Camouflage USV Boat

Camouflage USV Boat — Design-Complete, Production-Ready

Low-observable autonomous surface vessel with frozen baseline, kitted materials, and full FAT/HAT/SAT procedures.

Baseline Frozen Materials On-Hand Factory Acceptance Ready ILS & Training Included Signature Management Stack

1) Overview & Status

The Camouflage USV Boat is engineered for missions where visual, IR, radar, acoustic, and wake signatures must be minimised while maintaining robust, COLREGs-aware autonomy and secure C2.

Design maturity: SRR/PDR/CDR complete; Production Readiness Review closed; Design Change Rate = 0 (ECR/ECO required for future changes).
Documentation: GA drawings, CNC/DXF kits, wiring schematics, single-line power, network topology, software ICDs, FMEA, hazard log, test procedures.
Materials & LRUs: All long-lead and critical items kitted: structures, propulsion sets, batteries/BMS, compute, sensors, harnesses, coatings, RAM, anechoics.

2) Signature Management (“Camouflage Stack”)

Visual (day/night)

Multi-tone disruptive coatings matched to theatre; low-gloss clear to kill specular highlights.
Geometry breaks, shadow-reducing rails, low-contrast deck fittings.
Optional skyline-blend light panels (software-limited, hardware overrides).

Thermal / IR

Water-injected exhausts, heat-sink mufflers, insulated trunks.
Low-emissivity topside coatings; controlled thermal bleed to mimic sea background.

Radar (RCS)

Faceted topsides; flush closures; low-profile radomes; conductive gasketing.
Selective RAM patches on high-return zones (mast roots, hatch edges, stanchions).

Acoustic & Wake

Resilient engine mounts, soft coupling, anechoic matting; low tip-speed propulsors/ducts.
Wake-disciplined hull and throttle profiles to suppress persistent wake at patrol speeds.

3) Hull, Structure & Materials

Construction Options

Marine aluminium: 5083-H116 plating, 6082-T6 extrusions; qualified WPS/PQR; full anode plan.
Composite sandwich: E-glass/epoxy skins with PVC/SAN core; carbon in high-load paths; infusion or prepreg.

Serviceability

Large machinery hatches; sealed electronics bay with humidity control.
IP-rated glands; labelled harnesses; raised coamings; watertight bulkheads.

Hydrostatics & Fouling

Low-spray bow and chine management; patrol-speed wake suppression.
Barrier coats + antifoul (composite) or epoxy barrier + antifoul + bonding checks (aluminium).

4) Propulsion & Power

Propulsion Configurations

Diesel-mechanical: gearbox + shaft/prop for range efficiency.
Waterjet: shallow-water manoeuvrability, lower FOD risk.
Hybrid diesel-electric: silent loiter on battery; burst power on demand.

Electrical Architecture

24/48 VDC buses; tinned marine cable; IP67/69 connectors; fused spurs and isolators.
LiFePO₄ packs with BMS, contactor interlocks, cell-level balancing, fire mitigation.

Thermal Management

Dedicated loops for engine, power electronics, compute; seawater heat exchangers.
Temperature-based derating to protect IR envelope and components.

Power distribution snapshot

Indicative bus & protection layout
Rail	Primary Loads	Protection
48 VDC	Drive inverter, chargers, DC-DC	Main breaker, contactor, fuse block
24 VDC	Compute, sensors, radios	Distribution fuses, surge protection
12 VDC	Aux nav lights, accessories	DC-DC isolated, fused spurs

5) Autonomy, Avionics & Software

Navigation & Perception

Multi-GNSS + IMU; optional RTK; radar + EO/IR; AIS; weather; depth/ADCP optional.
Fanless mission computer with GPU; mirrored SSDs; hardware watchdog; time-synced logs.

Control Modes

Waypoint, track-hold, loiter, station-keeping; dynamic reroute; deny-area geofences.
Deterministic COLREGs logic for crossing/head-on/overtaking with conservative margins.

Cyber & Integrity

Secure boot; signed firmware; at-rest/over-link encryption; TPM-backed keys.
Role-based UI; audit logs; tamper-evident seals; removable mission storage.

6) Communications & Networking

Bearers

LOS RF for low-latency control; LTE/5G where available; satcom for BLOS.
Autonomy-first: link loss triggers safe behaviours (RTH/safe loiter).

Network Segregation

Dedicated VLANs for control, payload, maintenance; QoS for command traffic.
Signed config backups; IDS on maintenance ports.

Ground Control

Mission planner, geofence editor, health dashboards; authenticated operator roles.
Redundant link handover with latency budgeting.

7) Safety, Compliance & Governance

COLREGs lights/sound; AIS with privacy controls; safe-speed doctrine baked into autonomy.
Lockout/tagout, E-stop chain in hardware, isolation resistance checks, thermal/smoke/gas detection.
Compartmentalised non-conductive suppression; bilge/high-water alarms; electrical fusing throughout.
Data retention policies; role-based access; chain-of-custody for evidential logs.
End-user/end-use/destination vetting and export/KYC at order acceptance.

8) Verification & Acceptance (FAT / HAT / SAT)

FAT (Factory)

Power-up stability, brownout, polarity protection, fuse map verification.
Bearer failover, encrypted auth, latency budget; sensor calibration & drift checks.
Simulated COLREGs, geofence violation handling, watchdog resets, E-stop continuity.

HAT (Harbour)

Run-in, crash-stop, turning circle, station-keeping; link handovers in motion.
Hot restart after deliberate brownout; recovery drills.

SAT (Sea)

Speed-power curve, endurance at patrol profile, motions logging in sea state.
Live COLREG encounters with safety chase; launch/recovery rehearsals.

Signature audit (extract)

Daylight/low-light silhouettes; IR deltas at engine bay, exhaust, electronics.
Near-band RCS spot checks; near-field acoustic survey vs. baseline.

9) Logistics, Support & ILS

Packaging & Transport

Shock-isolated cradle; humidity control; tip/tilt and humidity indicators.
Proof-loaded lifting points; documentation wallet.

Maintenance (A/B/C checks)

A: daily/weekly fluids, filters, nav lights, bilge test, link check.
B: quarterly vibration survey, harness inspection, firmware review.
C: annual coatings/antifoul, anodes, bearing play, battery health, signature re-audit.

Training & Through-Life

Operator & maintainer syllabi; simulator profiles; emergency drills.
Remote diagnostics; signed software updates; obsolescence management.

10) Options & Payloads

Multibeam/side-scan sonar, ADCP, passive RF, environmental sensors.
Spotlight/PA, casualty markers, modular mast/rails, davit points for RIB hand-off.
Perimeter patrol & anomaly detection plug-ins; high-gain LOS; bonded LTE; low-profile satcom.
Expanded LiFePO₄, hotel-load DC rail, shore-power charger.

11) Acceptance KPIs (indicative)

Area	Measure	Acceptance
Navigation	Waypoint RMS error	Within contracted spec
COLREGs	CPA in scripted drills	No close-quarters incidents
Comms	Bearer failover time	Within latency budget
Endurance	Patrol profile duration	≥ mission energy budget
Signatures	IR/RCS/Acoustic	Within acceptance envelope
Reliability	Cat-A failures	Zero outstanding at handover

12) Deliverables

Vessel + cradle; build, buoyancy/stability, electrical certificates.
Illustrated Parts Catalogue, Maintenance Task Analysis, schedules, safety case summary.
Software/firmware manifest; ground station (if contracted); training pack; initial spares.

Risk controls (current)

Signature drift: scheduled re-coat + audits.
EMI/EMC coupling: spectrum scan + shielding reserves.
Thermal hotspots: configurable cooling pack + IR audit.
Comms denial: autonomy behaviours + store-and-forward logging.

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