HPC Based Electrical System Analysis

1. HPC Based Electrical System Analysis HPC User Forum April 12-15, 2010 Jeff Crompton, AltaSim Technologies Supported by DARPA contract #FA8750-08-C-0184

2. Presentation • Background • Technical issues • Business impact

3. Background • Power switching device for next generation US Navy ships • New technology provides miniaturization • Increased power density • Increased conductive EMI • Traditional EMI solution is ~30% over target cost and weight • Current solution uses experience and iterative testing/evaluation

4. Objective • Decrease technology development cost and time: • Develop tools for analysis of large electrical circuits • Demonstrate effectiveness of virtual product development • Quantify the benefit of virtual vs traditional product development

5. Desktop HPC Challenge – Circuit analysis Complexity Future application High power multiple units Multiple units Component increase ~10x Immediate application Unit Component increase ~10x Current capability Module Circuit Size Power increase ~10-20x

6. Computational solution • Isolated circuits • Optimize MATLAB/Simulink operation • Discrete solver reduces run time by 300x • Need knowledge of solver settings • Power units • Integrate parallelization strategies • MATLAB/Simulink parallelization • GHOST technology

7. Power unit analysis - HPC Simulink vs GHOST High power multiple unit is ~20x more complex than original baseline circuit and runs ~4x faster Circuits could not be analyzed previously

8. 325x ~6x faster ~2x complexity HPC-based Analysis: Time/Complexity Circuit Single unit ~30x 12x faster High power multiple units Circuit Multiple units

9. Business impact • Current development process • Direct: • Concept, PoC, Engineering model, Prototype qualification • Design escape • Pre-deployment • In the fleet • Current manufacturing methodology • Direct • Part consolidation and component selection • Structural • Weight, volume, additional ship structure • Future platform costs • Higher power switches, 10-20x increase in power

10. Direct Development Costs HPC analysis cost: 12% of physical cost Cost saving: $488,000 Time saving: ~ 12 weeks

11. Design Escape Costs Estimated savings using HPC analysis: $233,000 *HPC based analysis not applicable, existing desktop based analysis sufficient **Cost assumed to be for new unit design and qualification, installation costs ignored

12. Manufacturing Optimization: • Analysis to optimize component selection: • Present power unit is ~30% above initial cost • Estimated cost of unit: ~$100,000 • Estimated 30% saving: ~$30,000 per unit • Current unit exceeds target weight by ~50lbs • US Navy estimates additional 1.5lbs auxiliary structure needed per 1lb added weight @$120/lb • Estimated cost $6,000/unit/ship Total cost savings: $36,000 /unit/ship

13. Immediate Business Impact Total estimated saving : $730,000 Development costs reduced by ~90% Development time reduced by ~50%

14. Future Business Impact • NGIPS roadmap indicates 60MW required for future “all electric” ship • Power processed by solid state power switching devices • For 60MW power output: • Development saving: ~$105M per platform • Development time saving: Decades • Procurement saving : ~$34M-3M per ship • Associated structure saving: ~$3.5M-600K per ship Total cost saving: >$100M per platform Total cost saving: >$30M per ship

15. Summary • HPC based solutions have successfully analyzed large circuits that could not be analyzed previously • Immediate impact in excess of $700K and months in development • Projected impact estimated to be in excess of $100M and decades in development