CHAPTER 1

INTRODUCTION

With the development of projectiles it became necessary to produce

devices for activating them. Crude fuzes were employed from about the 16th

century and these were filled with mealed powder, sulphur and saltpetre.

They were ignited initially by hand when the gun fired, and later, by the

propellant gases. In the 18th century a time fuze was developed consisting of

a wooden plug with a cavity filled with gun powder which could be cut at a

suitable position to terminate the slow burning at a required time thus

sparking the bursting charge of the projectile. In the mid 19th century the

Boxer fuze was introduced and this was a great improvement. It was a shaped

wooden cone and fitted into a projectile rather like a cork in a bottle. Also

about that time a wooden concussion fuze was invented by Freeburn and a

percussion fuze by Pettman. Many fuzes have been designed, developed and

used since then and many are now obsolete but they all employ certain basic

devices.

A fuze, which is a device used to initiate an explosive store at the

correct time and place, must ensure that the explosive store is completely

safe to store, handle and fire and then function reliably when required. The

general requirements are safety and reliability, and to a lesser extent,

conformity with a standard profile. Fuzes should have an appropriate

multipurpose function and be easy to set in the field. Fuzes in guided

missiles are usually electronic devices and the explosive function devices are

contained in a separate safety and arming mechanism. Fuzes are used in

shells and rockets with nuclear, high explosive, high explosive squash head,

bomblet, minelet, pyrotechnic shells for producing smoke or illuminating and

special purpose ammunition for delivering a wide variety of cargoes

including chemical and biological agents and propaganda leaflets. The design

of a fuze is influenced by several closely related factors, the most significant

 2

of which are the need for adequate target effect, the need for good ballistic

performance to optimise range and accuracy, the need for adequate strength to

withstand the stresses that are created on firing and the ever present need for

economy in manufacture.
 CHAPTER 2

DESIGN SAFETY PRINCIPLES

The design safety principles are of fundamental importance and

therefore should be understood in depth. The following notes are a greatly

simplified version of the same.

Arming

The arming must be as simple as possible, and functionally and

physically distinct from other processes such as the initiation system.

Assembly

It must be impossible to assemble the system in an unsafe condition,

and it must be possible to check the safety arrangements during and after

assembly. It is desirable that it should be possible to check the state of

safety features at any time during the service life of the fuze.

Interruption of Explosive Train

If sensitive explosive compositions are used they should be separated

from the main filling by a physical obstruction, which should be locked in

the safe position by at least two independent safety features. The physical

obstruction must prevent the propagation of the explosive train to the main

filling if the sensitive composition is accidentally initiated.

In Bore and In Flight Safety

The system must remain safe until a specified safe separation distance

has been reached after launching, projection or release. Within this specified

distance the fuze should not function if it strikes an obstacle or receives a

firing signal. The probability of failure in this respect due to any single

circumstance must be less than one in a million. If a fuze contains two

independent safety features the probability of becoming unsafe of each must

be less than one in a thousand, so that the cumulative probability is less than

one in a million.
 4

In line and Explosive Train

If an in-line explosive train is used in an electrical fuze, there must be

no electrical energy in the firing circuit until a safe separation distance has

been reached.

Software

Any software used in electronic fuzes must be structured in accordance

with strict guidelines which specify the programming techniques to be used,

including defensive programming techniques and their clear identification in

system documentation.

The general requirements of the fuze are as under : -

(a) Safety.

(b) Reliability.

Safety

Fuzes must be safe and tested to a very high standard against premature

functioning. Prematures in weapons create damage to own troops and

equipment and have a seriou demoralising effect. It is therefore essential that

ammunition, particularly fuzes, are designed to be safe under all storage,

transport and firing conditions.

Reliability

Reliability is an important requirement to assure correct and timely

functioning of the fuze. Generally the more complex the design the less

reliable it may be. Therefore, an abundance of safety devices and

mechanisms may reduce the reliability of a fuze.

The above requirement have led to some extremely complicated designs

in order to provide 100% assurance of both safety and effectiveness. Service

environment, rough usage, vibration, climate and so on are all taken into

account.
 5

CHAPTER 3

FUZE DYNAMICS

The heavy and necessary emphasis on design safety principles tends to

obscure the fact that the purpose of a fuze is not to prevent functioning, but

to initiate it at the appropriate time. The peculiar forces acting upon the fuze

during firing transforms the fuze from safe state to the functioning state,

known as arming of the fuze. These forces are at least two orders of

magnitude greater than might be experienced during a handling or

transportation accident, so it is relatively simple to design mechanisms which

will function only when the projectile is fired. The most significant of these

forces are setback and centrifugal force, although other forces and forms of

energy are also used.

Forces Acting on a Fuze

The forces acting on a spun projectile also act on the fitted fuzes. All

components in a fuze are either fixed relative to the fuze or are free to move

within certain limits. The movement of free components, controlled or

restrained as necessary by friction or springs or both, depends principally

upon the forces arising from the firing environment. Forces can range from

spin, acceleration, deceleration and in some cases side slap from rifled

weapons to merely a pressure applied to a fuze in a mine.

Relationship Between Setback Force and Centrifugal Force

Axial acceleration is initially very high, reaching a peak about one

third of the way along the barrel. Velocity continues to increase until the

shell is clear of the barrel, but the rate of acceleration falls of sharply from

its peak. When the shell is clear of the barrel it starts to lose velocity, and at

a point the acceleration becomes negative, that is, it decelerates. The effect

of this on components in the fuze is that they setback on their supporting

members with great force initially. This force decreases as the rate of
 6

acceleration becomes negative. The components which have set back

gradually ease in their settings, and their inertia carries them forward as the

shell decelerates unless they are restrained by the fuze mechanism.

The rate of spin is initially low, and therefore centrifugal force is

initially low compared to setback force. Components can therefore be

designed to move in a given sequence, setting back and being locked

mechanically or by friction, then moving radially as centrifugal force

increases while set back force decreases and then disappears.

 CHAPTER 4

TYPES OF FUZES

Fuzes differ considerably in design, depending on the result to be

achieved at the target end. For instance, a shell designed a explode or

detonate immediately on impact, will require a different fuze from a shell

which is required to penetrate before explosion or detonation. The fuzes are

grouped according to their action as discussed in succeeding paragraphs.

Percussion Fuzes

Percussion fuzes operate on impact with the target due to sudden

retardation. They may be designed to function after impact to allow a degree

of penetration. Fuzes under this category are also referred to as Direct

Action, Graze or Delay Action Graze. Other interpretations may also be

encountered such as `Point Detonating and Post Impact Delay.'

Base Fuzes

Base fuzes are classed under the percussion type of fuze, and operate

on a detonator in an inertia pallet riding forward on a fixed needle (or vice

versa) when the projectile hits the target. A delay may also be incorporated.

These fuzes are referred to as High Explosive Squash Head Shells, but similar

principles apply to fuzes for initiating High Explosive Anti Tank warheads in

rockets and to Armour Piercing High Explosive ammunition.

Time Fuzes

These are capable of operating at predetermined time settings which

can be set on the fuze by hand or automatically before loading into the

weapon. The process involves the movement of a ring relative to the body of

the fuze and usually shows the amount of movement by graduation marks

embossed around it. Two basic types of time fuzes are combustion fuzes and

mechanical time fuzes.

Combustion Fuzes
 These fuzes rely on the burning of a train of compressed pyrotechnic

powder which burns at a constant rate. The powder is contained in

circumferential grooves in adjacent time rings, the powder burns in one ring

at a time and the burning proceeds to the other in a train.

Mechanical Fuzes

These fuzes rely for their timings on a clockwork mechanism which

arms the fuze at the preselected time. Clearly mechanical time fuzes are

more accurate than combustion types. Most mechanical time fuzes for

artillery shells can be set for any delay from zero to eighty seconds. Zero

delay allows the fuze to function at the minimum distance from the muzzle

which is dictated by the normal in - flight safety features.

Proximity Fuzes

Proximity fuzes have been in use since the invention of radars during

the Second World War. These fuzes have two main purposes as given below: -

(a) To initiate projectiles when in close proximity to aerial targets.

(b) To initiate projectiles at a fixed height above the ground.

Proximity fuzes, originally referred to as variable time, are essentially

a combined self powered radio transmitting and receiving unit linked to

electro and mechanical devices which operate at optimum lethal distances

from the target. Proximity fuzes of earlier design had the disadvantage of

taking up a considerable amount of space. They could be fitted only to shells

which were designed with deep fuze cavities to accept them, and this reduced

the explosive content of the shell. Modern technology has changed this. The

use of miniaturised components and printed circuits now makes it possible to

fit a proximity fuze to any shell. The greatest reduction in this respect has

been to replace cumbersome mechanical timing mechanisms with electronic

timers which not only save space, but also have more precise and versatile

applications.
Electric Fuzes

Although electric fuzes do not have the mechanical and other devices

fitted in most fuzes they are included for completeness. Electric fuzes are

usually functioned by means of a current passing through electric leads

connected to some form of battery.

Contact Fuzes or Percussion Fuzes

These fuzes are normally activated by pressure when target makes

contact. They are simple in design due to the static mode in which they are

used. Their main use is with mines.

Non Rotating Fuzes

When ammunition has little or no radial acceleration, as in fin stablised

mortar and rocket ammunition, the absence of centrifugal force makes it

difficult to satisfy the requirement for at least two independent safety

restraints which respond to different stimuli. Producing fuzes which are safe

to handle but which operate reliably is further complicated if the degree of

axial acceleration is relatively modest, and this is generally true of mortar

bombs and rockets. It is more difficult to incorporate safe arming mechanism

in mortar fuzes than it is in fuzes fitted to gun ammunition. The set back

force required to arm a mortar fuze is a great deal less than the force required

to arm a shell fuze. There are no centrifugal forces available to provide a

second key to unlock the fuze. For this reason, the simplest solution is to

provide a safety restraint which must be physically removed by the action of

the firer, like safety pins and bore riding pins. These fuzes include a delayed

arming mechanism which prevent them from being armed until approximately

one second after firing and incorporate both impact and delay settings.

Electronic Time Fuzes

These fuzes are smaller, more reliable and more accurate, then the

mechanical fuzes they have replaced. These fuzes have been developed for
fitting to all cargo, smoke ejection and illuminating rounds of 105mm -203mm

calibers. These fuzes operate using electronic time action, which is preset by

an electronic, hand held setting and reading the unit using standard tables or

a computer, the user calculates the time of flight of the projectile to impact

and then subtracts a predetermined time in order to achieve the optimum

deployment height of the shell. This data is fed to the fuze, where it is stored

in non volatile memory for an indefinite period. It can also be reprogrammed

as many times as necessary, prior to firing. On firing, an ampoule in the

battery is ruptured by the setback forces, releasing the electrolyte, which is

then distributed by centrifugal force among the plates, thus starting the

chemical reaction to power the electronics. A high resolution counter

calculates when the programmed time has elapsed, where upon a high energy

electric pulse is transmitted to the thin film electric detonator, thus initiating

the detonation chain.

Multi Role Fuzes

Multi role fuze refers to the modern generation of compact electronic

proximity fuzes which incorporate both proximity and direct action functions.

It is set using a manually operated electronic fuze setter. In the proximity

mode it has three settings for high, normal and low functioning. It can be set

for point detonating action, and in this mode it incorporates a graze action

that functions at upto 80 degrees of obliquity. It has two electronic timers

operating in parallel to switch on the oscillator in the final stage of the

shell's flight there by initiating a jamming detection sequence and initiate the

charging of the firing circuit and removing inhibitors on the proximity and

point detonation circuits as appropriate. If jamming is detected the fuze

automatically reverts to the point detonating mode. For example, the Swedes

have introduced a multi purpose fuze, the Bofors Zelar with both impact and

proximity functions. The Bofors Zelar fuzes are used in 155mm High
Explosive, shell 77B, 107 and High explosive Extended Range shells. The

fuze has 8 different settings. It is designed to meet the highest safety

demands and has five different safety systems. A typical multi role fuze is

illustrated at Appendix A.
 CHAPTER 5

NECESSITY OF A UNIVERSAL FUZE

With the introduction of 155mm FH 77B weapon system, India has

taken a giant stride into the hi -tech era and fulfilled the requirements of the

foreseeable future battlefield. With the ever changing concept of employment

of artillery in India's neighbourhood, several innovative features based on

contemporary technology have to be undertaken, appreciating the fact that the

effect of available conventional artillery rounds has become more and more

limited. It is therefore imperative that multi option fuzes (controlled radio

proximity fuzes with point detonating/ground burst action) are available to

use multi charge systems, to attain different ranges and different effects by

projectiles.

The Bofors Zolar, an all purpose fuze is presently in service with the

155mm FH 77B. Other weapons like 130mm and 105mm IFG do not have such

multi purpose fuzes. In order to use 155mm gun in an integrated manner and

overcome the following problems of the user, there is a need to develop a

Universal Fuze :-

(a) Inventory of Fuzes . Several fuzes like 117, 119 and 213 etc have

been used in the past, many of which are now obsolete or obsolescent.

Old designs have been modified using new techniques and technology.

The result has been a profusion of fuze designs, many of which are

modernised version of old concepts. Since numerous fuzes have been

used in the past, it is imperative to reduce or write off the obsolete lots

to maintain a manageable inventory of fuzes. If different fuzes are

existing in one theatre, it becomes very difficult to demand and issue

then separately, transport lot wise and store them separately. Also if a

particular fuze is in short supply at a particular theatre, units in that

theatre cannot exchange the fuzes with each other due to various

calibers of shells requiring different type of fuzes. Also considering

the problems of safety, arming and modes of different projectiles and

different effect of same projectile, these is a need for reducing the

inventory of fuzes to the minimum essential.

(b) Training . Ammunition is handled by troops in the field. It

becomes difficult for them to identify the multitude of fuzes which are

in service. Further, different fuzes require different handling

techniques and hence detailed training is required to be imparted

regularly to the troops to handle them quickly, smoothly and

efficiently. In addition, defective fuzes are required to be segregated

separately and qualified persons are required to inspect them. At times

the non availability of a particular type of fuze would inhibit the

training of the troops with its corresponding weapon system.

(c) Mechanical Time Fuzes . Mechanical time fuzes presently in use,

have a fuze zone of .2 to .3 seconds which causes large variations in

height of burst with trajectories having steeper angle of descent. Also

the corrector/fuze length require adjustment due to non standard

conditions. The performances of such fuzes in high angle fire tend to

be unreliable. Physical factors like pressure, temperature and spin

have an effect on combustion time fuzes causing erratic burning and

blinds at longer ranges and in high angle. The chemical, age and

climate factors give variable results due to difference in time of

burning of a fuze.

(d) Proximity Fuzes . Proximity fuzes in use have heavy weight

causing less contents of high explosive shells. They are also

complicated in supply since a given fuze is specific to a given shell and

cannot be used for other calibers. Crest clearance in this case require
special treatment. These fuzes also function if they pass close to

aircraft, those most likely to be affected being friendly air observers.

They produce erratic and early burst during heavy rains and also result

in blinds. These fuzes are also susceptible to electronic measures.

(e) Need to miniaturise components and improve reliability. to adapt

modern circuit assembly techniques.

(f) The current fuzes sometimes do not function at impact resulting

in blind and are required to be destroyed in situation by explosive

causing safety hazards.

(g) An all purpose, the Bofors Zelar Fuze has the following

drawbacks : -

(i) Green charges one, two and white charge three are not

fired with this fuze.

(ii) The fuze is not fired at fuze setting three in heavy rains.

(iii) The fuze is very costly.

(iv) The fuze is not fired with illuminating and smoke shells.
 CHAPTER 6

REQUIREMENTS OF A UNIVERSAL FIRE

It needs to be ensured that the fuze mechanism be completely safe to

store, handle and fire and then function reliably when required. In general, a

Universal Fuze must be compact, easy to handle, have bare minimum possible

electronic parts and is easily recognizable during hours of darkness while

setting to impact or proximity mode by troops. The fuze should be

impervious to jamming and has a number of operating modes as under : -

(a) Timed detonation or range detonation.

(b) Proximity detonation.

(c) Direct Action (impact)

(d) Combined time/proximity action. In addition to the above

operating modes, the following parameters should be able to be

incorporated :-

(a) In Proximity Mode .

(i) The fuze must function the projectile at a predetermined

time under all conditions and should not give erratic results due

to irregular height of burst. It must function at the optimum

height of burst irrespective of trajectory errors, to get better

splinter effect.

(ii) Delay interval before the proximity function is activated to

solve immediate crest clearance problems.

(iii) The fuze must be designed to give hundred percent result

in proximity mode. In case proximity mode fails due to

unforeseen reasons, it must have sufficient internal arrangements

to activate the projectile on impact thereby preventing chances of

blind and falling into enemy hands.

 (iv) It should have inherent electronic counter counter

measures to avoid enemy jamming and be able to automatically

revert to point detonating mode as and when jamming is detected.

(v) Selection of proximity sensitivity depending upon the

nature of terrain.

(b) On Impact .

(i) It should give long delay for ricochet burst and short delay

for penetration.

(ii) The fuze should always activate on impact.

(iii) It should have normal/high sensitivity as per nature of

terrain or ground.

(c) The fuze can be fitted to any shell of calibers ranging from

105mm to 210mm guns with a suitable fuze hole and adapter.

(d) The user should be able to fire any shell with all charges of all

calibers (105mm -210mm). Required revolution per minute and

gravitational force have to be taken into account by the designer while

developing the fuze.

(e) The user should be able to use this fuze under all climatic

conditions and all types of terrain.

(f) The fuze must be designed to cover a wide approach angle say 8

degrees to 80 degrees.

(g) In order to get accurate height of burst, its fuze zone should not

exceed 0.01 seconds.

(h) The fuze should have delayed arming mechanism to activate after

0.01 seconds keeping in view bore and muzzle safety.

(j) In case of bad ram, the detachment should be able to eject the

projectile using ejector projectile, without disturbing the fuze.

(k) The fuze should be supplied and stored in safe i..e point

detonating battle mode so that it can be fired as a point detonating fuze

even if the electronic fuze setter is not available or unserviceable.

(l) Fuze Setter Hand . The electronic fuze setter should have three

modes of operation i.e. read, set and change so that the detachment is

able to set, read the fuze settings and alter the fuze settings if required

by a rotating selector switch.

(m) The fuze should have safe setting facility to repack it when

required.

(n) It should not deteriorate due to rough usage, handling,

transportation and prolonged storage under field conditions. Its storage

life should not be less than 20 years. (o) It should have no battery

leakage problem, complete separation of liquids to maximize shelf life

and should have computerised inspection and testing equipment.

 CHAPTER 7

DESIGN PRINCIPLES OF A UNIVERSAL FUZE

The Universal Fuze should be a compact electronic proximity fuze to

incorporate both proximity and direct action functions. It should comprise of

the following main sub assemblies.

Electro Mechanical Impact Device

The electro mechanical impact device should be able to be set for

either of two sensitivity levels i.e. Normal Sensitivity and High sensitivity.

The normal sensitivity must always be engaged and the high sensitivity to be

set by the user as per appropriate conditions in the field.

Electronic Part

The electronic part should contain units for the proximity fuze

function, with a battery and an ignition circuit. Before firing, the electrodes

and electrolyte of the battery should be separated and

the electrolyte enclosed in a glass ampule. The electronic part should be

transistorized and have printed circuits encapsulated in a special compound

of good strength and storage properties.

Switching Devices

It should have two switching device i.e. Upper and Lower Switching

Devices. The Upper switching devices determine what electric functions will

be engaged after firing and the lower switching devices connect electric

igniters as per setting of the fuze.

Barrier

A portion of the fuze body must separate electronic portion of the fuze

from pyrotechnic position. It should have small channels to lead the ignition

impulse to the lower switching device and protect the pyrotechnical device

upon impact when a delayed action mode is set.

Pyrotechnical Part

This should be placed at the lower end of the fuze. It should cater for

long, short and normal delay and each delay connect to the detonator. In

addition, it should have safety and arming devices, and contact springs with

balls to provide good electrical contact during flight due to centrifugal force.

The fuze should incorporate both proximity and impact action is as

under :-

(a) Proximity functions . The fuze should function on normal

sensitivity, high sensitivity for dry ground condition targets, and low

sensitivity for wet ground condition targets.

(b) Impact Functions . The fuze should have long delay for ricochet

burst, short delay for penetration, instantaneous or superquick impact

burst for a snow covered ground/soft targets and superquick impact

burst for normal sensitivity.

In addition, the fuze should have a back up function i.e. if the normal

function fails, the fuze must function on impact.

 CHAPTER 8

SAFETY ARRANGEMENTS IN THE FUZE

A fuze is a mechanical device or an apparatus in which the action of

several moving parts is combined, with each part having a definite function,

and the proper working of the device depends upon the systematic functioning

of these parts. In addition to the above, these parts also ensure safety

during :-

(a) Storage and transport.

(b) Shock of discharge from the gun.

(c) Flight.

The object of safety devices is to make the fuze function at the right

time and place. In order o permit correct functioning of the fuze, safety

devices are either removed by hand or get removed by a combination of

forces operating in the fuze when it is projected from the gun. It is therefore,

desired that the fuze must have the following safety arrangements: -

(a) The battery must remain inactive until the shell is fired. It

should be activated by the acceleration or set back force on firing.

(b) It should have `safe' arrangement to break all electrical

connections between the electronic part and the pyrotechical part.

Further the connections to the lower switching device and the entire

initiation circuit system should be short circuited at this setting.

(c) The fuze should be provided with a delayed arming device which

should not get armed until the shell has cleared in bore and muzzle

safety distances.

(d) During proximity function, the fuze should have electronic

delaying device which should prevent functioning of the fuze for the

desired duration after firing.

(e) There should be a read back facility enabling the gun detachment

of verify the actual time currently set in the fuze.

 CHAPTER 9

POSSIBILITY OF A UNIVERSAL FUZE

The list of applications for artillery projectiles grows continually, as

technology opens up new possibilities or brings old ones closer to reality. In

response to changing requirements designs have to be modified using

established techniques and technology. Designing and developing a weapon

system is a costly exercise both in terms of money and time. The desirability

to have a fully integrated state of the art weapon system in our inventory

needs no emphasis. The introduction of a Universal Fuze to an extent will

rationalise the inventory of fuzes greatly reduce the type in service and

improve both efficiency and safety.

In addition to multi role fuzes, the electronic time fuzes for guns,

mortars and rockets have been developed in the world market fulfilling the

following requirements : -

(a) These are used with illuminating, smoke and cargo ammunition.

(b) Compatible with calibers ranging from 60mm to 160mm for

mortars and 110mm to 300mm for rockets and also for complete series

of 155mm.

(c) Fully withstand safety requirements and meets safety and

environmental test requirements.

(d) Highly advanced human engineering solution for manual fuze

setting.

However, for a developing country like India the financial constraints

do not permit to review the inventory frequently to keep pace with the

changing doctrines and employment philosophy. The Bofors Zellar fuze,

which is being imported, is frightfully expensive. Therefore, the best course

available is to manufacture the fuze indigenously. The Bofors Zolar fuze

which incorporates both proximity and direct action functions, fulfils most of

the requirements of multi role fuzes. Hence a Universal Fuze can be

produced indigenously, using established technology and used with other

shells of calibers ranging from 105mm - 210mm using an adapter with a

suitable fuze hole. It is therefore recommended that such a fuze be fabricated

by Armament Research and Development Establishment. This will

dramatically rationalise fuzing systems, while equally dramatically improving

fuze efficiency and safety.

 CONCLUSION

Considering the problems of safety, arming and modes of functioning of

different projectiles and different effect of same projectiles, there is a need

for reducing the inventory of fuzes to the minimum essential. Also to met the

challenging requirements of the modern technology and developments in

other parts of the world, it is essential to keep the artillery abreast with latest

technology.

Fuzes are complex, expensive, precision assemblies and their designs have

evolved slowly over the years. The introduction of a `Universal Fuze' will

rationalise the unsatisfactory situation, greatly reducing the types in service

and improving both efficiency and safety. It will also give greater flexibility

of use and reduce the user problems in battle conditions.

A Universal Fuze needs to be developed for calibers ranging from 105mm

to 210mm which could be used with all shells fired with all charges after

incorporating absolute minimum modifications and efforts. Such a Universal

Fuze should be a compact electronic proximity fuze which incorporate both

proximity and direct action functions.

 BIBLIOGRAPHY

1. "Ammunition (including Grenades and mines)" by KJN Goad and DHJ

Halsey.

2. "Ammunition for the Land Battle" by PR Courtney Green.

3. "The Illustrated Encyclopedia of Ammunition" by Ian V. Hogg.

4. "International Defence Review" volume 26 Jul 93 by James. 5.

"Ammunition Maintenance Instructions for Army Ordance Services, advance

information No 84.

6. Indian Defence Review by Lieutenant General Mathew Thomas, PVSM,

AVSM, VSM (Retired).