Intelligent Ordnance Initiation System

1
Aditya Patil, 2Virendra Kumar, 1Ashok Sapkal
1
Department of Electronics and Telecommunicaation, College of Engineering, Pune
2
Arnament Research and Development Establishment, Pashan, Pune

Abstract --This report presents a state-of-the-art for initiating
explosive devices. The design consists of a Setter unit which has
two level of security for avoiding mishandling of the device; two or
more detonator unit consisting of an arming circuit, a disarming
circuit, a firing circuit and a booster circuit for boosting the
available supply voltage to the desired voltage for firing of the
Electro-Explosive Devices; a communication protocol which allows
two way communication with a provision for addressing each
connected device with a unique identity number. A low energy
Semiconductor Bridge is used in this design. The circuit is ESD and
RF protected. A two stage firing trigger is used in case detonator
fails to explode on first trigger. Also each detonator unit possesses
decision making ability. Hence system is referred as “Intelligent”.
Keywords -- Semiconductor Bridge, arming circuit, disarming
circuit, firing circuit, boosting circuit
I. INTRODUCTION
The design discussed relates to the initiation of Explosive
and Pyrotechnic devices in aerospace and aeronautical devices.
Recently automotive industry is working on to explore various
field of application with this technology [2].
Explosive and Pyrotechnic devices comprises of explosive
bolts, bolt cutters, separation fairings, actuators, engine igniters,
etc. are used in aeronautical and aerospace industry to perform
various applications such as separation of one structure from
another, release of one structure from a stowed position to a
deployed position, etc. These devices are also used in safety
systems such as automobile industry for the deployment of air
bags. These devices are typically initiated by appropriate
electrical signals generated by an initiating system. Such
devices can be used to initiate plurality of initiators. The
combination of control unit, a plurality of initiators and an
electrical communication system through which signal can be
send from controller to the initiators is referred to be ‘ordnance
firing system’.
In this embodiment each detonator has a temperature sensor
inside it, which will set output logic level high once the
temperature of the surrounding reaches certain temperature
level. Sensors can be temperature, voltages, frequencies, etc.
Acceleration sensor is used in case of missile application to
trigger the effector once the missile has surpassed certain
distance from the aircraft. Thus, the proposed design is termed
as intelligent.
In the prior art of this technology consists of initiators
which typically comprised of a hot bridgewire initiating element
and an initiating charge of explosive or pyrotechnic material
which is sensitive to the initiating element. In order to initiate
hot bridgewire typically current of magnitude ten amps from
28V source for a period of 100ms. However, the system may
consist of plurality of initiators which finally will result in
requirement of very large current exceeding the energy
requirement of the circuitry that controls the device. As a result
a dedicated high power energy source such as thermal or
chemical battery is required for the system.
In recent art work Semiconductor Bridge (SCB) is widely
used as an initiating element. The key feature of SCB is that it
has very low energy requirement. Typically SCB has low
resistance, e.g., no longer than 10 ohms and a current
requirement of not more than 10 amps is required and for the
duration not more than 100 microseconds. SCB is a recent
innovation. This includes a doped poly-silicon layer formed on
a Silicon substrate over which aluminum lands are provided. A
current pulse of appropriate intensity through SCB causes the
bridge to burst into a bright plasma discharge within few
microseconds. This result in rapidly igniting the powder pressed
against the bridge [1]. Since the SCB is formed on thermally
conductive silicon substrate, the no-fire current levels are as
good as any conventional hot bridgewire igniter. Further the
igniter is tolerant to ESD and RF.
II. DESCRIPTION
The proposed design can be divided into three modules:
A. Setter Unit
The Setter unit consists of a 16X2 LCD Display to display
output and a 4X4 Matrix Keypad for capturing input from user.
The Setter unit has two kinds of password that the user must be
aware of. The first level of password is asked at the time of
system startup. The second level of password is used to prevent
misuse of the device. Hence this password is only asked at the
time when user gives FIRE command. In case the user fails to

*Author for correspondence, Dr. Virendra Kumar, dvkverma25@gmail.com, for presentation in International Conference on
“Emerging Trends in Electronics & Communication Engineering (ETECE-2015)” BVUCOE, during 2-3 April 2015, Pune
enter the valid password the Energy Reserve Capacitor (ERC)
discharges itself. Fig. 1 shows typical Setter unit with LCD
display and a Keypad.
Fig. 1. Block diagram of Setter unit
B. Serial Communication
The design uses I2C protocol for serial communication
between the Setter unit and the Detonation unit. It’s a Two-Wire
serial Interface (TWI) which is ideally suited for
microcontroller applications. The TWI protocol allows system
designer to connect at most 128 devices using two bi-directional
bus lines, one for clock (SCL) and other for data (SDA). Each
device thus connected can be addressed individually through a
unique identity number which all possesses. Two external pull-
up resistors for each of the TWI bus lines are required. Fig. 2
shows detonator units connected in bus topology with the setter
unit.
Fig. 2. Setter unit and Detonator unit in Bus Topology
C. Detonator unit
The detonator unit consists of a microcontroller which
controls all the activities around itself. The detonator unit has
various sub-modules:
 Arming circuit:
As soon as the detonator unit receives an ARM
command from the Setter unit, the microcontroller sets
the Arming switch results in the connection between
external power supply and the internal circuitry of the
detonator. Also with the ARM command, the
microcontroller also starts the booster circuit to boost
the available supply voltage to the required firing
voltage
 Booster circuit:
The Booster circuit works on the principle of DC-
DC Boost Converter. The key principle that drives the
converter is the tendency of inductor to resist changes
in current by creating and destroying a magnetic field.
In a Boost Converter the output voltage is always
higher than the input voltage [3]. Typically a boost
converter consists of at least two semiconductors and at
least one energy storing element. In proposed design
Energy Reserve Capacitor (ERC) is used to store the
boosted voltage. Tantalum Capacitor is used to lower
the leakage current. The available supply voltage is 5
volts which needs to be boosted for about 40 volts for
primary trigger and for about 60 volts for secondary
trigger.
 Disarming circuit:
A provision for disarming the circuit is provided in
the design. In case the user does not want to fire the
detonator then he can send a DISARM command. In
such case the ERC discharges through the Bleeder
resistor, thus avoiding any firing of the circuit further.
While in case of wrong password during the
authentication of FIRE command, the controller itself
generates a DISARM command, resulting in
prevention of any misuse of the system
 Firing circuit:
After proper authentication the firing circuit is
initiated. Once FIRE command is send to detonator
unit, the delay count is loaded into the inbuilt Timer of
the controller and thus giving the delay as required by
the user. The firing switch is triggered once the count
is reached, resulting in the discharging of ERC through
the SCB unit. A two level firing system is used. In case
after the firing of SCB with primary trigger, the system
fails to explode then a secondary trigger is applied after
boosting the supply voltage for about 60 volts.
  SCB unit with ESD and RF protection:
SCB used in the embodiment has very less energy
requirement of the order of mJ (<5mJ). Its response
time is less than few tens of microseconds. SCB has
All-Fire current of 2A and a No-Fire current of 1A for
300 seconds. SCB resistance is 1 ohm ±0.1 ohm [2]. A
Transient Voltage Suppressor (TVS) Diode is used for
ESD protection and a Low Pass Filter for RF
protection [4].
command, the ERC is discharged through Bleeder resistor. In
case of FIRE command, load the delay count in Timer and then
fire the SCB after the respective time has elapsed. In case if the
detonator circuit fails to explode, a secondary fire voltage level
is applied. A booster circuit is started again until 60 volts is
reached and secondary trigger is applied. The detonator unit has
an internal sensor which has its own intelligence and the circuit
is fired once the internal sensor sets the logic high. Fig. 5 shows
flowchart for Detonator unit.

Fig. 3. Block diagram of Detonator unit

III. FLOWCHART

The proposed system has two different modules with each

having a microcontroller in it.

A. Setter unit
The Setter unit first asks for a startup password [5]. In case
of a match setter unit Detonator ID to which the user wants to
communicate. Then a delay in the range of 1000 to10000
milliseconds can be set. After this the delay count is send to
respective Detonator unit. In case the user at a later instance of
time wants to abort the process then, he can send a DISARM
command. However in further steps, the user sends a FIRE
command the moment detonator unit is required to be fired. A
second level authentication password is asked by the Setter unit.
This password is only known to the manufacturer and the end
user. Failing to give the expected password, the detonator unit
disarms itself. Fig. 4 shows flowchart for the Setter unit.

B. Detonator unit
The detonator unit first initializes its unique Detonator ID.
Save the delay count in the memory for later purpose. After
getting ARM command, start Booster circuit and boost supply 5
volts to 40 volts and charge ERC capacitor. In case of DISARM Fig. 4. Flowchart for Setter unit
 IV. ASSEMBLY

The size of the detonator unit is 20mm in diameter and 45

mm in height. The detonator unit consists of two both sided
PCBs which are stacked one above the other. Input port of the
detonator unit has a four wire serial connector which 5 volts,
GND, SDA and SCL wires. Also the other end has a SCB at the
exterior end. The both PCB has size of 19mm diameter X 6mm
height. Fig. 6 shows mechanical assembly of the PCBs inside
Detonator unit.

Fig. 6. Mechanical assembly of Detonator unit

V. RESULTS

The simulation of the circuit was carried out with the use of
multisim software. Fig. 7 shows simulation of the firing pulse of
the Detonator unit. It can be observed that a two level firing has
been implemented. In case of the primary trigger, a 40 volts
impulse is applied across the SCB. In case the system fails to
fire then another impulse of 60 volts is applied across the SCB.
The current flowing through the SCB is calculated by measuring
the voltage across Current Viewing Resistor (RCVR). The
resistance of RCVR is 0.1 ohm. Fig. 7 shows a VCVR=3 volts
across RCVR. Thus current through SCB= VCVR / RCVR. Hence
Fig. 5. Flowchart for Detonator unit
current through SCB will be 30 amps. Also the current pulse TABLE I. Specifications of designed detonator
maintains substantial level for about 20 microseconds.
Primary Firing Voltage 40 Volts
Secondary Firing Voltage 60 Volts
Primary Trigger User specified
Secondary Trigger 1.1 seconds after primary trigger
SCB Current >30 amps
SCB Current duration >15 microseconds
SCB ESD Protection Yes
SCB RF Protection Yes
Internal Sensor Yes, Temperature sensor
Detonator Size 20mm in dia X 45 mm in ht

REFERENCES

[1] Virendra Kumar and C. B. Ghodke, “Specification of SCB Detonator MK-

I ARDE”

[2] Craig J. Boucher, Paul N. Marshall, David B. Novotney, “Ordnance Firing

Fig. 7. Simulation result of the firing unit System”, U.S. Patent 6,889,610 B2, May 10, 2005.

[3] B. M. Hasaneen, Adel Mohammed, “Design and simulation of DC/DC

Bosst Converterr”, IEEE, Power Systems Comference, 2008.

[4] Virendra Kumar, “Semiconductor Bridge Detonator and its applications”,

8th National Seminar & Exhibition on Aerospace Related echanism at
ARDE during 06-08 Dec 2012.

[5] Jayshree Pande, Virendra Kumar, Archana Singh, “Electronic SCB delay
detonator system for mines”

Fig. 8. Simulation result for the voltage across the RCVR

VI. CONCLUSION

The resulting specification of the design is shown in

TABLE I.

ACKNOWLEDGEMENT

The authors are thankful to Dr. K. M. Rajan, Director,

Armament R & D Establishment, Pune for support and
permission to present this work. Authors express their sincere
thanks to Shri. Kapil Deo, Sc. ‘G’ Associate Director, for the
guidance during the course of work.