COMMON / UNIVERSAL CONTROLLER STATEMENT OF WORK

Project: Common Controller Architecture & Feasibility Study Contract Type: Firm-Fixed-Price (FFP) Period of Performance: 60 Days from Date of Award

1 INTRODUCTION

This document defines the scope of work to develop a common controller design concept based on scalable modules. This architecture shall accommodate requirements for various Hull, Mechanical, & Electrical (HM&E) components (actuators, pumps, compressors, motors, at varying power levels) while minimizing unique hardware/software components.

Ideally, the architecture shall be expandable to accommodate future device types. To maximize modularity and reduce lifecycle costs, the architecture is based on a three-part concept, as depicted in Figure 1:

• Common Controller (CC): A common module architecture serving as the primary processor. It houses the application software, and cybersecurity features.

• Interface Module (IM): Modules providing physical, low-power signal conditioning for all control and feedback I/O to power modules and application devices, and all primary network interfaces. NOTE: The IM may be physically integrated into the CC enclosure to form a single component.

• Power Module (PM): A scalable family of modules sized to handle the electrical power conversion and switching required to drive the devices in Table 1. This module includes associated Power Module hardware controller (ie. switching controller, modulators, timers).

PMs and IMs shall utilize an identical, standardized low-level control and data interface to the CC.

Figure 1 Common Controller Architecture

2 SCOPE

The Contractor shall provide a concept design for the Common Controller (CC) and Interface Module (IM). The concept shall establish a path to control and monitor a notional Family of Power Modules (PMs) and devices as defined in this document.

The Contractor shall:

• Provide a CC/IM concept design focusing on software architecture, physical configuration, processing capabilities, cybersecurity, and standardized interfaces.

• Leverage existing product lines where applicable. A completely new hardware design is not required if existing products can be adapted or modified to meet the goals of this study.

• Assess feasibility in a Naval shipboard environment, identifying technical hurdles and cost drivers.

• Validate design scalability utilizing the power module requirements and application list (Table 1).

Component(s)

IM - Interface Module

CC - Common Controller

HMI/

Local

Control

Remote Interface

Power Module

Input (Rectifier)

Controls and

Interface

Power Module Output

(Inverter)

FilterFilter

Power Module

Ships Power

Multiplexer (if capable)

N

Component Control/Feedback

3 REQUIREMENTS

The Contractor shall utilize open architectures, if possible, and avoid proprietary information in the concept design.

3.1 Common Controller (CC) Requirements

The CC shall function as a device/component-level controller and meet the requirements in this section. Some preliminary device parameters and control schemes are defined in Appendix B.

• Monitored Points: The CC/IM component shall be capable of monitoring a range of parameters, to notionally include:

o Electrical Metrics: Phase voltages (line to line), currents, internal PM DC link voltage, input voltage and current to the PM, output voltage and current to the PM, and ground fault status (resistance-to-ground for each phase). The bandwidth of these sensors shall be such to allow evaluation of the system against MILSTD requirements for electrical interfaces and environmental conditions (EMI, EMC, etc).

o Thermal Parameters: Internal controller temperature, external motor/component casing temperatures.

o Position & State: Discrete end-device limits (open/shut, extend/retract) and position feedback (LVDT, resolver, encoder) and motor speed.

o Vibration and Acoustics: Raw and processed vibration and acoustic measurements.

• Processing & Edge Computing: Support edge computing capabilities. The architecture shall separate deterministic real-time control loops from high-bandwidth, non-deterministic data logging and provide capabilities to do onboard processing of data.

• Human-Machine Interface (HMI): Support a local HMI interface (touchscreen or hardwired switches and indicators). Approaches for a common HMI layout for all devices shall be considered to reduce training and operational burdens. Some example signals it may be providing:

o Controls: Open/Shut/Start/Stop commands, local Emergency Stop, and a Local/Remote command selector.

o Indications: Open/Shut/Running status, Fault/Alarm status, and health indicators for assessing controller status.

• Multiplexing (Multi-Device Control): The CC architecture shall support scaling for multiplexing. Describe how a single CC/IM component can be configured or expanded to control multiple independent end-devices (e.g., driving several discrete valves) using shared PM resources. Controlled devices may be placed in groups based on location and end use system functional requirements to determine what actuated components can make use of a common set of power conversion electronics.

The common controller devices shall have a method to allow two or more controllers to synchronize their operation with each other. This would allow two devices to move together at the same time within a certain distance of each other. Controllers should therefore be configurable as a master or slave and include the ability to communicate with each other without the need to rely on a higher-level control network.

• Software Configurability: Software shall be configurable for different device types and control schemes without source code modification. See Appendix B for a notional list of device types and control schemes.

3.2 PM & IM Interfaces to CC

The CC component shall interface with IMs and control a notional family of PMs and devices. The concept shall demonstrate interfacing with modules meeting the following:

• Family of PMs: Support scalable PMs with some examples listed in Table 1. The devices in Table 1 are typical VFD or VSD applications, but the vendor shall explain how their CC may be capable of controlling multiple topologies (induction & permanent magnetic motors, brushless DC motors or servo-controlled devices) and address suggested controller safety features for these applications. The intent is to define boundaries where the CC and IM modules are common for a collection of power levels for the same PM. The study should define the breakpoints in the PM power levels.

• IM I/O Capabilities: Control and monitoring I/O (Digital and Analog), encoders/position data and higher data sampling rate I/O (voltage, current, temperature, high-resolution vibration/acoustic inputs), 4-20mA, ProfiBus, ModBus. Physical IM connections shall adhere to the standards identified in Appendix A.

• Standard Interface: Define the standard control/data interface connecting the CC/IM to the PM/IM families.

• Supervisory Network Interface: The IM shall incorporate interfaces necessary to connect the CC/IM component to the overarching shipboard machinery control system for high-level command, status reporting, and CBM+ data reporting. Provisions should be available to physically lock unused data points (as well as capability to be disabled in firmware).

• Power Semiconductor Devices: Latest state-of-the-art devices (e.g., WBG semiconductors & SiC MOSFETs) shall be considered as part of the selection of power electronic components and circuitry.

• No special tools should be required to diagnose or perform maintenance on these components.

3.3 Cybersecurity & Information Assurance

The design should incorporate defense-in-depth cybersecurity compliant with NIST SP 800-82 revision 3 Operational Technology (OT) principles. The Contractor shall describe how their proposed architecture addresses the following capabilities, where applicable to the design:

• Hardware Root-of-Trust (RoT): Capabilities to ensure platform resiliency, including verification of signed firmware updates, and hardware-based encryption or storage.

• Interface Protection: Mechanisms for secure network communications and capabilities for logical or physical port hardening, including the ability to actively disable unused ports (physically and via firmware).

• RMF & Zero Trust: Alignment with the security and privacy controls used by the DoD to facilitate future Risk Management Framework (RMF) assessments. The Contractor shall propose how the architecture supports Zero Trust principles at the device level.

3.4 Open Standards & Network Reporting

Controllers shall utilize a common industrial network protocol for reporting to the shipboard machinery control system and CBM+ data:

• Protocols: In addition to traditional protocols (EtherNet/IP, Modbus TCP, CANBus), the Contractor shall describe the feasibility of using data-centric standards like OPC UA or suggest an open standard for their family of devices.

• Network Management: Describe how the controller prevents or packages data to prevent it from degrading primary shipboard control network traffic (e.g., utilizing QoS, dedicated ports, or local data compression).

• Open Systems: Align with Modular Open Systems Approach (MOSA) principles. Propose a common hardware form factor (standard card/module size) to ensure modularity and interoperability between different IM cards, PM interfaces, and future technology insertions.

3.5 Obsolescence & Lifecycle Management

• Explain obsolescence mitigation strategies for architecture and past experience with obsolescence management.

• Assess feasibility and cost impacts of providing technical data packages utilizing Government Purpose Rights (GPR) to enable competitive, multi-source procurement.

• The overall hardware/software design shall include the ability support design upgrades with potential future state-of-the-art electronics/power electronic devices

3.6 Testing & Validation

• Assess feasibility of integrating proposed Common Controller components into a Government-defined test stand or Controller Hardware-in-the-Loop (CHIL) test environment.

3.7 General Shipboard & Power Requirements

Physical Footprint: Provide notional dimensions, weight, and mounting configurations.

Dimensions shall demonstrate consideration for "hatchability" (transport through standard naval hatches/passageways).

CC and IM shall derive their control power directly from the primary input power feed of the PM.

The available ship power interfaces are: 440VAC and 115VAC in accordance with the standards identified in Appendix A (60Hz systems).

The concept design shall comply with the shipboard requirements detailed in Appendix A.

4 Deliverables and Schedule The Contractor shall execute the following tasks and provide the associated deliverables.

Deliverable Description Due Date

4.1 Kickoff Conduct a 1-hour virtual meeting to discuss the task. Award + 1 Week

4.2 Technical

Interchange Meetings

Participate in weekly 1-hour virtual technical meetings with the Government to discuss design and boundary conditions.

Weekly

4.3 Concept

Design Report

Provide a concept report addressing Section 3.0. Shall include system diagrams, feasibility assessments, obsolescence plans, and hardware form factor. This report shall identify how the proposed architecture utilizes or adapts the Contractor's existing hardware lines.

Award + 45 Days

4.4 ROM

Estimate

Provide modified Rough Order of Magnitude (ROM) cost (+/- 5% variation) and schedule estimate for follow-on design, manufacture, and qualification in accordance with test standards identified in Appendix A.

Award + 45 Days

4.5 Outbrief Conduct a 1-hour virtual presentation of findings to the Government.

Award + 50 Days

5 Security & Clearances All work conducted under this SOW is UNCLASSIFIED. Required data will be provided at the Controlled Unclassified Information (CUI) level. The Contractor must have the capability to securely receive, process, and store CUI in accordance with DoD Instruction 5200.48.

Table 1 Notional HM&E Device Applications

ID Application Notional Power

Duty Cycle Notes

01 ¼ Turn Discrete Valve (Trim/Drain)

20W – 2.5 kW Intermittent (<5%)

Assuming 70% efficiency.

2-10 second operation.

700 in-lbs-20,000 in-lbs

02 ¼ Turn Discrete Valve (Seawater)

75W – 10 kW Intermittent (<5%)

Assuming 70% efficiency.

2-10 second operation.

260 in-lbs-51,000 in-lbs

03 Multi-Position Damper (Ventilation)

850W – 5.4 kW Intermittent (<10%)

Assuming 70% efficiency.

1-3 second operation.

10,000 in-lbs-21,000 in-lbs

04 Proportional Control Valve (Chilled Water)

1-5.5 kW Modulating (50%)

Assuming 70% efficiency.

2-5 second operation.

10,000 in-lbs-42,000 in-lbs

05 Fixed-Speed Pump (Lube Oil / Transfer)

1-5kW Continuous -

06 Linear Actuator (Hatch/Mast)

1-20kW Intermittent (<10%)

2”-140” stroke 3,000-40,000 lbs

07 Variable Speed Drive (Aux.

Seawater Pump)

150-300 kW

(450VAC)

Continuous -

08 HVAC Compressor Motor 200-400kW

(450VAC)

Continuous -

09 Electro-Hydraulic or Electro-Mechanical Control Surface Actuator (Ship Control)

14kW- 150kW

(450VAC)

Continuous Assuming 70% efficiency.

5 +/- 1 degrees/second

100,000 ft-lbf-700,000 ft-lbf

7 APPENDIX A: APPLICABLE MILITARY STANDARDS

In addition to the requirements in section 3.7 the concept design report shall address compliance with the following standards:

The CC, IM, and PM architecture shall interface with standard shipboard power systems (utilize the latest published version of the below standards):

• IEEE 1676: Guide for Control Architecture for High Power Electronics (1 MW and Greater) Used in Electric Power Transmission and Distribution Systems

• MIL-STD-1399-300-1 (Low Voltage AC Power): The design shall focus on supporting Type 1 single-phase and three-phase applications utilizing MIL-STD-1399-300-1 (115 VAC or 440 VAC, 60 Hz, ungrounded) for the devices defined in Table 1.

The Concept Design Report shall address how the proposed architecture and PM family can be scaled or adapted to support MIL-STD-1399-300-2 (Medium Voltage AC:

4,160/13,800 VAC) and MIL-STD-1399-300-3 (850 VDC) power buses for future applications.

• MIL-STD-810H (Environmental): Assume all controllers will be contained within the pressure hull. They shall meet typical requirements of temperature, humidity, and drip-proofness and salt fog standards in machinery space locations.

• MIL-S-901E (Shock): Meet Grade A requirements for high-impact shock

• MIL-STD-167-1A (Vibration): Meet shipboard mechanical vibration requirements

• MIL-STD-461G (EMI/EMC): Meet electromagnetic interference and compatibility requirements for submarine applications.

• MIL-STD-740-1 (Structureborne Vibrations): Limits are not currently defined but design should address past performance with submarine structureborne noise compliance.

• MIL-STD-740-2 (Airborne Noise Measurements): Limits are not currently defined but design should address past performance with submarine airborne noise compliance.

• MIL-DTL-917F (Electric Power Equipment): Meet the material, design, enclosure, and construction safety requirements for low-voltage naval shipboard electrical hardware.

8 APPENDIX B: Preliminary Device Parameters and Control Schemes The following parameters and control schemes are preliminary and should be used as a guide for the design. The Contractor is encouraged to recommend changes or additions where a technical benefit exists.

• Type of Motor/Device: Establishes the motor control algorithm and sets appropriate inputs (e.g., sensored or sensor-less open/closed loop based on HM&E machine load):

o Induction o Brushless o Permanent magnet (linear or rotary)

• Motor Parameters: Configured as applicable for the machine application:

o Inductance and winding resistance o Motor/rotor inertia and number of poles o Kt (In-lbf/Arms) and Ke (Vrms/Krpm) o Voltage and maximum current o Rotor/shaft position feedback method o Temperature sensor type and limits

• Type of Device: Establishes the machinery control algorithm and prompt the need to set the appropriate device parameters and sensor inputs:

o Discrete/Multi-position components (e.g., valves, dampers) o Continuous/Regulating components (e.g., pumps, fans, servos, motors) o Linear controlled devices (e.g., lifts, hatches)

• Device Parameters:

o Gear, transmission, or coupling ratios o Total travel, stroke, or displacement (angular, linear, volumetric) o Normal and maximum/not-to-exceed operating load (torque/force/head) o Not-to-exceed speed and acceleration/deceleration rates o Transit or cycle times (seconds, RPM, flow rate) o Position, speed, or process feedback method o Braking (no regeneration permitted) o Loop tuning parameters (PID) for regulating components

• Controller Parameters:

o Power electronics switching frequency (adjustable for performance and EMI) o DC Link voltage o Controller temperature and overload limits

• Control Schemes:

o Motion / Position Control: Dynamically adjusts output frequency and voltage to match velocity, acceleration, and torque setpoints across an operational stroke.

o Process Control: Regulates a system variable (e.g., pressure, flow, temperature) using control loops (P, PI, PID, etc.) based on direct sensor feedback, modeled system/component observers, or command inputs.

o Synchronization: Coordinates multiple devices moving a common load using leader-follower topologies or shared feedback.

o Multiplexing Control: Uses a single controller to operate multiple distinct loads sequentially by dynamically switching stored parameters and feedback routing.