Company:
Ehmke Manufacturing Company

Project Details

Fabric 1

18 oz High Abrasion Resistant Neoprene Kevlar Coated (HANK)
Producer/Manufacturer: Trelleborg
Primary Use: Main Fabric

Fabric 2

1/2" Thick Ethylene Vinyl Resistant (EVA) Extreme Temperature
Producer/Manufacturer: Berry Compliant Supplier
Primary Use: Main Fabric

Fabric 3

1050 Denier Ballistic Nylon Cloth
Producer/Manufacturer: MMI Textiles
Primary Use: Secondary Fabric

Fabric 4

4" Mil-Spec Hook & Loop Tapes AA55126A
Producer/Manufacturer: MMI Textiles
Primary Use: Additional Fabric


Engineer Company 1
Magee Technologies LLC

Design Name
Chris Jachimowski

Design Company
Ehmke Manufacturing Company, Inc.

Fabrication Name
Bob Rosania

Fabrication Company
Ehmke Manufacturing Company, Inc.

Project Manager Name
Greg Nichols

Project Manager Company
Ehmke Manufacturing Company, Inc.


Please describe the project specifications

2024 ATA International Achievement Awards
Project Entry
2024

Project: P8-A Poseidon Multi-Role Sensor Maintenance Cover

Project Description:

The U.S. Navy utilizes an array of multi-purpose aircraft to effectively manage the modern-day battlefield. The Boeing P-8 Poseidon is an American maritime patrol and reconnaissance aircraft developed and produced by Boeing Defense, Space & Security, and derived from the civilian Boeing 737-800. The $175 Million aircraft (with a Global fleet of 200 aircraft) serves multiple missions; including, anti-submarine warfare (ASW), anti-surface warfare (ASUW) and intelligence, surveillance, and reconnaissance (ISR) roles. The P-8 Poseidon's effective ability to search relies upon multiple sensors in a top-down approach. Searches start with radar and then shift to the plane's advanced optics that can zoom down to the surface of the waves. The expensive advanced optics and multi-mode sensors are highly complex and require extensive service & maintenance to function properly. The U.S Navy calls on Maintenance, Repair and Overhaul (MRO) facilities to properly maintain their investment.

The sensor protected communicates with the U.S. high-capacity Wide Band Satellite Communications (WBSC) system. The WBSC satellites are the next-generation Defense Satellite Communications System (DSCS) and Global Broadcast Service satellites serving as the primary satellite communications system of the military. This new technology provides increased capabilities for ISR, battle management, and combat support information purposes by improving satellite bandwidth and communication. Consequently, great care must be taken to prevent any damage to the multi-mode sensor.

The requirement set forth by the customer required a Berry-Compliant, engineered solution that was design with tight tolerances within a restricted space. Most importantly, the materials could not contribute to the degradation of the aircraft skin or damage the sensor. The ability of the 6’ x 10’ cover to support the mechanics during servicing was critical.

Project Complexity:

Our Company was called upon to partner with an engineering firm to design and fabricate a WBSC high-capacity Radome Sensor maintenance cover that is quickly deployable, extreme weather resistant, lightweight, and robust. The criteria required was for the fabric and substructure to withstand the rigors of the maintenance cycle, not scratch, damage, or impair the sensitive sensors or aircraft skin, resilient to environmental conditions, and be reusable & within budget. The innovative design utilizes multilayer exterior fabric with a robust padded interior, interconnected sections that allow reconfiguration of the protective cover and the pliability to store and retain the cover. The cover components vary in size with high tolerances. The foam inserts must take into account the center of gravity weight and contour of the sensor. Along with a myriad of environmental testing, the sensor cover and their contents are subjected to a series of impact tests from heights ranging from 1-4 feet. All materials selected for the construction of the cover were required to meet military specifications.

Project Results:

Our Company worked through a Research & Development process with our Customer and the End-User resulting in the optimal product design and finished product. Successful deployment of the prototype has resulted in a low-rate initial production (LRIP) order for the remaining fleet of P8 -A Poseidon aircraft.


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