
 For this purpose, some mechanism must also be incorporated in the ammunition to
sense the environment and initiate the ammunition. [5][6]
 The safety mechanism should work until the ammunition is launched and after the
launch, the firing mechanism should take over. [5][6]
 In order to achieve this requirement, an arming mechanism is also required in the
ammunition. All the above mention requirement of the ammunition is fulfilled by the
device called fuzes. [5][6]

Figure 1.1: Section view of electronic Fuze

AISSMS COE PUNE/Production Department/2016-2017 2

1.1 Function of Fuzes :

 Fuzes are the device attached to ammunition for the purpose of safe handling and
storing, arming and firing [5][6]
 Basic function of fuze is to fire the ammunition when desired and ensure safety during
other time. [5][6]
 Therefore, the fuze is also referred to as the brain of the ammunition. [5][6]

1.2 Classification of Fuzes :

Fuze are classified in to sub-categories based on their ammunition, tactical application,

function, location etc. [5][6]

A. Based on functioning :

Based on the principle of operation, fuze are classified as follow:

 Impact Fuze (time to arm/impact to detonate) : The device arms after a set
period of time and detonates on impact. This type of fuze is typically used in
ammunition, bombs and missiles. Impact fuze are futher classified as follow: [5][6]

 Point Detonating Fuze (PD)

 Base Detonating Fuze (BD)
 Point-Initiating, Base-Detonating (PIBD)
 Delay Fuze.
FUZE

MISSILE
E

Figure 1.2: Different activation type in Fuze.

AISSMS COE PUNE/Production Department/2016-2017 3

 Proximity Fuzes : The device arms after a set period of time and detonates when at
the closet point of approach to a target. This type of fuze is typically on ammunition,
rockets and missiles. [5][6]

 Time Fuze (time to arm/time to detonate) : This device arms after a set period of
time and explodes at the end of a set delay from the time of arming. Either or both time
increments can be set able prior to firing or fixed within the design of the device. These
fuzes are typically used in ammunition and missiles. One current example of time fuze
is the U.S. Army's M762, now transitioning to production after close to ten years in
development. Another example is MOFA (multi-optional fuze for artillery). [5][6]

 Remote Detonators : Remote detonators use wires or radio waves to remotely

command the device to detonate Barometric fuzes cause a bomb to detonate at a certain
pre-set altitude above sea level by means of a radar, barometric altimeter or an infrared
range finder. [5][6]

 Command Fuzes : command fuze are remotely controlled device. Command fuzes
function through a signal communicated to the fuze from a remote point through
electrical, mechanical, optical or other means. [5][6]

 Combination Fuzes : Fuzes involve more than one of the principal of operation
discussed above are called Combination fuze. These fuzes have multiple option so that
same fuze can serve for different tactical application, with one mode of operation as
principal action and other as secondary action. [5][6]

B. Based on type of mechanism :

 Various mechanism in the fuze such as safety, arming, firing, can be
designed by using mechanical linkages or electrical / electronic circuits etc.
Based on the mechanisms in the fuze, they are classified Mechanical Fuzes,
Optical Fuzes, Chemical Fuzes, Electrical fuzes etc. [5][6]

C. Based on the Purpose : [5][6]

 Antipersonnel (APERS)
 Armor-piercing (AP)
 Blast or High Explosive (HE)
 Concrete-piercing (CP)
 High Explosive Anti-Tank (HEAT)
 High Explosive Plastic (HEP)
 Illumination

AISSMS COE PUNE/Production Department/2016-2017 4

 D. Based on Ammunition : [5][6]

Ammunition Fuzes
Artillery Guns Direct Action Fuzes (PD), Time Fuzes (M,EI),
Proximity Fuzes, Combination Fuzes.
Mortars Direct Action Fuzes (PD), Time Fuzes (M,EI),
Proximity Fuzes, Combination Fuzes, Time Fuzes
(M,EI)
Naval Guns Direct Action Fuzes (PD), Time Fuzes (M,EI),
Proximity Fuzes, Combination Fuzes, naval Guns

Tank Guns Direct Action Fuzes (PD, PIBD), Graze Fuzes

Bomb Fuzes Direct Action Fuzes (PD), Time Fuzes (M,EI),
Proximity Fuzes, Combination Fuzes.
Land Mines Pressure Fuzes
Sea Mines Time Fuzes (MEI), Delay Fuze.
Surface Target missile Direct Action Fuzes (PD), Time Fuzes (M,EI),
Proximity Fuzes, Combination Fuzes.

Air target Missile Direct Action Fuzes (PD), Time Fuzes (M,EI),
Proximity Fuzes, Combination Fuzes.

Small Calibar Guns Direct Action Fuzes (PD), Time Fuzes (M,EI),
Proximity Fuzes, Combination Fuzes.

1.3 The main components that make up a fuzes are : [5][6]

1. Electronic circuitry to initiate warhead

2. Power supply for the electronic circuit
3. Safe & arm unit
4. Detonator & lead charge

The power supply unit is a very critical component of a fuze. It fulfils the power requirements
of the electronic circuit, which controls the warhead detonation.

1.4 The various power sources previously used in fuzes are : [5][6]

 Piezoelectric power supply.

 Thermal battery
 Reserve battery
 Turbo generator

AISSMS COE PUNE/Production Department/2016-2017 5

 1. Piezo-electric power supply :
The piezoelectric element has been placed in the nose of the fuze give to produce electrical
energy upon impact of the warhead. This produced energy is allowed to pass through a
detonator which is a thin wire surrounded by a sensitive explosive, such as lead azide.
Explosion of the lead azide causes the main explosive charge in the warhead to detonate. [5][6]

Drawback :
Piezoelectric elements located in the nose offer only a limited area of impact, and the voltage
output is a function of the impact angle, falling of as the angle increases. [5][6]

2. Thermal battery :
Setback forces, which are generated when the round is fired, produce the electric energy. A
fuzed salt is released on setback, which subsequently causes an electrical charge to be
generated between two electrodes. This charge is stored in a capacitor and used to set off the
detonator upon of the warhead. [5][6]

Drawback :
Requires a considerable volume of space, necessitating minimization of the amount of
explosive for a given warhead size. It also increases the weight of warhead. [5][6]

3. Reserve battery :
They have been primarily lead/lead dioxide/fluboric acid based batteries. Further they may be
either dry cell based or wet cell based. Dry cell batteries have limited useful lives. Wet cell
batteries are used such that the electrolytic fluid is injected automatically into the electrodes,
as a result of shell spin after leaving the gun. Batteries may not be stored separately from the
electrical portion of the fuse, which they are to power, but must be preassembled with the fuzes,
for logistic and ready available reasons. [5][6]

Drawback :
Some types of battery-equipped fuzes have proven to be unreliable, as a result of electrolyte
fluid leakage. They have a low shelf life (5-10 years). Another problem is that these batteries
are difficult to manufacture so that at the onset of a national emergency production levels are
expected to lag requirements for several months, thereby creating logistics problems. Also they
are expensive. [5][6]
To overcome the drawbacks of the previously employed power supply sources, so as to avoid
logistics problems in case of a national emergency, new avenues in the case of power supply
source have been sought. Some of these are, [5][6]

 Thermoelectric power supply.

 Fluidic generator.
 Turbo generator.

AISSMS COE PUNE/Production Department/2016-2017 6

 4. Thermoelectric power supply :
Comprises of a plurality of junctions, which are coupled to the propellant for sensing the
temperature and means of generating a voltage in response to the temperature sensed by the
generator. It works on the thermocouple effect. Integrated with a compatible impact sensor
(triboluminescent) it will initiate the warheads explosive warhead. The voltage generated by
the thermoelectric power supply is stored in a capacitor, which supplies it to the detonator
when the warhead impacts the target. [5][6]

Drawback :
It requires the use of temperature sensitive elements/alloys, which makes the unit costly. [5][6]

5. Fluidic generator :
It comprises an air inlet means and a helmoltz resonator. The resonator consists of a resonating
cavity, a diaphragm and a metallic reed set in a magnetic field. The air entering the resonating
cavity produces acoustical vibrations. These vibrations cause a diaphragm, which is mounted
in the resonant cavity, to oscillate. The oscillating diaphragm drives a metallic reed set in a
magnetic field. This induces a current in the coil, which is used to power electronics. At high
flight velocities there is large mass flow of air. As a result, the diaphragm experiences large
displacement, which in effect causes the metallic reed to bang against the pole pieces. This
leads to reel fatigue and eventual failure, causing power loss. [5][6]

6. Turbo generator :
It comprises an electric generator assembly housed within a projectile. The assembly includes
an air driven turbine and an electric generator. A common shaft carries the turbine and the
permanent magnet of the electric generator. The generator rotor is a small permanent magnet
and the stator a series of coils. [5][6]

AISSMS COE PUNE/Production Department/2016-2017 7

 CHAPTER 2

ELECTRONIC FUZE

Introduction :
 Basic function of fuze are Safe handling, Arming, Target Sening and Firing.
[4]
 Mechanical Fuzes achives these objective by less accurate and unreliable
mechanism. [4]
 Electronic Fuze achives the functions by means of electronic circuit or with
a combination of both Electronic circuit and Mechanical Mechanism [4]

2.2 Basic element of electronic Fuzes : [4]

a) Antenna
b) Radio Frequency Generator, Transmitter and Receiver.
c) Signal Processor unit
d) Electronic Time Delay Circuit
e) Electronic Safety Circuit
f) Power Supply
g) Impact Switch
h) Firing Circuit

2.3 Working Principal of an Electronic Fuze : [4]

TIGGER PULSE
FROM AUDIO
AMPLIFIER CIRCUIT

ELECTRONIC SWITCH
ELECTRONIC SSSWITCHSDSWITC
POWER SAFETY H
SUPPLY CIRCUIT

FIRING ELECTRIC
CONDENSER DETONATOR

FIRING CIRCUIT

AISSMS COE PUNE/Production Department/2016-2017 8

2.4 Types of Electronic Fuze :
 Depending upon the target sensing mechanism and electronic circuit involved, the
electronic fuzes are classified in following types: - [4]

a) Radio Proximity (PRX) Fuze

b) Electronic Time (ET) Fuze
c) Electronic point Detonator (EPD) Fuze
d) Universal Fuze

2.5 Advantages of Electronic Fuze : [4]

1. Proximity Fuze Action.
2. Precise time setting with a wide discrete range, programmability and remote setting
facility.
3. Universal Fuze gives user more Flexibility to choose the Fuze action as per the
requirement.
4. Light Weight and Compact
5. Additional safety to the fuze during Marketing Handling and Transportation.

AISSMS COE PUNE/Production Department/2016-2017 9

 CHAPTER 3

MINITURE TURBO GENERATOR FOR ELECTRONIC FUZE

Introduction :

It comprises an electric generator assembly housed within a projectile. The assembly includes
an air driven turbine and an electric generator. A common shaft carries the turbine and the
permanent magnet of the electric generator. The generator rotor is a small permanent magnet
and the stator a series of coils. The principle of power generation is similar to the wind turbine-
generator unit except that the turbo generator assembly is very compact and operates at
substantial rotational speed. The impellers used in prior art electrical generators were very
inefficient in that most of the air taken in by the turbine is diverted rather than used to drive
the impeller. The prior art turbines were placed outside the fuze body resulting in increased
size of the projectile. The new developments in the case of the turbo generator have resulted
in reducing the size of the fuze by incorporating the unit inside the fuze body. The next
generation turbo generator power supply makes use of an efficient turbine (centrifugal unit).
The next generation turbo generator has improved dynamic balance than the prior art
generators. Since it has a life span equal to that of the whole fuze, and other advantages as
mentioned above, it has turned out to be the choice for the next generation electronic fuze. [1]
[2] [3]

Turbo generator of different dimension have already been developed and tested. The new. The
new development in the case of the miniature turbo generator have resulted in reducing the
size of the fuze. The main objective of this paper is to further minimize the dimension of the
turbo generator and test it for various operation condition . [1] [2] [3]

Figure 3.1: Turbo Generator Assembly

AISSMS COE PUNE/Production Department/2016-2017 10

3.2 Design Methodology :
The development of miniature turbo generator has been completed. Free air jet testing facility
was designed, developed and established for testing of turbo generator. The study of magnet,
stator coil assembly, housing, ball bearing etc. was carried out to arrive at the basic design
requirements. [1] [2] [3]

The assembly comprises of


 Air-driven turbine/Rotor (Fig. 2)

 An electric generator, comprising,
 Stator element (Fig 3).
 Shaft & Magnet Assembly (Fig. 4)

Figure 3.2: Sectional view of Turbo-generator assembly.

3.3 Rotational Turbine Speed/Torque on Turbine :

The flow of gas is much more complex than that of liquid due to greater compressibility of the
former. The gas flow may take place isothermally, adiabatically, or at constant total energy.
The flow may be resisted by friction which partially or totally adds heat to the gas. If large
changes of temperature occur during the flow, the variation in the specific heats will be
considerable and are to be taken into account. The type of flow is also affected by velocity. It
may be subsonic, sonic or supersonic depending on its relation to velocity of sound in the gas
the latter will vary according to its temperature or its pressure and density. At speed above
sonic speed compression waves and shock waves are transmitted which affect the resistance to
flow. [1] [2] [3]

AISSMS COE PUNE/Production Department/2016-2017 11

 Figure 3.3: Rotor, Stator assembly, Shaft & Magnet Assembly

When the projectile travels through the atmosphere at supersonic speeds, it sets up a normal
shock wave in front of it. The air pressure just in front of the projectile and entering air inlet is
represented by P2. [1] [2] [3]

At subsonic speeds no shock wave is formed & air pressure just in front of the projectile and
entering air inlet is equal to P1. [1] [2] [3]

𝑃2 = 𝑃1 ---- (1)

During supersonic operation the generator, total pressure at the air inlet is equal to P2which is
determined by the flight Mach number and altitude expressed by the equation : [1] [2] [3]

AISSMS COE PUNE/Production Department/2016-2017 12

For a given flight Mach number and altitude, the corresponding pressures of P1and P2
determine the amount of ram air mass flow that enters the generator, and thus the amount of
electrical energy generated. The maximum temperature rise during the projectile operation, is
obtained at highest operating speed i.e. 700m/s. based on the following equation, [1] [2] [3]

Available power based on the flow rate is given by

𝑚̇ = 𝜌𝐴𝑐12 --- (4)

𝑃 = 0.5𝑚̇ 𝑐2 --- (5)

During flight, ram air enters the fuze housing through an intake duct. Air impinges axially on
the turbine, and is diverted laterally by the blades. The action from the change in fluid
momentum produces a torque 'τ' that drives the shaft. The dependence of this torque, 'τ', on the
mass flow fluid through the blades and the angle, β2 that the departing flow makes with the
trailing edge of the blades is given by, [1] [2] [3]

𝜏 = 𝑚̇ 𝑟2(𝑉𝑟2𝑐𝑜𝑠𝛽2 − 𝜔𝑟2) --- (6)

would correspond to the blade tips curving enough so that the flow would leave tangent to
the rim of the turbine. Above equation also shows that the torque decreases as a result of two
effects: an increase in β2 or an increase in rotational speed ω. The angle β2, could increase, if
the blade were slightly flexible and could bend out under the influence of centrifugal force.
This furnishes a method of limiting the rotational speed that will be explored later in this
report. The rotational speed can increase until a theoretical maximum value is reached such
that [1] [2] [3]

Vr2.𝑐𝑜𝑠𝛽2
𝑤= --- (7)
r2

At this speed, the applied torque would be zero, and the turbine would maintain constant
rotational speed. To calculate the torque one must know the fluid velocity Vr2. In practice, this
quantity is difficult to calculate because it is a function of the flow pattern and depends on the
blade configuration and duct design. The propeller design can be developed by an experimental

AISSMS COE PUNE/Production Department/2016-2017 13

approach based on the above mentioned theoretical considerations. Power based on the
rotational speed/angular velocity of the turbine is given by [1] [2] [3]

P = τω --- (8)
Designing for 125 m/sec at ground level, here the values of density, pressure and temperature
of air is maximum as compared to high altitude. Calculation for least operating velocity is done
so that constant electrical output is obtained [1] [2] [3]

 Considering no losses in air intake duct 


 No losses due to friction 

 No energy loss or gain occurs due to 
heat transfer to or from the air 


The air leaves the impeller in such a way that flow would leave tangent to 
the rim of the
turbine 
For the present turbine rotor diameter of 20.0mm, maximum theoretical rotational
speed of 1,50,000 (approximately) has been observed and also when the rotor radius is being
decreased the rotational speed of the rotor is further increased.

3.4 Air Intake Valve :

Figure 3.4: Air Intake Valve Assembly

The wind energy is utilized for driving a rotor which rotates the magnet positioned in the coils.
The emf is generated in the coil which is used as energy source for the fuzes. The rotor rotation
is proportional to the velocity of the projectile and can go very high which may damage the
device. To overcome the said problem, escape holes have been provided which ensures
constant rotation beyond a certain limit. The rotational speed of the turbine is proportional to
the air velocity. [1] [2] [3]

AISSMS COE PUNE/Production Department/2016-2017 14

An Air Intake Valve Assembly (Fig. 6) has also been designed and developed for the
applications in the turbo generators used in very high wind velocity. The high velocity may
induce very high speed and damage the system; it is required to control the air intake. The Air
Intake Valve controls the wind flow by restricting it with an arrangement of valve. [1] [2] [3]

3.5 Rectifier & Firing Circuit :

Figure 3.5: PCB for Rectification, Regulation & Firing

As the generated power output from the turbo generator coils is an alternating voltage, it is
essential to rectify the power and regulate the voltage as per the circuitry design. An on board
rectifier and firing circuit has been integrated with the turbo generator. A Circular PCB (Fig.
7) comprising of integrated rectifier, regulator & firing circuit has been designed which also
holds the micro detonator. [1] [2] [3]

AISSMS COE PUNE/Production Department/2016-2017 15

CONCLUSION :

The fuze is a critical component of the warhead as it controls its flight path and accuracy of
hitting the target. The design and development of a Miniature turbo generator as per the
requirement for missile can been design from above paper document. Further changes can be
made in design, manufacturing and other aspects, so as to make it more reliable, more efficient
and also cheaper.

AISSMS COE PUNE/Production Department/2016-2017 16

REFERENCE :

[1] Dr Virendra Kumar, "Fuze Power Supply Systems" ARDE Technical Report No. 1127
of 2004 (unpublished).

[2] D.Y. PATIL College of Engineering, 2013-14 (unpublished). A project on “Reverse

Engineering of Turbo Generator”.

[3] Virendra Kumar, DN Joshi, Sunil Kumar Nema, Armament Research & Development
Establishment, Pune, India. “Turbo generator for Electronic Fuze”

[4] Vikas Chandra “Mechanical & Electrical Fuze” .

[5] Pooja Sharma, Dr. Virendra Kumar, Archana Singh , G. S. Moze COE Balewadi, Pune
Savitribai Phule Pune University, Pune , 2 ARDE-DRDO Pashan, Pune. “Integrated Pyro SCB
Chip”.

[6] Dr. A.P.Pandhare
 Dr. Virendra Kumar Aniket Chaudhari
 Aakash Borude
 Sanjog
Gawade
 Neil Fernandes smt. Kashibai Navle College of Engineering Vadgaon (BK),
Pune – 411 041
 Savitribai Phule Pune University
 “Value Engineering Analysis of Turbo-
Generator in Electronic Fuze”.

AISSMS COE PUNE/Production Department/2016-2017 17

BIBLIOGRAPHY :

[1] Fuze A. P. Pandhare1, Aniket Chaudhari, Sanjog Gawade, Aakash Borude, Neil fernandes
& Virendra Kumar “Structural Analysis of Turbo-Generator in Electronic”.

[2] Y. Zhang Northwestern Polytechnical University Xi’an China, L.G. Chen Systems
Engineering Research Institute Beijing China, B. Qiao Northwestern Polytechnical University
Xi’an China. “Design and Implementation of the Fuze Circuit Board Tester”.

[3] Charlie H. Robinson, Potomac, MD (us); Robert H. Wood, Laurel, MD (us) “Air-powered
electro-mechanical fuze for submunition grenades”.

AISSMS COE PUNE/Production Department/2016-2017 18