As autonomy transforms the landscape of ground vehicles, particularly for military and heavy construction applications, human safety remains paramount. The integration of automated, telerobotic, and autonomous systems introduces complex challenges- not only due to intricate software but also because these vehicles often operate in environments with nearby personnel. This mix of humans and machines requires rigorously safe control solutions that don't hinder rapid innovation.
Introducing the Moog Safe Motion Controller (MSMC)
Moog has developed a groundbreaking safety system called the Moog Safe Motion Controller (MSMC). Acting as a safety cocoon around complex autonomy software and hardware, the MSMC allows developers to rapidly innovate while ensuring robust safety at the system level. In practical terms, the MSMC independently monitors vehicle operations and can safely limit or halt movement if unsafe conditions arise—protecting personnel during training and simulations without sacrificing full combat capability in operational scenarios.
What is Functional Safety and Why It Matters
Functional safety in automated systems ensures that a device behaves safely even if faults or failures occur. For industries like defense, where equipment failures can have severe consequences, functional safety is non-negotiable. It involves comprehensive hazard analysis, safety design, fault detection, and adherence to international safety standards such as ISO 13849 and IEC 61508. The MSMC is engineered to meet these stringent standards, specifically providing safety integrity comparable to SIL 2/PL D—meaning single faults in safety-critical systems won't compromise the safety function.
Core Components of the MSMC
The MSMC consists of three integrated elements:
- Safety Computer: A certified dual-channel safety controller acting as the system's processing system, ensuring reliable monitoring and intervention.
- Interface Board and Sensors: This includes emergency stop buttons (both wired and wireless), remote control capabilities, GNSS positioning for precise locations, inertial measurement units (IMUs) for tracking motion, geofencing to enforce operational boundaries, and radar-based obstacle detection to sense nearby personnel or objects.
- Power Conditioning Board: Maintains clean and stable power supply to all components even amidst the harsh electrical environment of ground vehicles, ensuring continuous safe operation. This architecture facilitates comprehensive vehicle safety through sophisticated sensing, control, and power management.
Advanced Safety Features for Complex Environments
The MSMC supports multiple safety interventions such as emergency stops triggered locally or remotely, including fleet-level emergency stops for coordinated control of multiple vehicles. Remote control capability offers human oversight in unpredictable scenarios. The system also employs advanced positioning through GNSS and IMUs to maintain precise vehicle localization, while geofencing prevents unauthorized vehicle movement into restricted zones—a critical safety measure to protect personnel and assets.
For obstacle detection, the MSMC employs Frequency Modulated Continuous Wave (FMCW) radar sensors strategically placed around the vehicle to detect obstacles and personnel within a few meters, even at slow speeds. This multi-target, angle-sensitive radar enhances situational awareness around autonomous platforms.
Designed for Rugged Field Use and Integration
Mark Underhill and Richard Delecki are Moog engineers involved in developing the MSMC. They have authored a White Paper about the controller that is presented at Ground Vehicle Systems Engineering & Technology Symposium (GVSETS) on August 12, 2025. Underhill and Delecki emphasize its ability to withstand harsh environmental conditions typical of military and construction operations. “The controller is housed in a rugged, water-resistant enclosure with excellent thermal management and shock/vibration resistance” says Underhill. “Integration into existing vehicle control architectures is flexible, allowing electrical or hydraulic interventions to meet different safety needs” adds Delecki.
Looking Ahead: Expanding Capabilities
Moog plans to enhance the MSMC further by exploring ultra-wideband (UWB) sensors for real-time personnel tracking around vehicles and point cloud sensors like Lidar and stereo cameras for improved obstacle perception. The MSMC may also be extended to host the actual functional computer within its housing, offering a more compact and robust implementation when compared to physically separate enclosures.
The Moog Safe Motion Controller represents a significant advancement in ensuring the safe deployment of automated and autonomous ground vehicles. By balancing rapid innovation with uncompromising safety, MSMC empowers operators to push technological boundaries without risking personnel or mission assets. In a rapidly evolving autonomous vehicle landscape, solutions like MSMC are vital to safely navigating the future of ground vehicle operations.
Contact Moog Defense media at defense@moog.com