Throughout the Army, recycling often refers to innovative approaches to reusing paper, ink cartridges, plastics and other items that would normally be disposed of in a landfill.
But by looking at possible ways to reuse outdated military hardware, some programs on Redstone Arsenal are using the idea of recycling to give new purpose to hardware that's aged beyond its normal life cycle.
At the Redstone Technical Test Center, engineer Chris Dobbins is now in possession of six infrared sensors (also known as pods) that will add new capabilities to Test Area 3's testing program. Though of value to RTTC, these sensors - known as the Star SAFIRE I, the first generation forward looking infrared sensor, for the Black Hawk -- were deemed unusable by Medevac Black Hawk, Utility Helicopters Project Office, which has long since replaced them with the more technologically advanced Star SAFIRE II.
"When they initially came out for use, these Star SAFIREs represented expensive capability, expensive technology. But they got relatively little use and were not used in combat operations," said Lt. Col. Dan McCarthy, assistant program manger for Medevac, Utility Helicopters Project Office.
The sensors were used on Medevacs prior to Operation Enduring Freedom and Operation Iraqi Freedom.
"They are of an older generation and today's aviation platforms are looking for something more advanced," McCarthy said.
But the Star SAFIRE I systems deemed obsolete for medical evacuation purposes and sitting useless in inventory were actually the kind of forward looking infrared sensors needed at RTTC.
"These systems are of benefit to them," McCarthy said. "And this eliminates the requirement for us to maintain these systems in inventory. We are sharing resources that are benefiting another organization. It's a win-win situation."
Dobbins worked with Dan Holder of the Utility Helicopters Project Office to secure the sensors. He has already determined how the sensors will be incorporated in the testing environment at Test Area 3.
"We have a 75-foot tower that we use for developmental testing on the range where we plan to mount one of these sensors," Dobbins said. "It will really increase our situational awareness during night testing and give us better documentation. It will allow us to collect infrared video of testing on the range. Customers can then have a time tagged record of events as they transpired."
Plans also call for mounting a sensor on one of RTTC's "Mad Max" trucks - known as the Mad Max III "Road Warrior" -- that has a mast extending 60 feet in the air and that is used in field testing.
"The sensors will be great for helping us collect video," Dobbins said. "Mounting one on Mad Max will basically give us a lot of flexibility on the test range. Wherever we need video, we can take Mad Max to that spot, put the mast up and record the data."
Infrared sensors allow for the collection of data on ground targets, such as tanks, trees and buildings. This data is provided by RTTC to its customers, such as the Aviation and Missile Research Development and Engineering Center and defense companies that are developing various military systems.
"Sensors, similar to these, allow us to collect radiometric data of targets so that our customer can construct 3D models for simulations that systems such as Javelin and NLOS can use," Dobbins said. "Infrared sensors are similar to our eyes, but instead of seeing visible light, they sense the radiation being emitted or reflected from an object. Everything radiates, but not always where we can actually detect it. These sensors will help us with that."
The sensors, which use technology developed in the mid-1990s, are valued at about $170,000 each.
"These sensors were basically taken off helicopters to do an upgrade," Dobbins said. "They are no longer being supported by the company that developed them because they use older generation technology.
"These sensors were functioning, but they were old. For the purposes of the Black Hawk they had basically reached beyond their life cycle. But for testing they can be used in ways they are not normally used. They can help us develop cutting edge technology for tracking and finding targets."
RTTC received six full systems and one turret-only system from the Black Hawk Project Office-Medevac. Dobbins said plans are to give one sensor to AMRDEC and two to another branch of RTTC. The other sensor and the seventh incomplete sensor will be used for spare parts.
It's not unusual for RTTC to give new life to outdated hardware systems, many of which are located through the Defense Reutilization Management Office.
"They have a list of now unused things out there that other government entities can request," Dobbins said. "I was searching for particular key words and stock numbers related to infrared sensors. Some have photos, but most only have a short description. Sometimes you find useful items at the very best price - free."
Dobbins did locate some similar sensor systems through the reutilization office. But when two of the systems arrived at RTTC, engineers attempted to identify exactly what they were. Dobbins contacted a local representative of FLIR Systems Inc., a contractor in the field of infrared cameras, night vision and thermal imaging systems, for assistance. Through FLIR, Dobbins learned about the sensor systems at the Medevac office that were in storage. He then worked with Holder to obtain them.
"It was a good initiative, especially with the work Dan Holder did on it," McCarthy said. "We no longer have to include these sensors in our inventory or maintenance costs, and another organization is benefiting from the capabilities. RTTC has everything to gain from it."
The technology exchange shows the Army's commitment to recycling hardware and software systems.
"If these sensors had sat three or four more years and had not been maintained, then they wouldn't have been usable," Dobbins said. "Even though they were near their end of life with Black Hawk, we can extend their life much, much longer until we run out of parts to repair them. If we can reutilize these systems while also enhancing capabilities then they carry a cost benefit that is very, very high."
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