SOFC Based APU Industry Day_Dobbs.ppt
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TARDEC Non-primary Power Source Requirements Presentation to High Temperature Fuel Cell (SOFC) Based Auxiliary Power Unit Industry Day
Herb Dobbs, US Army RDECOM-TARDEC Lead for Fuel Cells, Non-primary Power Systems Team Herbert.dobbs@us.army.mil 586 574-5157 DISTRIBUTION STATEMENT A. Authorized for full public distribution Reference to specific products in this briefing is not a recommendation or endorsement by the US Army.
Unclassified
Current Ground Combat Vehicle Non-primary Power Systems
Ground Vehicle Platform Current NPS Solution Available Engine-Off Energy Continuous Power & Energy Requirement Fuel Consumption Requirement Available Space Claims (in addition to battery boxes)
From Common NPS Specification 275 L 200 L 100 L 6T VRLA = Valve Regulated Lead Acid Batteries, i.e. “Hawker” 6TMF = Maintenance Free Flooded Lead Acid Batteries Engine-Off Power Requirements From Common NPS Specification 275 L 200 L 100 L
6T VRLA
6T VRLA
6TMF
2 Batteries for Vehicle Auxiliaries 2 Batteries for Engine Starting 8 Batteries for Vehicle Auxiliaries 4 Batteries for Engine Starting 4 Batteries for Vehicle Auxiliaries + 1 24V Turret Battery 2 Batteries for Engine Starting Battery Type
Abrams M1A2 SEPv2 10.6 kW-Hrs 8 kW (Threshold) 10 kW (Objective) for 12 hour mission [ 96 kW-hrs (T) 120 kW-hrs (O) ] 1.75 gal/hr (T)
1.5 gal/hr (O)
| Bradley M3A3 | 5.8 kW-Hrs |
| Stryker FOV | 2.6 kW-Hrs |
TARDEC’s Non-primary Power Source Engine-Off Project Portfolio
X
TARDEC NPS Program Fielded Army NPS Solution Current Platform Requirement Technology Readiness Level X
X CERDEC NPS Program Noise Level Continuous Power*
* For 10 hour mission
Decreasing Noise
Increasing Power
70kW 40kW 20kW
Requirements Trend M1A2 EAPU Diesel APU 3 kW Abrams SEPv4 CDD ~40 kW
FCS NLOS-C
51 kW
FCS RSV
70 kW
M1A2 SEP v2 8 Hawker AGM Lead Acid Batteries 1 kW TARDEC Fuel Cell Program 10-20 kW Predicted Patrick Power Rotary APU 10 kW Honeywell HGT-80 Turbine APU 12 kW Abrams SEPv3 Bradley Stryker MRAP II 10 kW
M88 Diesel APU 14 kW M915 Proposed No-Idle APU
2.8 kW
Common Non-primary Power Source Performance Requirements Requirement Traceability:
| APU requirement traces back to the M1A2 ORD page 11, paragraph 4.b (4) to require an under armor APU (UAAPU) on the tank. |
| The PEO GCS/TARDEC Common Modular Power System (CMPS) IPT completed a gap analysis of Abrams, Bradley and Stryker on-board power requirements through FCS Spinout 1. |
| This resulted in the Common Non-primary Power System (CNPS) performance specification and a Request for Information (RFI) was sent to industry 1st QTR 2006 |
| Abrams | Stryker Bradley | |
| 275 L | 200 L | 100 L |
| Abrams, Bradley and Stryker CNPS Performance Requirements | ||
| Continuous Power | 8 kW (Threshold) / 10 kW (Objective) | |
| Mission Duration | 12 hours | |
| Fuel Consumption | 1.75 gal / hour (Threshold) / 1.5 gal / hour (Objective) | |
| NPS Volume |
NPS Weight 205 kg Abrams/Bradley (internal cooling system) 115 kg Stryker (can use engine’s cooling system) Procurement Cost < $40K
Current TARDEC NPS Programs
* Contractor production estimate
| NPS Technology Option | Patrick Power Gen III Rotary APU | Honeywell HGT-80 Gen II Turbine APU | Hatz M88FOV APU |
| Maximum Continuous Power | 10 kW | 12 kW | 14 kW |
(6 kW Electric/8 kW Hydraulic)
| Fuel Consumption | 1.6 gal/hr @10kW | 6.4 gal/hr @10 kW | ~2 gal/hr @ 14 kW | |
| Size | 264 L | |||
| (14 inch height) | 220 L | |||
| (13 inch height) | 318 L |
(18.88 inch height)
| Weight | 108 kg | 93 kg | 205 kg |
| Production Cost* | ~$35-50K | ~$100-120K | 20K |
| TRL (Gov’t Assessment) | 5 | 5 | 8 |
| Current Status | Gen II hardware laboratory tested and integrated into M1A2 SEP space claim |
Met Power and Fuel Consumption Met Abrams Space Claim Gen II meets TRL 5 definition.
Gen III NPS Hardware to be delivered 1st QTR FY09 Designed to meet CNPS requirements at TRL 6 Prototype hardware from a modified commercial aircraft APU delivered in FY06 for performance characterization.
Met power requirements Failed fuel consumption requirement Did not fit Abrams compartment.
Gen II unit Sized for UAAPU compartment Planned delivery in 4th QTR FY08 Currently fielded in M88A2 Hercules vehicles and the FAASV platforms.
Fails to meet space claim (height) requirements Having sustainment issues due to commercial engine upgrades outpacing the existing APUs manufactures discontinuing to support replacement parts
International Battery NPS solution is at TRL 3 Reference the Field Tasks on Slide 7
| All testing under section 3.1 must be completed to verify TRL 4 |
| Battery Management System has not been demonstrated as reliable |
| Possible failure in Deep Cycle Testing at Sypris |
| Failure of BMS in one TARDEC supplied unit |
| Possible failure in second BMS at TARDEC |
TARDEC NPS Program Fielded Army NPS Solution Current Platform Requirement Technology Readiness Level X
X CERDEC NPS Program Noise Level Continuous Power*
* For 10 hour mission
3 kW Abrams SEPv4 CDD ~40 kW
FCS NLOS-C
51 kW
FCS RSV
70 kW
Lithium Ion Battery 2 NPS Modules + 2 Hawker Batteries
1.2 kW M1A2 SEP v2 8 Hawker AGM Lead Acid Batteries 1 kW TARDEC Fuel Cell Program 10-20 kW Predicted Patrick Power Rotary APU 10 kW Honeywell HGT-80 Turbine APU 12 kW Abrams SEPv3 Bradley Stryker MRAP II 10 kW
M88 Diesel APU 14 kW M915 Proposed No-Idle APU
6T Hawker Armasafe Fielding History Non-primary Power Application
After becoming familiar with the characteristics and performance of the Hawker Armasafe Plus batteries as a Starting Lighting and Ignition option, PM Abrams internal effort was undertaken to integrate an additional 6 Hawker batteries in the M1A2 SEP v2 to extend silent watch.
This configuration was successfully tested, and has been adopted by the PM as an option for Non Primary Power to extend silent watch mission duration
Current M1A2 SEP v2 Interim NPS Solution Comparison
| Durability, sustainment, and safety concerns with the proposed pack solution in | a relative vehicle environment are unverified and unknown. |
| TARDEC is planning extensive life cycle cost analysis | |
| TARDEC has multiple ongoing and pending projects to provide performance | improvements to the 6T sized battery. |
* Based off present 44 amps continuous current draw silent watch mission profile ** Contractor estimated procurement cost based off of potential production volumes.
| Current M1A2 SEP v2 Performance Capability | Proposed Lithium Ion Battery Pack Solution | |
| Left Sponson UAAPU Space | 6 Hawker ARMASAFE AGM Lead Acid Batteries | 2 Li-Ion Battery (1100 Series) Li-Ion APU Modules |
| Right Sponson Vehicle Battery Box | 2 Hawker Lead Acid Batteries (available for silent watch) + |
4 Hawker Lead Acid Batteries (reserved for vehicle start)
| TRL | 9 | 3 |
| Silent Watch Mission Duration* | 10 hrs | 11.6 hrs |
| Procurement Cost | $2K | ~$10K** |
TARDEC NPS Program Fielded Army NPS Solution Current Platform Requirement Technology Readiness Level X What is TARDEC doing about this?
X CERDEC NPS Program Noise Level Continuous Power*
* For 10 hour mission
3 kW Abrams SEPv4 CDD ~40 kW
FCS NLOS-C
51 kW
FCS RSV
70 kW
Li-Ion Battery 2 NPS Modules + 2 Hawker Batteries
1.2 kW M1A2 SEP v2 8 Hawker AGM Lead Acid Batteries 1 kW TARDEC Fuel Cell Program 10-20 kW Predicted Patrick Power Rotary APU 10 kW Honeywell HGT-80 Turbine APU 12 kW Abrams SEPv3 Bradley Stryker MRAP II 10 kW
M88 Diesel APU 14 kW M915 Proposed No-Idle APU
Future Non-primary Power Requirements
The FCS net-centric systems are driving the current forces modernization non-primary power requirements several multiples past current capability
- Example:
Increased electrical loads cause increased cooling burdens (fans, liquid cooling loops) driving total power requirements higher.
TARDEC is engaging several efforts to address these future requirements:
| Embedded in PM and OEM modernization trade studies and requirements reviews to provide input and assist in requirements formulation. |
| Working efforts in power and thermal management to increase efficiency in how on-board power is used and to minimize the electrical burden associated with thermal management systems. |
| Actively working advanced vehicle power architecture specifications (Common Modular Power System IPT) to drive future vehicle architectures to common, upgradeable systems. |
| Continuing development efforts in fuel cell technology that have the potential to provide extremely high power and energy densities with low noise. |
*Data from Abrams Evolutionary Design first round trade study with PM HBCT, TARDEC and GDLS Abrams M1A2 SEP v2 vs.
Abrams M1A2 SEP v4
| <2 kW | Silent Watch Average Power | ~40kW* |
| ~16kW | Full Combat Mode | ~75kW* |
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