FUTURISTIC TRENDS OF ENGG SP IN INTENSE CONVENTIONAL OPS

Intoduction

1. Fourth industrial revolution or Industry 4.0 is progressing very fast in India and
is expected to make significant impact in the area of supply chain management.
These developments are also going to impact Army supply chains and engineering
support (MRO) functions. Future wars will be characterised by multi domain, swift and
techno-centric operations. In this scenario, the greatest danger to our Nation
continues to be external aggression with collusive threat of adversaries as well as
internal instability due to state/non state sponsored proxy war 1. To meet this challenge
Indian Army has embarked on capacity development and moved towards a broad
spectrum ‘Capability Based Force’. Enhancing capability to meet these emerging
contours of conflict in multi front environment, mandates the Indian Army to be
prepared for techno-centric combat by imbibing technology, utilising human resources
efficiently and ensuring optimal utilisation of the defined budget for force
modernisation2. Industry 4.0 revolution can effectively enhance efficiency and
responsiveness of engineering support functions of the Army to a great extent.

2. The methods adopted by NATO & US Expeditionary forces for rendering

engineering support during Op Iraqi Freedom incl latest advancements ushered in by
automobile & technology leaders such as Tesla, Bosch, Chrysler motors etc have
revolutionised the manner in which logistics support may be imagined, planned and
exec. These advancements need to be incorporated in ‘Force Development Plans’
or ‘Long Term Integrated Perspective Plan’ of Indian Army. It will enable to
channelise the R & D on indigenisation efforts in synch with ‘Make in India’
campaign.

Aim

3. Aim of this paper is to study how the futuristic trends of Industry 4.0 revolution
can enhance engineering support functions of Indian Army.

Exoskeletons : To Augment Capb of Foot Based Repair Teams (FBRTs)

4. Brief Description. Mil exoskeletons have evolved into smaller, lighter and
more specialized devices weighing as less as 5 Kg. The obj of these exoskeletons is
to enable a soldier to carry addl lds & enable mov (over harsh trn) for sustained
durations. They are cat as fwg:-

(a) Lower Body Powered Mil Exoskeleton. These provide asst to

legs & therefore are meant to provide mobility asst incl enhancing ld carrying
cap of tps. DARPA Warrior Web Exo suit is an example inducted into the US
Army. Actuators harness mech mov for ch of btys & powering comn eqpt.

1
(2018). Land Warfare Doctrine
2
Ibid
 2

Fig 14 : HULC Exoskeleton Used by US Army

(b) Passive Mil Exoskeleton. Passive exoskeletons do not have any
actuators, batteries or electronics. They are meant to reduce loading of human
muscles enabling enhanced endurance & ld carrying cap.

5. Global Utilisation.

(a) Human Universal Load Carrier (HULC) devp for the US Army weights 24
Kg and allows payload upto 200lbs/91 Kg to be carried. Soldiers can move at a
max speed of 11 Kmph over a long duration and up to 16 Kmph burst speed.
Soldiers can remove and pack the suit in less than 30 secs 3. It also has att such
as armour, heating and cooling sys and addl sensors.

(b) The Op Exoskeleton emp by Royal Australian Army is a sys of Bowden

cables designed to tfr a percentage of the wt of a soldier’s hy backpack directly
into the grnd4.

6. Application in Indian Army. The exoskeletons can be enablers not only for
fighting troops, but also for Foot Based Repair Teams for enhancing capb in mtns to
carry addl lds of Special Maintennance Tools and Test Equipment, Tools, Spare-parts
for enhanced effectiveness of in-situ repairs.

Wearable Power Sys

7. Brief Description. To lighten the ld carried by the soldiers, the US Army is

testing bionic charging/wearable power genr suits with lithium-ion btys or wearable
fuel cells for power genr in order to decrease bty wt by 50%. These “wearable power
sys” can produce 20W of continuous output and 35W of peak power for the
dismounted soldier5.

3
https://www/army-technology.com/projects/human-universal-load-carrier-hulc/
4
https://www.gizmodo.com.au/2015/08/this-is-the-australian-defence-forces-take-on-exoskeleton-technology/
5
https://www.bionic-power.com/wp-content/uploads/2017/09/marketing-Brochure-Apr 2018-v.4sm.pdf
 3

Fig 15 : Bionic Power Genr Sys Indicating

Multiple Btys that Can be Ch

8. Global Utilisation. The US Army is validating wearable named ‘bionic power’

for utilisation & on the mov bty ch by the US soldiers.

9. Application in Indian Army. Can be of immense use to Foot Based Repair

Teams enabling utilisation of bty op power tools, spl diagnostic eqpt & conduct
component level repairs of electronics eqpt in situ 6.

Augmented Repair Sp incl Remote Diagnostics

10. The OEM as part of the ESP may be asked to provide augmented repair sp kit
both for dvrs & technicians. The OEM CAD files prep during design stg are useful in
creating Augmented Repair (AR) Database. This may be done in fwg manner:-

(a) Level 1 - Standalone. A Tech onsite (on highway) can scan through
the AR glasses or a tablet to view sub sys & PCB overlays to iden fault & plan
onsite repair.

Fig 16 : Hyundai AR Based Diagnostic Sys

(b) Level 2 - Remote Diagnostics. Emp to provide real time 3D instr by

a remote expert on how to perform the selected repair task.
6
https://www.therobotreport.com/industrial-exoskeletons/
 4

11. Global Utilisation.

(a) Hyundai and Volkswagen have intro AR ‘Owner’s Manual’ which

connects to techs Smartphone. An in-built camera recogs different components
under the hood or inside the veh. It then displays overlays explanations and
offers tutorial on how a Tech can apch the component to conduct diagnosis &
repair/replacement.

(b) Israel is introducing the AR concepts for trg & rendering emergency med
aid to tps in fd incl trg of paramedics.

12. Application in Indian Army. Through an ‘AR app’ installed on the tablet to
either remotely connect or scan through embedded tech literature & CBTs. Remote
connection may be based on VSAT/Satl or mil secure internet connection.

Thermal Imaging Diagnostic Tools

13. Brief Description. With enhanced electronics components & sensors in

vehs, the fault diagnosis is complicated such as in case of ‘parasitic draw of current’
from bty by a sensor/component remaining activated overnight even though the eng is
off. However, when tested using a diagnostic tool all parameters of the veh will be
normal. In such cases a thermal image can visually indicate heat profile thus
conforming existing faults.

Fig 17 : Thermal Imaging Diagnostic Tools

14. Global Utilisation. Emp by highway diagnostics to resolve the breakdowns

onsite. Bosch has already devp ‘Connected Repair’ sys based on Bosch diagnostic
sys for a wksp, wherein, veh data will be imdt available at a PC-based sys in the
wksp7. Complete veh service history including all test results can be accessed and
continuously updated remotely over the internet link/cloud.

15. Application in Indian Army. On the lines of the Bosch diagnostics, the
diagnostic tools incl scan tools should be networked through a secure software to the
Repair Workshops and Repair Control Centres.

Deep Learning Based AI Predictive Platform

7
https://www.aasdn.com.au/the-connected-workshop-trends-from-automechanika/
 5

16. Brief Description. In the era of RMA, mgt of resources is very imp and this
mgt needs to be done by intelligent apparatus. This has led to prominence of AI in
modern TBA. AI models to iden anomalous behavior, converting critical eqpt sensor
data into meaningful, actionable insights for proactive maint and preventing downtime
or critical failure are under devp stg. Emerging tech such as Internet of Things (IoT),
Big Data Analytics and Cloud Storage are enabling eqpt to share condition based data
with a centralized server making fault detection easier, faster and economic.
Continuous devp in these fds have created new possibilities for investigating info
derived from critical war like assets. The concept of preventive maint is being replaced
by predictive maint. With plethora of eqpt & incr complexity traditional predictive
methods cannot eff analyse & predict the future trends & fault patterns 8.

17. Global Utilisation. The Machine learning AI sys are being emp in
sophisticated vehs & eqpt to conduct predictive maint & timely wksp recall to avert a
maj failure. Data is utilised in fwg manner:-

Input Interpretation by AI Sys Output

(i) Part codes, iden of (i) Genuineness of (i) Predictive analytics.
spares used, barcode spares.
(ii) Recommendations
scanning of OEM spares.
(ii) Raise timely wty for pre-emptive fleet
(ii) Wty timelines & alerts to users. maint.9
clauses,
(iii) Quality & completion (iii) Recommendations
(iii) Servicing tasks carried of servicing reqmt. for enhancing
out at service wksps. efficiency.
(iv) Life enhancement &
(iv) Maj replacement or next scheduling reqmt. (iv) Alerts for
recap actions. indicating anomalies.
(v) Recall before maj
(v) Record of recurrent emp/failure. (v) Recurrent failure
failures in components. database to OEM for
(vi) Product improvement
product improvement
(vi) Climatic conditions in (PI) reqmts.
(PI).
which the veh/eqpt is emp.

Fig 18 : Deep/Machine Learning Sys Input, Interpretation & Outputs

18. Emp in US Army for Comb Fleet Maint.

(a) A ‘machine learning software’ has been trial validated to predict veh
reqmt for repairs & indicating faults to technicians before failure. The pilot
scheme is being impl for Bradley M2A3s dply in active service 10.
8
Martin Prescher; Venture Beat; How AI will play a major role in the auto industry; June 2017;
https://venturebeat .com/2017/06/24/how-ai-will-play-a-mojor-role-in-the-auto-industry/
9
https;//www.predii.com/use-cases/automotive-repair
10
https://www.theverge.com/2018/6/26/17506170/us-army-machine-learning-ai-predict-vehicle-failure-update-
technologies
 6

(b) Sensors installed in veh engine compartment, veh txn & elec sys record
temperature, RPM & other veh hlth parameters. This info is continuously
transmitted to server which uses machine learning to look for patterns & predict
which sys/sub sys is likely to malfunction.

19. Application in Fd Indian Army. Enables predictive maint, utilisation of wty

claims & raising product improvement reqmts (incl defect reports) as per op
conditions. During ops, it will enable desp of Repair Teams to spec ld centre to timely
address a predicted fault ensuring msn reliability.

TESLA Model of Diagnostics – Internet of Things

20. Brief Description. The future veh fleet, Software Defined Radios (SDRs)
and other complex comb sys with onboard electronic & sw interface will have lesser
mech components. The Tesla model of Internet of Things (IoT) model gives an
indication of future diagnostics.

21. Global Utilisation. Tesla vehs have a number of sensors onboard meaning
multiple data streams are genr, collected and analysed. With the sensor data it
collects, Tesla can remotely mod its products and exec sw updates.

(a) As a famous case study, during Hurricane Irma in Sep 2017, Tesla
temporarily extended the rg of the cars that were in the storm’s path by
changing consumption pattern of btys. This enabled dvrs to safety steer
through Storm’s path without reqmt of recharge.

(b) In another instance, Tesla was able to complete a mandated fix of

charger plugs on more than 29,000 vehicles via a software update.

(c) These ‘over the air’ fix are imdt and seamless, and saved its customers
and the company countless hr.

3-D Printing Tech (Additive Manufacturing)

22. Additive manufacturing ref to an additive process wherein an object is created

by laying down successive layers of spl mtrl. 3D printing is being used to produce a rg
of medical items, prosthetics, spares incl shelters. In May 2015, Airbus announced
that the firm was already using upto 1,000 components in its new Airbus A350 XWB
manufactured by 3D printing.
 7

Fig 19 : 3D Printed impellers

23. Global Utilisation. The U.S. Army has started emp customized steel
alloy powder to 3D print high str spare parts for grnd vehs in fd dply. The US Army is
using a Laser Powder Bed Fusion (LPBF) process, and a spec alloy mtrl is being
applied to create vehicular components said to be 50% stronger than commercially
available equivalents11. US Army mtrl scientists have also commenced research into
nickel-titanium alloys for stronger, more heat-resistant 3D printing mtrls.

24. Application in Indian Army.

(a) Initially the facility may be est at the Base Wksp level to commence mfr
of components which is the charter of the Army Base Wksps. However,
sustained availability of mil gde raw mtrl (metal compound) is a necessary
reqmt.

(b) As the tech matures, in Ph 2 the same can be est at Corps Z Wksp level
for high tech low population eqpt.

Fwd Del

25. Terminal Obj of Autonomous Fwd Del Sys.

(a) Just-in-time (JIT) mil lgs.

(b) Lighten ld of foot soldiers.

(c) Enhance reach of lgs sustenance.

(d) Enhance op availability of eqpt.

26. Autonomous Last Mile Resupply Sys (ALMRS). The sys are being devp
with an obj to transform the del of lgs for land & maritime ops. The sys has the
potential to reduce the amt of stks stored at the frontline and incr speed of repl. The
design under devp is likely to have fwg features:-

(a) Twin-engine unmanned aircraft with a dry weight of just under 20kg.
(b) Made of lt wt composite mtrl. Modular in design & capb of tn in a lt veh.
(c) Run on Li-ion bty pack or gasoline eng.

11
https://3dprintingindustry/com/news/u-s-army-develop-ultra-strong-3d-printed-steel-parts-to-revolutionize-
battlefield-logistics-150367/
 8

(d) On Board Features12.

(i) Broadband satl data relay service.
(ii) Autopilot sys & a GPS receiver.
(iii) Three HD cameras with video recording.
(iv) Thermal imager for ni imaging.

Fig 20 : Two Variant of ALMRS

27. Autonomous Ariel Cargo Utility Sys (AACUS). The US Navy is validating
an ‘Autonomous Kit’ for manned & unmanned heptr sys which consists of an all wx
sensor and sw package capb of in flt detection & avoidance of obstacles (like
telephone wires, other vehs or large grnd obj) 13. The sys will enable autonomous,
unmanned flt of both manned & unmanned heptrs. AACUS will enable the Marine
Corps to rapidly resupply forces on the front lines. The sys can be cont by single opr
using a hand tablet.

28. FigJt 21
Tac: AACUS Kit Installed
Autonomous Ae Replon a Bell
Sys Heptr of US Navy
(JTAARS). The Making
US Armyit is
Autonomous
devp the
sys which is a lt wt UAV of less than 599 Kg & can be easily carried on a small-sized
veh, with minimal sp eqpt and maint reqmts. The services want the UAV to be able to
carry 136 Kg to 636 Kg of cargo. The spl features are as under:-

(a) Single flt leg with min rg of 80 Km.

(b) Vertical take-off and landing (VTOL) capb.

12
https://www.army-technology.com/features/autonomous-delivery-drones-military-logistics/
13
https://www.engadget.com/2018/18/aurora-aacus-autonomous-helicopter-supply-delivery/
 9

(c) Propulsion sys based on electric, hybrid, fuel cell and petrol-powered
engines.

(d) Automated launch, flt, nav (incl GPS-denied), cargo drop, landing &
return to original launch loc.

(e) Bell has devp & flown two bty-powered cargo UAVs called Autonomous
Pod Transports (APT). These incl APT 20, having a 9.1 Kg cargo cap & the APT
70, with a 32 Kg cargo cap14.

Fig 22 : Bell APT 20 & APT 70

29. Disposable Gliding Drones for Repl Msns. A disposable low-cost cargo
drone designed to enable ac to re-supply grnd forces over greater dist has entered a
new phase of flight testing. The LG-1K is meant to be rel from fixed-wing ac or heptr.
The drone will be compatible with MV-22 and CV-22 Osprey ac, C-130, & C-17 tpt ac
and UH-60, CH-53 & CH-47 heptrs. The drone has the ability to glide autonomously to
a LZ with GPS precision15. Spl features are as under:-

(a) Dropped at 30,000 ft, the drone can travel up to 130 Km.

(b) 10 ft long, 23 Ft wingspan fly at a speed of 155 Kmph 16.

(c) Payload cap of upto 200 Kg.

(d) GPS enabled navigation. Dply parachutes in terminal ph for pin pt

landing.

Fig 23 : Gliding Drones

14
https://www.flightglobal.com/news/articles/analysis-drone-delivery-of-bread-and-bullets-for-th-456894/
15
https://i-hls.com/archives/90019
16
https://www.popularmechanics.com/military/aviation/a26885819/marines-plywood-supply-drone/
 10

30. Ae Del of Critical Spares by Drones. New genr comn and svl epqt rely a lot
on embedded sys and digital electronics. Failure of critical PCBs modules under battle
condts will render fighting tps op with reduced efficiency due to non avlb of Ni vision
devices and comn eqpt. Autonomously or remotely Op devices as shown at Image II
below can be emp for del of time sensitive spares for in-situ repair by FRTs. The same
would otherwise have been difficult to del with conventional mode of tpt under battle
condts. Del Drones have the potential to achieve last mile del and realistically achieve
‘Push Model’ concept of tech spares sp17.

Fig 24 : Fwd Del of Critical Spares Using

Drones

31. Application in Indian Army.

(a) APT 20 & APT 70 type of drones may be dply for repl of MUAs & spares
incl replacement of STEs for own FRTs.

(b) ALMRS type of sys may also be emp for repl of critical spares.

Conclusion

32. The technology is rapidly proliferating and becoming complex. This requires the
engg sp ech to adapt to the changes to provide eff engg sp in a time sensitive envt of
the battle fd. This paper endeavours to enlist all futuristic aspects of engg sp with a
focus on mtnous trn. It provides guideline to plan future acquisitions and focus on
R & D efforts to enhance eff of engg sp. Some of these aspects can be applied to
other ops & lgs functions also.

17
www.fehrandpeers.com