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

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).