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1 TECHNICAL. INFORMATION CENTERA . 1111 I 11 111111II III IIIr/ ,5 0644 00004879 7 AGT 1500 POWERPACK IMPROVEMENT PROJECT (M41 TMEPS)CONTRACT NUMBER DAAE07-87-C-R006 MARCH. 1991 VOLUME I OF IIJ. Edwards and R. BrayerGeneral Dynamics Land Systems Mound RoadSterling Heights, MI 48310By GDLS DOCUMENT O0. DB-87-04057-00]AAPPROVED FOR PUBLIC ARMY TANK-AUTOMOTIVE COMMANDRESEARCH, DEVELOPMENT & ENGINEERING CENTERW arren, Michigan 48397-5000ao;. 12)_NOTICESThis report is not to be construed as an official Department of the of any trade names or manufacturers in this report shall not beconstrued as an official endorsement or approval of such products ofcompanies by the US this report when it is no longer needed. Do not retura it to CLASISIFICATION -OF THIS PAGE RE O T D C M N A I N P GREPORT DOCUMENTATION PAGEia. REPO SECURITY CLA FCATOM lb RESTRMCTVE MARKINGSU nclassified None2.

2 SECURITY AUTHORIT & oISTRIBUTrN/.LANuTY O REPOF RN/A APPROVED FOR PUBLIC RELEASE:21. DECLASSIFICATIONIDOWNGRAING SCHEDULE DISTRIBUTION IS PERFORMING ORGANIZATION REPORT NUMBER(S) 5. MONITORING ORGANIZATION REPORT NUMBER(S)DB-87-04057-001A DB-87-04057-001 le Oe 7vI?. /35? vGO. NAME OF PERFORMING ORGANIZATION Sb OFFICE SYMBOL 7X. NAME OF MONITORING ORGANIZATIONG eneral Dynamics (NApWomb,) U. S. ArmyLand Systems Division Tank Automotive CommandS. ADDRESS (C11% Se and ZiP Code) 7b. ADDRESS (ct. mSI and ZIP Code)38500 Mound Road U. S. ArmySterling Hts, MI 48310 Tank Automotive CommandWarren, Michigan 48397-5000Si. NAME OF FUNDING/SPONSORING St OFFICE SYMBOL & PROCUREMENT INSTRUMENT-IDENTIFICATION NUMBERORGANIZATION (IfAppENCae)DAAE0 7-8 7-C-R00 6Or- ADDRESS (City, State and ZIP Code) 10. SOURCE OF FUNDING NUMBERSPROGRAM PROJECT TASK WORK UNITELEMENT NO. NO. NO.

3 ACCESSION TITLE (Inchufd S1curtty Clme1dckn)UGT 1M. Powezpac. rove ment Project (Ml TMEPS)-P nT f.;P n .TC l =a RKeport ..12. PERSONAL AUTHOR(S)Edwards Jonathan Robert13a. TYPE OF REPORT 13b. TIME COVERED 14. DATE OF REPORT Oer. Month, Day) IS, AGCOUNTF inal IRos5/87 To6/90 119 90, 10, 25 1781W. SUPPLEMENTARY NOTATION17. COSATI CODES IL SUBJECT TERMS (Cowinue on ,wnmw if nemmm y ddentlfy by block num er)FIELD GROUP SUBsGROUP TMPES, Transverse Mounted Engine Propulsi nSystem, Automotive Test Rig, Self CleaninAir Filter, Vehicle Accessory Gearbox1It ABSTRACT (Cmndnue an imwue Nf , Vy aid kwewo' y &/bj& nwnftqThe Transverse Mounted Engine Propulsion System Scientific andTechnical Report presents the design, trade-of fs, performanceand cost data developedunder contract DAAE-07-87-C-R006. Thisreport contains design summaries for all automotive hardwaredesigned and integrated into the automotive test rig.

4 Follow-ongoals are also presented for future design OISTRIBUTIONIAWJILABILTY OF ABSTRACT 21. ABSTRACT SECURITY [ SAME AS RPT. C3 OTIC USERS Unclassified22s. NAME OF RESPONSIBILE INDIVIDUAL 22b, TELEPHONE NUMBER 22C. OFFICE SYMBOLM. JeffersonAm Co)M. eferon574-7513 AMSTA-RGRDO FORM 1473, 84 MAR 83 APR EDITION MAY BE USED UNTIL EXHAUSTEDALL OTHER EDITIONS ARE OBSOLETE. SECURITY CIBIFcaTION OF THIS PAGEU nclassified109/2417 SUMMARYThe Transverse Mounted Engine Propulsion System (TMEPS) is a lowcost, low risk evolutionary step for powerpack design. TMEPS offers an integrated, compact automotive system including:"o Compact space efficient powerpack."o Improved fuel efficient transversely mounted AGT-1500engine." XT1100-3 seven speed transmission with transversegearbox." A new compact mounted selfcleaning air filtrationsystem." Integrated demand responsive powerpack cooling systemwith a dynamic increase in heat rejection.]

5 "o Integrated underarmor auxiliary power unit for reducedfuel consumption, longer engine life, and independentNuclear, Biological and Chemical (NBC) supports improvement in lethality and survivability byproviding the following benefits:"o As a result of more efficient packaging, the TMEPSA utomotive Test Rig (ATR) powerpack opens up 47 cubicfeet of usable space in the powerpack compartment, percontractual requirements. The follow-on configurationcan provide up to 76 cubic feet of usable space."o Improvement in vehicle performance and agility."o Improvements in fuel economy over MIAI."o Top speed is improved over MIA1."o Improved diagnostic/prognostics are incorporatedthrough digital engine and controls." Powerpack commonality is maintained with 90 percent ofthe engine and 46 percent of the transmission withrespect to MIAl hardware. Fifty-six percent commonalityis achievable for the transmission with TMEPS ATR successfully rolled-out on May 9, 1990.

6 Followingbreak-in testing at the Detroit Arsenal Tank Plant (DATP), the2vehicle was sent to Milford Proving Grounds (MPG). The ATR wassubjected to six days of intensive vehicle testing on primaryand hilly cross-country roads. The vehicle was then returned toGeneral Dynamics Land Systems (GDLS) for instrumentation removaland vehicle OF CONTENTSS ection Title INTRODUCTION Background OBJECTIVES CONCLUSIONS RECOMMENDATIONS DISCUSSION Concept Description Engine and Air Induction Transmission and Final Drive Auxiliary Power Unit and Accessory Drive Cooling and Exhaust System Hydraulic System Fuel System Electrical System Driver's Control System Vehicle Structure Life Cycle Cost Design Engine and Air Induction Transmission and Final Drive Auxiliary Power Unit and Accessory Drive Cooling and Exhaust System Hydraulic System Fuel System Electrical System Driver's Control System Structures Vehicle Performance Performance Goals Automotive Performance Life Cycle Cost 1544 TABLE OF CONTENTS (Cont.)

7 Section Title Introduction LCC Methodology LCC Assumptions LCC Results LCC Summary 166 DISTRIBUTION LIST DIST. 1 APPENDIX I TME Interchangeability Demonstration TestReport No. LYC 90-18 APPENDIX II AGT 1500A TACOM TME Fuel Economy DemonstrationTest Engine T202 NReport No. LYC 88-39 APPENDIX III Final Report for the Development of a RotatingElement Self-Cleaning Air Filter (RESCAF)5 LIST OF ILLUSTRATIONSF igure Title Page1-1. M1 Current and TMEPS Propulsion Systems 11 Installation5-1. TMEPS Engine Compartment 195-2. Engine (AGT 1500) and Air Induction 20 Installation5-3. Engine Hardware Improvement 215-4. Transmission (XT1100) Installation 235-5. Auxiliary Power Unit and Accessory Drive 24 Installation5-6. Cooling and Exhaust System Installation 265-7. Hydraulic System Installation 275-8. Fuel System Installation 285-9. Electrical System Installation 295-10.

8 APU/SCAF Control Panel 305-11. MI Current and TMEPS Propulsion System 34 Installation5-12. Self-Cleaning Air Filter (SCAF) System 355-13. Engine Hardware Improvements 365-14. Casting Processes and 42 Benefits of Single Crystal Blade5-15. Comparison of Present Production Bearing 44and Improved RAM-D Conrad BearingConfigurations5-16. Five Percent (5%) and Production HP 45 Nozzle5-17. Sungear 475-18. RAM-D Position 5 Seal Design 486 LIST OF ILLUSTRATIONS (Cont.)Figure Title Page5-19. RAM-D Position 10 Seal Design 495-20. TMEPS XT1100 Transmission 565-21. XT1100 Transmission Envelope 605-22. Range Number Optimization 625-23. XT1100 Final Drive Schematic 635-24. Final Drive Sprocket Design 705-25. Auxiliary Power Unit 725-26. Hydrostatic Drive System 775-27. Direct Drive System 785-28. Multiple Speed Transmission Drive System 795-29. Main Engine Bleed Air and Direct Drive 81 Gearbox System5-30.

9 Multiple Power Supply System 825-31. Transmission Accessory Drive System 835-32. Direct Drive and Hydrostatic Drive System 845-33. Cooling and Exhaust System 875-34. Fan Performance -Static Pressure 90 Versus Flow Rate5-35. Single Fan Cooler -Heat Rejection Versus 91 Airflow5-36. Single Fan Cooler -Air Pressure Loss 92 Versus Airflow5-37. Single Fan Cooler -Oil Pressure Versus 93 Oil Flow5-38. Cooling System Flowpath 957 LIST OF ILLUSTRATIONS (Cont.)Figure Title Page5-39. Seal/Retainer Configuration 995-40. TMEPS Hydraulic System Block Diagram 1025-41. Hull/Turret Drive System 1035-42. Accessory Cooler and Fan Drive System 105 Flow Block Diagram5-43. TMEPS Fuel System 1145-44. Vehicle Electrical Power Block Diagram 1265-45. APU/SCAF Control/Display Panel 1275-46. System Block Diagram 1285-47. Auxiliary Networks Box 1315-48. TMEPS Brake Control System 1345-49.

10 Structural Design Modifications 1375-50. TMEPS Vehicle Rear View Configuration 1395-51. Test Cell Configuration 1455-52. Test Cell Installation 1465-53. Clean Barrier Filter Media 1485-54. Contaminated Barrier Filter Media 1495-55. Contaminated Barrier Filter Media 1505-56. Life Cycle Cost Comparative Analysis, 155 MIAl 1991, MIAI 1986 and TMEPS5-57. Hardware Work Breakdown Structure 1565-58. Fleet Size and Commonality Perspective, 159 Adding TMEPS Configuration to Fleet5-59. Life Cycle Cost Methodology 1608 LIST OF TABLEST able Title Page1-2 Engine Improvements 135-1 Transmission Features Comparison 645-2 Transmission Range Comparison 655-3 Air Side Fin Comparison 965-4 Grill and Cooling Fan Areas 975-5 Induction-Exhaust Cooling, TMEPS/MIAI 985-6 TMEPS Electrical Load Analysis 1215-7 Engine Performance (Comparison) 1445-8 Engine Power in Vehicle (Installed) 1475-9 Hardware Commonality 1585-10 TMEPS Average Unit Production Cost 163 Estimate Summary by WBS5-11 Total Life Cycle Cost Results, MIAI 1641991, MIA1 1986 and TMEPS5-12 Comparison of Total Life Cycle Costs, 165 Cost Drivers/Cost INTRODUCTIONThis Science and Technology report on the TMEPS program wasprepared by GDLS for the AGT1500 Powerpack Improvement Projectin accordance with the requirements of the Army TankAutomotive Command (TACOM)