DON27BZ02-NV024 TITLE: Zero-Retrofit Robotic Ammunition Handling for the MK 45 Mod 4, 5-Inch Gun Magazine

COMPONENT TECHNOLOGY PRIORITY AREA(S): Human-Machine Interfaces;Trusted AI and Autonomy

PROJECTED CMMC LEVEL REQUIREMENT: Level 2 (Self)

D The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. 

OBJECTIVE: Develop a zero-retrofit robotic prototype capable of identifying, lifting, and loading 70-pound, 5-inch projectiles within the unmodified physical constraints of a DDG 51 class ships’ MK 45 Mod 4 ammunition magazine during Sea State 5 conditions. This effort seeks a human-capable equivalent that matches the agility and operational tempo of a well-trained sailor, successfully removing human crews from the most physically exhausting and hazardous steps of the kill chain.

DESCRIPTION: The tight confines of a DDG 51 5-Inch ammunition magazine present a difficult challenge for automation. Traditional robotic arms require fixed mounting and large clearance envelopes, requiring complete compartment redesigns. To avoid extensive shipyard work, the robotic prototype must adapt to the ship. The prototype must navigate narrow aisles, step over "knee-knocker" coamings, and load ammunition into the existing hoists and stowage racks alongside or in place of human sailors.

The robotic prototype must execute capture and lift of 70-pound projectiles and their propelling charges, change their orientations while captured (i.e., pivot), move ammunition between stowage racks and hoists, and safely place the projectiles into the stowage racks and hoists in the proper orientation. Furthermore, the prototype must keep kinematic stability in high sea states (up to Sea State 5) while being able to continue to complete its tasking. The prototype must be resilient to electromagnetic interference (EMI)/electromagnetic pulse (EMP), and have a power supply architecture that enables sustained fire missions without the need for recharge or obstructive cables, and ability to rapidly swap power supplies without substantial downtime.

KEY PARAMETERS FOR ZERO-RETORFIT INTEGRATION:

• Payload Capacity: Continuous capability to lift, pivot, and load 70-pound projectiles and associated propelling charges. System must meet a minimum Threshold of 6 rounds per minute, with an Objective of 12 rounds per minute.
• Form Factor: Must fit within standard 24-inch shipboard aisles and maneuver in confined magazine spaces.
• Locomotion: Able to traverse standard deck plating, step over 6-inch coamings, and brace against ship motion.
• Stability: Maintain balance and load control up to and during Sea State 5 conditions (significant pitch/roll/heave).
• Power: Minimum 2-hour continuous operational endurance with rapidly hot-swappable battery packs (changeable in under 60 seconds).
• Hardening: Built to Military Standard (MIL-STD)-461 (EMI/EMP) and MIL-S-901D (Shock) thresholds.
• Safety/Fallback: Zero-retrofit integration (i.e., no structural alteration), ensuring the space stays 100-percent operational by human fallback crews in case of robot failure.
• Explosive Safety: Must adhere to NAVSEA OP 4 protocols for the safe physical handling of ordnance (Note: meeting specific electrical power level compliance is out of scope for this effort).

PHASE I: Develop a concept for a humanoid or pseudo-humanoid robot meeting the key parameters for zero-retrofit magazine operations. Conduct kinematic and dynamic simulations modeling the robot extracting, pivoting, and loading rounds in a virtual MK 45 magazine under Sea State 5 conditions. Perform trade studies on single-arm versus multi-arm torque constraints and bipedal versus pseudo-humanoid (quadruped, tracked, or other) stability. Prepare a report on physical design, power management strategy, and a Phase II prototyping/testing plan.

PHASE II: Fabricate a functional prototype based on Phase I designs. Assess the prototype in a land-based magazine mockup. Mount the mockup on a multiaxis motion simulator to replicate Sea State 5 roll and pitch. Demonstrate the robot successfully extracting dummy 5-inch projectiles from standard horizontal racks, navigating an aisle, and vertically seating the propelling charges and projectiles into a simulated hoist. Refine grasping effectors and stabilization software. Deliver a prototype, testing data report, and a Phase III ruggedization and integration plan.

PHASE III DUAL USE APPLICATIONS: Ruggedize the Phase II prototype to meet MIL-STD shock, vibration, and EMI/EMP requirements. Integrate the system at a live testing facility (e.g., Naval Surface Warfare Center (NSWC), Dahlgren, or NSWC, Port Hueneme) alongside a fully functional MK 45 Mod 4-gun mount. Demonstrate a sustained, full-rate fire mission using the prototype as the primary loader. Finalize production designs, deliver the testing data, and mature the prototype for transition to Navy for shipboard demonstration. Primary commercial dual-use sectors for this technology include: Power Infrastructure, Offshore and Onshore Oil Rigs, Mining, and Nuclear facilities. Ultimately, this technology establishes a commercial benchmark for removing human operators from high-risk, physically grueling industrial roles. Doing so preserves human capital for critical cognitive tasks while drastically reducing injury rates in hazardous environments.

REFERENCES:

1. Lattimer, B. Y. et al. "SAFFiR: Shipboard Autonomous Firefighting Robot." Virginia Tech/Office of Naval Research (ONR), 2014. https://www.navy.mil/Resources/Fact-FIles/Display-FactFiles/Article/2160601/shipboard-autonomous-firefighting-robot-saffir
2. Sentis, L. et al. "Design and Control of the Valkyrie Humanoid." NASA Johnson Space Center, Radford, N. A. et al. (2015). "Valkyrie: NASA's First Bipedal Humanoid Robot." Journal of Field Robotics, 32(3), 397–419.https://onlinelibrary.wiley.com/doi/10.1002/rob.21560
3. Johnson, M. et al. (2015). "Team IHMC's Lessons Learned from the DARPA Robotics Challenge Trials." Journal of Field Robotics, 32(2), 192–208 https://onlinelibrary.wiley.com/doi/10.1002/rob.21571
4. Hwangbo, J. et al. "Learning agile and dynamic motor skills for quadrupedal robots." Science Robotics, 2019. https://www.science.org/doi/10.1126/scirobotics.aau5872
5. Khatib, O. et al. "Ocean One: A Robotic Avatar for Oceanic Discovery." IEEE Robotics & Automation Magazine. 2016. https://ieeexplore/ieee.org/document/7742315
6. Vahrenkamp, N., Berenson, D., Asfour, T., Kuffner, J., & Dillmann, R. (2009). "Humanoid Motion Planning for Dual-Arm Manipulation and Re-Grasping Tasks." IEEE/RSJ IROS, pp. 2464–2470 https://ieeexplore.ieee.org/document/5354625/
7. Bostelman, R., Hong, T., & Marvel, J. (2016). "Survey of research for performance measurement of mobile manipulators." Journal of Research of the National Institute of Standards and Technology, 121, 342-366. https://nvlpubs.nist.gov/nistpubs/jres/121/jres.121.015.pdf
8. Kaneko, K. et al. "Humanoid Robot HRP-3P: A Robot Operating in the Real World." 2008 IEEE/RSJ International Conference on Intelligent Robots and Systems, Nice, France, pp 2471-2478. https://ieeexplore.ieee.org/document/4650604

KEYWORDS: humanoid robotics; pseudo-humanoid; biarmed manipulation; quadrupedal robotics; MK 45 Mod 4, 5-Inch Gun; counter unmanned surface and aerial systems, counter-UxS; ammunition magazine; ammunition handling; heavy-lift robotics; zero-retrofit integration; dr

TPOC 1: Nathan Lambert
nathan.a.lambert10.civ@us.navy.mil

TPOC 2: Matthew Buckler
matthew.t.buckler.civ@us.navy.mil

TPOC3: Luke Steelman
sanford.l.steelman.civ@us.navy.mil