A monthly house bulletin of Defence Research & Development Organisation ■ Vol. 31 No.

7 ■ July 2011
ISSN : 0971-4413
BULLETIN OF DEFENCE RESEARCH AND
DEVELOPMENT ORGANISATION
Vol. 21 No. 6 December 2013

A self-reliant and strong navy to protect India’s maritime interests is central to

our national policy. DRDO is involved in design and development of highly complex
and technologically intensive naval warfare systems to meet the requirements of
the Indian navy. Naval weapons and platforms operate under entirely different
environmental conditions. The different set of technologies, which require
integration of multi disciplinary technologies, therefore, need to be developed.
This issue of Technology Focus focuses on some of the underwater weapons and
associated technologies developed by Naval Science and Technological Laboratory
(NSTL), DRDO.

Advanced Lightweight Torpedo

Actuation System
Electro-mechanical actuator has been designed
and developed for operation of control surfaces of
advanced lightweight torpedo (ALWT). The actuator is
a permanent magnet brushless motor with extended
motor shaft and a lead screw and guide nut with balls
arrangement to achieve high efficiency and low co-
efficient of friction. The supply voltage of motor is 56-
75 V dc with 20 amps peak. The actuator will generate a
stall force of 135 lbs with a minimum linear velocity of 7
in/s. The weight of actuator is 600 g approximately.
The actuation system has been successfully tested
in torpedo dynamic trials. Assembly Actuation System
 Development of CFRP shell
requires very high level of stringent
quality standards like resin handling
system, autoclave facility, four-axes
computer numerically controlled
(CNC) filament winding and
advanced collapsible mandrel and
tool design.

DRDO has developed CFRP

shell using heat curing ciba geigy
epoxy resin. The required optimised
filament winding angle patterns
were generated through finite
Assembly actuation system—Compact link system design
element analysis. The shell has been
Salient Features reinforced using 6 K high strength carbon fibre roving.
The shell is capable of withstanding shock, vibration
aa Number of actuating : 4
and structural load to the tune of 60 bar of external
channel
hydrostatic pressure.
aa Torque on signal control : 16 N-m
Salient Features
surface
aa Density : 1.65 gm/cc
aa Operating voltage : 64 V dc
endurance = 33 min aa Elastic modulus : 133 GPa
aa Accuracy : < 0.5
o along the fibre

aa Elastic modulus : 9 GPa

CFRP Structural Shell Development across fibre

Composite Fiber Reinforced Plastic Shell aa Poisson's ratio : 0.29

Heavy-weight torpedoes are designed to operate

up to a depth of 600 m. Presently structural shells of
these torpedoes are made of aluminium alloy forgings
and castings. However, composite fibre reinforced
plastic (CFRP) cell structure acts as a good damper for
structures-borne noise with an advantage of reduction
in weight.
CFRP Assembly Battery Shell
The CFRP assembly battery shell accommodates the
battery for conducting dynamic trials. The assembly
battery shell comprises CFRP battery shell with
aluminium alloy end flanges fitted at either end through
titanium alloy tie rods. The shell is manufactured with

2 December 2013
 Composite fibre reinforced plastic battery shell
Inside view of the composite fibre reinforced plastic battery shell
filament wound special purpose CNC filament winding
machine.
The resing quality of the CFRP assembly battery shell
has been controlled. The specified viscosity of the resin
is maintained within the limits by suitably controlled
heating of the incoming resin. A special purpose
collapsible mandrel has been used in the machine
within the specified run out limits. The CFRP shell is
cured in fully controlled curing ovens for proper curing
of the laminate.
Composite shell
Global Positioning System Ejection
Mechanism for Torpedo
Global positioning system (GPS) is assembled inside
an ejection system in a torpedo. It helps in locating and
recovering of the torpedo during exercise trials. Also,
some other critical trial parameters can be determined
from GPS transmission while torpedo is still in the
water and helps in saving the time which otherwise is
wasted in bringing the torpedo back to the laboratory,
in opening it and then downloading the data. The
December 2013 3

Maximum stress contours in the housing
critical trial parameters which are known in the lab
immediately after trials are run termination, total run
time, and homing contacts and steer aways.
A GPS-based electronic mechanism has been
designed to eject signal transmitting unit of GPS
out of the lateral surface of the torpedo as per signal
Ejected condition from torpedo shell
4 December 2013
transmission requirements. The
system can withstand an external
hydrostatic pressure of 60 bar
corresponding to the maximum
operating depth of 600 m. Mass of
the total assembly is 5 kg. Overall
dimensions of the system are:
390 x 130 x 100 mm. The major
dimension is along perpendicular
to the longitudinal axis of the
torpedo.
Integrated Pneumatic
Recovery System
Unlike a missile, a torpedo
records its own data during
experimental trials for evaluation of the system. This
recorder is housed in the exercise head section of
torpedo. Recovery of the torpedo is, therefore, essential
after each mission trial at sea.
An Integrated Pneumatic Recovery System (IPRS)
has been developed to provide a buoyancy of more
than 100 kg at 100 m depth. The basic function of the
system involves expansion of compressed air (330
bars) to inflate a torroidal balloon to 120 kg buoyancy
against a hydrostatic pressure of 10 bar in two to three
seconds time. When the torpedo starts ascending with
this buoyancy, the external pressure keeps reducing
thus expanding the balloon further. A selectively
designed bleed valve has been catered in the balloon
to maintain the external pressure with required
differential pressure to avoid bursting of balloon. Since
reliability of the system is of immense importance, a
redundant design of mechanical activation for releasing
the pressure on balloon has been incorporated in case
the pyrotechnic fails to operate the valve to release
of pressure. A especially designed spherical titanium
alloy bottle has been designed to cater for more than
660 bar pneumatic pressure. Maximum capacity of the
bottle is 5 liter and a 300-cycle life.
The challenge of development of a leakproof,
reinforced balloon system to withstand 1.3 bar
differential pressure at 160 liter volume in air with a
thickness of not exceeding 0.7 mm has been realised
in the system. The entire balloon system is packable
in an annulus area of torpedo. The IPRS system has
undergone all environmental tests as per the naval
QR and is being used successfully in experimental and
developmental trials of ALWT test vehicles at sea.
The IPRS system testing in air
The IPRS broadly comprises the following:
aa An aluminium alloy shell weighing 16 kg and
capable of bearing an external pressure (maximum)
of 16 bar
aa A polyster fibre reinforced torroidal shape puncture
resistant rugged inflatable bag having maximum
capacity by volume of 160 litre and capacity to bear
a maximum differential pressure of 1.3 bar
aa The covers for sheathing inflatable bag and to
maintain a smooth surface of Φ324 mm from
hydrodynamic standpoint
aa Retaining belts to keep the balloon within the
annular space intact
aa The pressure transducers for measuring and
recording air bottle (0-330 bar) and seawater
(0-20 bar) pressure
December 2013 5
 aa Valves and piping to meet the performance
parameters
aa Interface electronics to initiate/trigger IPRS and to
control the air discharge into balloon based on the
positive ascent rate information
aa A 24 V dc battery

Ship-fired Decoy Launcher

A reliable ship-fired decoy launcher has been
designed and developed to meet the requirements
of the Indian Navy. The system comprises pedestal
assembly, a stationary support base, rotary base, local
control panel, pneumatic charging panel, launch tube
assembly, main valve assembly and an air bottle. The
purpose of the system is to deploy countermeasures
against torpedo and other attacking threats. The
intrinsic capabilities of countermeasures have been
designed to protect critical assets against the ever
expanding threats of modern warfare with accurate
positioning of the decoy or individual placement of
sub-munitions.

Trainable launcher consists 10 x 100 mm caliber

barrels mounted horizontally on a turntable. The
launcher works on the principal of expansion of
compressed air in to the barrel, thus resulting in
necessary thrust to attain required muzzle velocity of
the decoy from launcher tubes.

Each decoy launcher weighs 850 kg. Electro-

pneumatic controls and remote, local, emergency
firing modes have been provided to suit Navy’s
requirements. Main modules of the launcher are:
Assembly training mechanism; assembly launch tube;
IPRS components assembly pneumatic charging panel and assembly

6 December 2013

Decoy launcher
launch control panel. Mode of operation of the launcher
is both power and manual. It has a launching range of
more than 20 meters away from the ship.
Technical Specifications
Overall weight : 850 kg
Overall height : 1025 mm
Overall width : 1260 mm (dia)
Overall length : 1560 mm (dia) Torpedo
Bore of barrel : 102 mm
Battery Technologies
Underwater weapons, vehicles and systems like
lightweight torpedoes, heavy-weight torpedoes,
underwater mines, autonomous underwater
vehicles, static and mobile decoys, targets, etc., are
electrically propelled, and therefore require power
plants as a source of power. Electrochemical power
systems like batteries are used both for propulsion as
well as powering the electronics and other
sub-systems. Batteries are of primary (one
or number of times usage till the capacity
exhausts), secondary (rechargeable/reusable)
and reserve primary (non-rechargeable and
use once on activation) types and converts
chemical energy into electrical energy and vice
versa. For a given battery chemistry, each type
possess different power and energy content
for the given weight and volume.
Because of high drag encountered by the
underwater systems while moving underwater,
volume and weight are critical components
while designing these. Accordingly, the power
sources also need to meet these essential
criteria resulting into choosing systems with
high energy and power density, both gravimetrically
as well as volumetrically. There are very few battery
systems, which fall under this category, and available
commercially. NSTL has developed some of these
technologies, which are described here:
250 kW Silver oxide-Zinc Secondary
Propulsion Battery for Heavy-weight
Silver-Zinc system has the highest mass energy
density (watt-hours per kg) and the highest volumetric
energy density (watt-hours per litre) of all battery
systems in use today. This system fits suitably in many
applications, generally military, better than any other
system presently operational, especially if one considers
the combination of high rate capability, high energy
densities and above all, safety. Silver oxide–Zinc (AgO-
Zn) secondary battery is used as a power source for
propulsion and other requirements of sub-systems of
December 2013 7

250 kW AgO-Zn secondary propulsion battery
a heavy-weight torpedo. This battery is rechargeable
and thus suitable for repeated use.
A 250 W AgO-Zn secondary battery has been
developed for torpedo propulsion. The battery is
capable of providing 10 charged discharge cycles in 12
months wet life period. It comprises a number of cells
connected in series. Each cell has the nominal capacity
of 153 Ah. Length and weight of the battery are 2.5 m
and 600 kg, respectively.
Silver oxide–Zinc Secondary Battery for
Autonomous Underwater Vehicle
NSTL has successfully developed AgO-Zn
rechargeable secondary battery for Autonomous
AgO-Zn secondary battery with trays for autonomous underwater vehicle
8 December 2013
Underwater Vehicle (AUV). The battery has been tested
for 50 service cycles within 12 months wet life period
with 4 hours discharge duration. This long endurance
battery is being used as power source for AUV to power
propulsion, sensors, electronics, communications,
recovery aids and other sub-systems. Battery with
multiple voltages packs, i.e., 150 V, 28 V stacks with
120 Ah cells, and 48 V stack with 40 Ah cells, arranged
in series, delivers the required power for more than 7
hours at 4 knots approximate speed. The battery meets
30 days charge retention and 30 days discharge stand
o o
periods at 15 C to 55 C operating temperature and 0
o
to 35 C storage temperature..
28 V/65 V Silver oxide-Zinc Reserve
Primary Auxiliary Battery
A 28 V/65 V AgO-Zn reserve primary battery has been
developed for powering auxiliary power requirement
of combat version of heavy-weight torpedo. This
battery comprises two different sections, namely,
28 V section and 65 V section. Cells in each section are
connected in series to form cell monoblocks. The cell
monoblocks are assembled suitably over distribution
manifold blocks and are provided with relief valve for
uniform filling cum bleeding of excessive pressure.

28V/65V AgO-Zn reserve primary auxiliary battery
The electrolyte (potassium hydroxide solution), for the
activation of the battery, is stored within the battery
in two stainless steel cylinders with piston mechanism.
The battery contains two gas generators of 1200 cc (for
28 V section) and 2400 cc (for 65 V section) to inject the
electrolyte into the stack. The output wires from both
sections and gas generator are connected to output
connectors, mounted on the container of the battery.
220 kW Magnesium-Cuprous Chloride
Seawater Activated Reserve Primary
Propulsion Battery for Heavy-weight
Torpedo
Magnesium-Cuprous Chloride (Mg-CuCl) seawater
activated (SWA) battery is used for propulsion of
torpedoe. Seawater acts as an electrolyte in the battery.
Since the electrolyte does not essentially constitute
a part of the battery, the dry weight of the battery
is low. This battery comprises electrochemical pile
stack (cartridge); scoop bulkhead to scoop seawater
and other hardware units such as front flange which
accommodates the terminal; distribution plate for
uniform circulation of seawater; conduit pipes for
cables; tie rods for clamping; etc. All the components are
lightweight and occupy less volume and are assembled
in a shell with electrical and mechanical interfaces of
other sub-systems of the vehicle. The electrochemical
pile stack consists of duplex electrodes stacked under
end-to-end compression in a pile configuration. Each
duplex is made up of CuCl cathode, Mg alloy anode,
Cu foil current collector (separates anode and cathode)
and epoxy separators.
The 37 kW battery modules is the building block for
220 kW full battery. When seawater enters through the
scoop bulkhead into the cartridge, the electrochemical
reaction commences generating power. Scoop
bulkhead is capable of scooping the required quantity
of seawater for the required rate of discharge. The
battery is 1.95 m long and realises energy density of
71.51 Wh/kg out of theoretical value of 386 Wh/kg.
220 kW Mg-CuCl seawater activated reserve
primary propulsion battery
70 kW Magnesium-Silver Chloride
Seawater Activated Reserve Primary
Battery for Lightweight Torpedo
Magnesium-Silver Chloride (Mg-AgCl) battery is SWA
reserve primary type high energy and power density
battery indigenously developed by NSTL. This battery
comprises electrochemical pile stack with scoop
bulkhead, CFRP shell, end flange, etc. Electrochemical
pile stack is made of duplex-bipolar electrodes stacked
one above other. The duplex comprises Mg alloy
December 2013 9
 in dry state at temperature and humidity controlled
conditions.

120 kW Aluminum–Silver oxide Seawater

Activated Reserve Primary Battery for
Lightweight Torpedo

Aluminum-Silver oxide (Al-AgO) SWA battery is a

reserve lightweight and light volume primary type
high energy and power density battery. The battery is
the most powerful in its class, and is being developed
indigenously for lightweight torpedo application.

The battery is shell integrated and comprises

70 kW Mg-AgCl battery for ALWT practice version electrochemical pile stack, electrolyte management
system, etc. EPS consists of multiple cells stacked
anode, AgCl cathode, and Ag foil current collector. under end-to-end compression in a pile configuration.
Seawater has been used as an electrolyte. Theoretical, EMS consists of mode valve, solid electrolyte reservoir,
open circuit and nominal voltage of the battery is thermostatic valve, heat exchanger, gas separator,
approximately 2.59, 1.9 and 1.3 V, respectively. When recirculation pump and motor, valves, diaphragm,
seawater enters through the cell, electrochemical sensors, electronics control units, etc. All the
reaction commences generating power
along with secondary corrosion reaction.

Being exothermic reaction along with

heat, it generates hydrogen gas and
precipitates. Sufficient seawater flow
as electrolyte is, therefore, necessary to
remove the heat generated, sludge formed
and hydrogen gas evolved. Performance of
the battery depends on both temperature
and salinity of the seawater. Scoop bulk
head of the battery has been specially
designed to scoop and ensure desired rate
of seawater flow. The battery is being used
for propulsion of ALWT practice version. It
has a storage life of five years when stowed Model of Al–AgO reserve primary battery

10 December 2013
components with lightweight, low volume and with as electrolyte, is stored separately in a stainless steel
required functionalities are integrated in a shell as a vessel. A pressurized nitrogen gas cylinder has been
single unit with electrical and mechanical interfaces of provided in the module to pump the electrolyte into
other sub-systems of the vehicle. the cells when it is opened.

250 kW Silver oxide-Zinc Circular Plate A pyrotechnical device is attached to the gas
cylinder to rupture its metal diaphragm and to open
Reserve Primary Propulsion Battery for
the gas to the electrolyte tank. The electrode stacks
Heavy-weight Torpedo
of the cells develop voltage as soon as they receive
A 250 kW Silver oxide-Zinc (AgO-Zn) reserve primary the electrolyte, as they are assembled in dry charged
battery has been developed to power the combat condition. Length and weight of the battery are 2.5 m
version of HWT propulsion. Electrodes of the battery and 650 kg, respectively.
are made circular in shape to occupy maximum
volume. The battery module comprises two groups
Lithium-Thionyl Chloride Primary Battery
of cells. The cells in each group are connected in for Underwater Mines
series. The output polarities of the two groups are
Lithium-Thionyl chloride (Li-SOCl2) primary battery,
connected to the main terminals of the module.
a high energy density battery technology, has been
Each cell of the module contains a set of positive
developed indigenously for sea mine applications.
and negative electrodes suitably connected to form
Li-SOCl2 primary battery with low self-discharge
a high rate discharge cell. Potassium hydroxide, used
rate, high energy content
in less weight and volume,
is preferred compared to
other primary and secondary
batteries. The 28 V battery, with
more than 700 Ah, powers the
sensors and instrumentation
systems of the mine.
Li-SOCl2 cells are connected in
serial-parallel combinations
to get desired voltage and
capacity. Fuse and diodes
have been used in the battery
to avoid high current drain and
reverse current flow. The battery
250 kW AgO-Zn circular plate reserve primary propulsion battery has five years of storage life.

December 2013 11
 Li–SOCl2 primary cells for multi influential ground mine module

Li-Ion Polymer Secondary Battery for more service life are available for long endurance.

Underwater Mines Lithium-Ion polymer secondary battery pack (26 V, 75

Though, AgO-Zn battery has high energy content, it
generates gas, provides less number of service cycles,
has limited wet life period causing high maintenance
and cycle costs. Nowadays, lithium-based secondary
batteries, i.e., Li-Ion and Li-Ion Polymer batteries
with high energy density, more service cycle,
Ah) is being developed and tested by NSTL. It is the
power source for exercise version of multi influential
ground mine. This battery comprises high capacity
Li-Ion polymer pouch type cells connected in series
with protection circuits and assembled in FRP battery
housing. This battery has five years of service life and
provides more than 500 service cycles.

Technology Focus focuses on the technological developments in the Organisation, covering the products, processes and technologies.