The Project Director Sensors-Aerial Intelligence Common Sensor Payload (CSP) team, in collaboration with the Aviation and Missile Center Software, Simulation, Systems Engineering and Integration Directorate Joint System Integration Lab, developed a new cooling shroud designed to slip over the CSP turret unit, which houses the electro-optical/infrared cameras and laser range designator, and provides cool air to the system to prevent overheating while the aircraft is still on the tarmac. The finalized design provides a tough outdoor performance fabric with a non-porous monolithic membrane adhered to the underside of the fabric, which forms a barrier to environmental elements.

The Common Sensor Payload is the electro-optical/infrared/laser range designator sensor for battlefield commanders onboard the MQ-1C Gray Eagle uncrewed aircraft system. It provides real-time imagery for detection and classification of targets and threats for battlefield commanders with day and night imaging sensors, laser designation, pointing, target marking, and spot tracking for aerial intelligence.

Two years ago, Project Director Sensors-Aerial Intelligence engineers developed and shipped out Common Sensor Payload cooling shrouds in six days after learning the sensors were being exposed to extreme heat. The heat caused the sensors to overheat and shut off, or in some cases, caused more significant electronic equipment failure, requiring the Soldiers to return the turret to the depot for repair.

Every combatant command has its own set of challenges that Soldiers need to overcome and adapt to. In the Operation Inherent Resolve (OIR) theater in U.S. Central Command one of these challenges is extreme heat.

Two years ago, Soldiers identified a need to provide cooling to the unit’s Common Sensor Payloads (CSP) that were being exposed to extremely high temperatures while sitting on the tarmac before missions. This would cause the sensor to overheat and shut off, or in some cases, cause more significant electronic equipment failure, requiring the unit to return the turret to the depot for repair.

The CSP is the electro-optical/infrared/laser range designator (EO/IR/LRD) sensor for battlefield commanders onboard the MQ-1C Gray Eagle uncrewed aircraft system. It provides real-time imagery for detection and classification of targets and threats for battlefield commanders with day and night imaging sensors, laser designation, pointing, target marking, and spot tracking for aerial intelligence.

“In just six days from initially being notified of the issue, Project Director Sensors – Aerial Intelligence [PD SAI] engineers were able to develop a prototype turret cooling shroud and get three shipped out to the unit,” said Doug Haskin, Product Manager Aerial Enhanced Radars, Optics, and Sensors (PdM AEROS), under PD SAI.

The prototype successfully performed as expected out in the field and Soldiers began asking for more, creating a high demand. Leveraging joint expertise from the Naval Surface Warfare Center – Crane Division, the AEROS team quickly began work on a new design. This culminated last month when the PdM AEROS CSP team successfully performed a technical and system assessment of the newly designed cooling shroud at Redstone Arsenal in Huntsville, Alabama.

A collaborative effort between PdM AEROS and the Aviation and Missile Center Software, Simulation, Systems Engineering and Integration Directorate Joint System Integration Lab, the assessment consisted of a technical review of the cooling shroud’s installation work packages, review of user-caution details, and review of the final engineering design implementations.

“I am definitely impressed by our team’s efficient and rapid process of turning an idea into a finished product in support of the warfighter,” said Wilson White, the CSP training subject matter expert for PdM AEROS.

The new cooling shroud is designed to slip over the CSP turret unit, which houses the EO/IR cameras and LRD, and provides cool air to the system to prevent overheating while the aircraft is still on the tarmac. The finalized design provides a tough outdoor performance fabric with a non-porous monolithic membrane adhered to the underside of the fabric, which forms a barrier to environmental elements. The shroud also provides protection from moisture, corrosion, ultraviolet light, sand, dust, foreign object debris, pests, and other environmental degradation.

There will be an initial delivery of shrouds and corresponding technical manual updates to ensure all Gray Eagle companies are equipped with the latest environmental hazard solution. The new shrouds are expected to arrive in theater at the end of Fiscal Year 2025 (FY25). The PdM AEROS CSP team will continue to coordinate with Army units to ensure mission requirements are met.

The cost of each shroud will be about $2,100.

“The cost is well worth the investment,” Haskin said. “The cost of a turret is over $1 million and costs about $350,000 to repair each system. Total repair turnaround time at the depot including transit is over six months. The shroud has proven very successful at preventing these avoidable repairs, saving time and money.”

Compatible with future CSP version 3 (v3)

Along with being compatible with all CSPs currently deployed, the new cooling shroud will also provide longevity to the future CSP v3.

PD SAI completed the development of the new CSP v3 system in 2023 with the delivery of six prototype systems for integration and testing. Initial flight testing in May 2024 achieved outstanding results and initial production is underway with the first CSP v3 deliveries to occur later this year.

“The CSP v3 is the latest iteration of the CSP, which resolves several critical subcomponent obsolescence issues present on the currently fielded CSP v2 and incorporates updated sensor hardware to provide enhanced imaging capabilities,” Haskin said.

The CSP v3 will add a Target Location Accuracy (TLA) capability that will enable precision, near-real time engagements with coordinate seeking weapons by reducing the sensor-to-shooter process from minutes to seconds.

The CSP v3 is the first step in providing a fully modernized sensor package that will support Multi-Domain Operations for the new -25M Gray Eagle. The CSP v3 production systems are expected to begin delivering to the Army in June 2025.

Additional flight testing and demonstrations will be conducted as the CSP v3 prepares for fielding in FY27 to develop tactics, techniques, and procedures for this new capability.