TECHNOLOGY AREA(S): Ground/Sea Vehicles

ACQUISITION PROGRAM: USMC PEO Land Systems, PM Ground Based Air Defense (GBAD), SMC PEO Land Systems, PM LTV

OBJECTIVE: Develop a compact, lightweight, engine-driven power generation system for vehicle and export electrical power with high specific power (kilowatts per kilogram) that fits within the confines of the chassis of recreational off-highway vehicles (ROVs) to meet expected power and energy demands and allow for future mission growth.

DESCRIPTION: Currently available vehicles capable of being internally transported in rotary wing aircraft have insufficient export power capabilities to meet power and energy demands of current Counter-Unmanned Aerial Systems (C-UASs) and allow for future mission growth. The current Light Marine Air Defense Integrated System (LMADIS) uses a 5 kilowatts (kW) diesel generator weighing 300 lbs. that results in the vehicle weighing 15 lbs. over the maximum gross vehicle weight (GVW) of the current ULTV. Future mission growth to add additional communications equipment to LMADIS is expected to increase the power demands to 10 kW. Currently available diesel generators that meet the higher power requirements weigh close to 500 pounds (lbs). and would result in the vehicle weighing 100 to 150 lbs. over maximum GVW. Compact and lightweight power generation systems are needed to power C-UAS and C2 systems and keep the vehicle safely within its allowable GVW. The system requirements are:
• Integrated system using the existing vehicle engine (current engine is approximately 85 horsepower)
• Export power output of 5 kW at idle Threshold (T); 10 kW at idle Objective (O) at 24 volts direct current (VDC)
• Reduced physical size of export power system (same approximate size as an alternator, 8 inches wide x 10 inches long x 8 inches high)
• Physical weight of export power system less than 225 lbs.
• Compatible with 24-VDC tactical electrical systems and 12-VDC vehicle electrical systems
• Electrical component and connections with an ingress protection rating of Ingress Protection( IP67) or higher in accordance with (IAW) American National Standards Institute (ANSI) / International Electrotechnical Commission (IEC) 60529-2004
• Modular design that can be inspected, serviced, and repaired in the field
• Full power output across the range of engine speeds, 400-4,000 Revolutions Per Minute (RPM)

PHASE I: For this Direct to Phase II (DP2) topic, the Government expects that the small business would have accomplished the following in a Phase I-type effort. It must have developed a concept for a workable prototype or design to address at a minimum the basic requirements of the stated objective above.
Documentation showing an engine driven power generation system concept is feasible and that the system requirements discussed in the description are in the realm of possible. The small business should have produced a model to evaluate different approaches to optimize on vehicle generator technologies. The small business should show they have identified higher power density electrical generator/alternator designs to at least double power output in a similar form factor when compared to existing military alternators.

FEASIBILITY DOCUMENTATION: Proposers interested in participating in Direct to Phase II must include in their responses to this topic Phase I feasibility documentation that substantiates the scientific and technical merit and Phase I feasibility described in Phase I above has been met (i.e., the small business must have performed Phase I-type research and development related to the topic, but feasibility documentation MUST NOT be solely based on work performed under prior or ongoing federally funded SBIR/STTR work) and describe the potential commercialization applications. The documentation provided must validate that the proposer has completed development of technology as stated in Phase I above. Documentation should include all relevant information including, but not limited to: technical reports, test data, prototype designs/models, and performance goals/results. Work submitted within the feasibility documentation must have been substantially performed by the proposer and/or the principal investigator (PI). Read and follow all of the DON SBIR 20.1 Direct to Phase II Broad Area Announcement (BAA) Instructions. Phase I proposals will NOT be accepted for this BAA.

PHASE II: Based on the Phase I equivalent effort and the Phase II plan, develop and use analytical modeling to assist in design and integration. Build prototypes for both fitment and functionality of power generation system. Support evaluation of prototypes to determine if the performance goals defined in the Phase II development plan and the requirements outlined in MIL-STD-1275E and MIL-STD-810H have been met. Demonstrate system performance through modeling and dynamometer testing. Refine the design based on the results of testing/modeling and support on vehicle testing. Prepare a Phase III plan to transition the technology to the Marine Corps and the commercial marketplace.

PHASE III DUAL USE APPLICATIONS: Upon successful completion of Phase II, provide support to the Marine Corps in transitioning the technology for Marine Corps use. Refine a power generation system for evaluation and determine its effectiveness in an operationally relevant environment. .Support the Marine Corps test and evaluation program to qualify the system for the Marine Corps use.

Commercial applications include law enforcement vehicles, search and rescue vehicles, tractor trailers, and general automotive to reduce vehicle weight and improve fuel economy.

REFERENCES:

1. “MIL-STD-810H - Environmental Engineering Considerations and Laboratory Tests”. U.S. Army Test and Evaluation Command, January 31, 2019.  https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=35978

2. “MIL-STD-1275E Characteristics of 28 Volt DC Input Power to Utilization Equipment in Military Vehicles.” U.S. Army Tank automotive and Armaments Command, March 22, 2013. https://quicksearch.dla.mil/Transient/CFF7229D4AE841AA8C3229140257B53A.pdf

3. “Test Operations Procedure (TOP) 2-2-601 Electrical Systems (Vehicles and Weapon Subsystems)”. U.S. Army Developmental Test Command Test Operations Procedure, US Army Aberdeen Test Center, June 20, 1977. https://apps.dtic.mil/dtic/tr/fulltext/u2/a045343.pdf

4. “ANSI/IEC 60529-2004 Degrees of Protection Provided by Enclosures (IP Code)”.  https://www.nema.org/Standards/ComplimentaryDocuments/ANSI-IEC-60529.pdf

KEYWORDS: Tactical Vehicle; Power Generation; Weight Reduction; Size Reduction; ULTV; UTV; LMADIS; NOTM-UTV; Permanent Magnet Generator; Exportable Power; Power