Integrated High Power Generation for the Joint Light Tactical Vehicle

Navy SBIR 22.2 - Topic N222-088
MCSC - Marine Corps Systems Command
Opens: May 18, 2022 - Closes: June 15, 2022 (12:00pm est)    [ View Q&A ]

N222-088 TITLE: Integrated High Power Generation for the Joint Light Tactical Vehicle

OUSD (R&E) MODERNIZATION PRIORITY: General Warfighting Requirements (GWR)

TECHNOLOGY AREA(S): Ground / Sea Vehicles

OBJECTIVE: Develop an integrated, compact, prime engine-driven high power generation system for the Joint Light Tactical Vehicle (JLTV) that will support both onboard and export electrical power capabilities while fitting within the confines of the chassis to meet expected power demands and allow for future mission growth.

DESCRIPTION: The JLTV is currently capable of generating between 12.8-14.6 kW of electrical power and while this capability allows for future vehicle system growth, it is insufficient to support future systems. Currently the system is limited by the onboard power capability of the JLTV, forcing us to either accept a reduced capability or carry an additional standalone generator. These approaches unnecessarily restrict capability and/or complicate the mission by reducing mobility, fuel efficiency, reliability, and cargo capacity. Vehicle integrated power generation systems will be needed to power future Missile and Air Defense systems, Counter Unmanned Arial Systems (C-UAS), and Command and Control (C2) systems without burdening the mission with standalone generators.

The system requirements are:

Integrated electrical power generation system kit driven by the existing JLTV General

Motors Duramax 6.6L Turbodiesel V-8 engine

Power output of 50 kW Threshold (T); 70 kW Objective (O), at 28 volts direct current (VDC) while stationary and on the move

Stationary power output shall not require the engine to exceed tactical idle (1800 RPM)

Compatible with 28-VDC tactical electrical systems and 14-VDC vehicle electrical systems

Physical size of generator no larger than 11"H x 11"W x 16"D

Physical weight of export power system less than 225 lbs.

Operate in hot and cold mission environments between -40C to 52C

Operate in a JLTV environment to include: Primary Roads, Secondary Roads, Trails and Off-Road / Cross-Country.

Electrical component and connections shall comply with MIL-STD-810H where appropriate and have an ingress protection rating of IP67 or higher in accordance with American National Standards Institute (ANSI) International Electrotechnical Commission (IEC) 60529-2004

Initial quantities for these systems is approximately 66, but could be higher if other Marine Corps platforms and other services decide to use this capability.

Quantities will also depend on the cost of the conversion kit estimated to be between $50K and $75K.

PHASE I: Develop concept(s) for a generator technology and its supporting control equipment that can meet the system requirements in the Description. Demonstrate the feasibility of the concept(s) in meeting Marine Corps needs. Establish that the concepts can be developed into a useful product for the Marine Corps. Feasibility will be established by material testing and/or analytical modeling, as appropriate. Provide a Phase II development plan with performance goals and key technical milestones, and that addresses technical risk reduction.

PHASE II: Develop a full-scale prototype for evaluation. Evaluate the prototype through bench or lab testing to determine its capability in meeting the performance goals defined in the Phase II development plan and the Marine Corps requirement for the integrated power generation system. System performance shall be demonstrated through prototype evaluation and modeling or analytical methods over the required range of parameters including numerous deployment cycles. Evaluate the results of the demonstration and refine the design as necessary. Conduct on-vehicle testing in a relevant environment. Evaluate and compare the results to Marine Corps requirements. Prepare a Phase III development plan to transition the technology for Marine Corps use.

PHASE III DUAL USE APPLICATIONS: Provide support to the Marine Corps in transitioning the technology for Marine Corps use. Refine a power generation system for further evaluation and determine its effectiveness in an operationally relevant environment. Support the Marine Corps test and evaluation program to qualify the system for Marine Corps use.

Commercial applications include law enforcement vehicles, search and rescue vehicles, tractor trailers, and general automotive platforms to provide integrated power capability and reduction of both weight and space claim, supporting a more demanding future mobile power environment.

REFERENCES:

  1. "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/qsDocDetails.aspx?ident_number=36186
  2. "MIL-STD-1332B Tactical, Prime. Precise, and Utility Terminologies For Classification of the DoD Mobile Electric Power Engine Generator Set Family". Naval Facilities Engineering Command, Naval Construction Battalion Center, March 13, 1973. https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=36687
  3. "MIL-STD-705D Mobile Electric Power Systems". Communications Electronics Research Development Engineering Center (CERDEC) Product Realization Directorate (PRD), November 22, 2016. https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=35902
  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; Integration; Joint Light Tactical Vehicle; JLTV; Exportable Power; Onboard Power

** TOPIC NOTICE **

The Navy Topic above is an "unofficial" copy from the overall DoD 22.2 SBIR BAA. Please see the official DoD Topic website at rt.cto.mil/rtl-small-business-resources/sbir-sttr/ for any updates.

The DoD issued its 22.2 SBIR BAA pre-release on April 20, 2022, which opens to receive proposals on May 18, 2022, and closes June 15, 2022 (12:00pm est).

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** TOPIC Q&A **
Questions answered 05/16/22
Q1. A weight limit of 225 lbs is given for an export power system, what are the export (off-vehicle) power requirements?
A1. The 225 lbs. is a goal that was set to keep from exceeding the axle weight on the current prototype. The eventual pulse power system is not defined and may replace some of the current systems. We would like to see a system in this weight category, but we realize that may not be possible while meeting all of the other requirements. The term "export power" may be misleading. It basically means power that would be available for things that are not currently on the platform. The example in the topic description is the High Energy Laser, Expeditionary (HELEX).
Q2. What is the weight limit of the entire power generation system?
A2. The 225 lbs. was intended as the goal for the entire power system, but it may depend on the design. The HELEX, for example, has its own battery system that would not be included in this weight. Lower weight is better but not at the expense of reliability or cost.
Q3. Is there a space claim limitation for components other than the generator?
A3. The only space claim in the topic description is "Physical size of generator no larger than 11"H x 11"W x 16"D". This is the space available around the current alternator (C.E. Niehoff & Co. N1630 - 20.7 kW (740 amp at 28VDC)). There is space available other places. Drawings should be available if a contract is awarded.
Q4. What is the required power output on the 14 VDC bus?
A4. The 14 VDC requirement is small and is currently taken off of one of the two 6T batteries on the vehicle.
Questions answered 04/27/22
Q1. What is the required load current at 28VDC?
A1. The system, if replacing the current C.E. Niehoff & Co. N1630 alternator for the platform completely will need to provide 20.7 kW (740 amp at 28VDC). The JLTV has a power take-off on the transmission, so a second system could be installed for the higher power demands. Part of this effort will be to investigate the best way to deliver the power required for the high energy systems like the High Energy Laser, Expeditionary (HELEX) and other pulse power requirements. This could include using energy storage, higher voltages and/or AC power. Use of energy storage, higher voltages or AC power will require a safety analysis and logistics considerations like shipboard safety.
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