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Issues Supporting the Need for Primary Power Management

Issues Supporting the Need for Primary Power Management. Reliable engine starting after long term storage AGM Battery loss on Vehicles aboard Pre-Pro Ships (USNS Pomeroy) War Reserve, National Guard, etc with long periods of inactivity

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Issues Supporting the Need for Primary Power Management

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  1. Issues Supporting the Need for Primary Power Management • Reliable engine starting after long term storage • AGM Battery loss on Vehicles aboard Pre-Pro Ships (USNS Pomeroy) • War Reserve, National Guard, etc with long periods of inactivity • Total power available for high electrical duty and demands (e.g. A/C, C4ISR, CREW, IED countermeasures, lighting) • Longer operation during ‘silent watch’ • Reduced logistics burden • Lower lifecycle costs • Simplified maintenance and diagnostics Battery Graveyard, Kuwait

  2. Approach: Primary Power Management System (PPMS) A common vehicle power & energy architecture across platforms • Employs a split energy storage system to optimize energy delivery Uses planetary gear starter Accepts Modular External Charging Sources (e.g. BB-2590, Solar, etc). Provisions DC–AC, DC-DC Power Sources Uses Ultra-capacitor for vehicle starting Integrates power management & control Uses a hydraulically-driven alternator /generator for high electrical power drive & accessory loads Accommodates variety of batteries to meet mission requirements

  3. PPMS Prototype System Built and Tested PPMS CTIS, ATC, ABS Ultra Cap and Controller for Hybrid Starting System Scalable across TWV’s

  4. PPMS Split Energy Storage System Design Benefits • Utilize ultra-capacitors for engine starting • Use the appropriate battery technology for specific silent watch requirements • Address two, different vehicle energy/power requirements • No battery exists that can be optimized for both functions Operate here for silent watch Operate here for engine starting

  5. Results- Energy Storage for Silent Watch and Life Cycle Costs Runtime estimates based on 60A @ 24VDC, with battery pack = size/weight of (4) 6TMF batteries; assumes no energy required for engine start at conclusion of silent watch FTTS Objective FTTS Threshold Lifecycle costs based on 25 year vehicle lifetime with two high intensity conflicts and 6000 charge/discharge cycles.

  6. Modular Hydraulic Powered Generator Installed a hydraulically-driven generator on vehicle for supplying high power loads In place of large (> 400A) belt-driven alternators Benefits: Allows flexibility of placement Not subjected to engine compartment temperatures Not tied to engine speed (taken off PTO) Low cost APU capability Reliable operation, minimal maintenance required Multipurpose hydraulics: Power Steering, Winches, Power generation Click Here for Movie - May have to Exit slide show mode

  7. PPMS and hybrid starting system accommodates multiple, new external charging sources (e.g. BB2590, hand-crank, solar panel) Recharge of Hybrid Starting System with External Source Click Here for Movie - May have to Exit slide show mode BB2590 External Recharge 126 sec’s from dead to start; 6-7 charges from one BB2590 Battery

  8. Key Findings • Findings Con’t- • Hydraulic Powered Alternator Proved Functional • Ultra-Cap Recharge Control System Proven using BB 2590 Findings- • Hybrid Starting System proved functional • Works with wide range of batteries • Ultra-Cap’s can restart vehicle many 1000’s of times Impact • Life cycle cost reduction; Reliability; Improved performance in Silent Watch runtime; modularity; applicability across family of TV’s

  9. Path Forward • Better integrate and package the power and energy control system into the demonstrator vehicle (with Vehicle Information Backbone) (TRL-8) • Perform electrical noise characterization and testing (like Mil. Std. 810, but short of certification) • Conduct System Integration Test • Update cost benefit analysis • Complete performance specification for transition

  10. Primary Power Management System Integration Task Plan KICKOFF Reqgmts Definition IPR #1 Reqmnts, test plan Review, approval IPR #2 Interim results FINAL REPORT IPR #3 SIT Testing Document Performance Requirement Develop Sys Integration Test Plan w/ gov’t Conduct packaging assessment for fieldable design, estimate cost Perform Test Series Tuning Conduct System Integration Testing on Demonstrator Vehicle Add, Fix, update, refine H/W, S/W Deliver Performance Specification, H/S, S/W, Test & Performance Report

  11. Primary Power Management System Cost GFE -HEMTT demonstrator vehicle -batteries, alternators, starters, OEM equipment as required

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