u.s. army combat capabilities development command – … · • channel 2 – fixed voltage •...

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1 DISTRIBUTION A. See first page. U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – GROUND VEHICLE SYSTEMS CENTER George Hamilton VEA CCDC GVSC Power Electronics and Architecture DISTRIBUTION A. Approved for public release; distribution unlimited.

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Page 1: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

1DISTRIBUTION A. See first page.

U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND –GROUND VEHICLE SYSTEMS CENTER

George Hamilton

VEA

CCDC GVSC

Power Electronics and Architecture

DISTRIBUTION A. Approved for public release; distribution unlimited.

Page 2: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

2DISTRIBUTION A. See first page.

WHY IS TARDEC DEVELOPING POWER ARCHITECTURES?

• Electrical power requirements continue to grow as more electronics are added to Military Ground Vehicles (radios, displays, computers, cameras, turret motors)

• Vehicle designs utilize proprietary electrical architectures to meet power requirements

• The Army pays for a new power architecture implementation every time a new vehicle is developed. A reusable standardized architecture implementation is needed to reduce development cost and schedule

0200400600800

10001200140016001800

28VDC Power (Amps)

Alternator Size(Amps)

Page 3: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

3DISTRIBUTION A. See first page.

ELECTRICAL POWER ARCHITECTURE SYSTEM REQUIREMENTS

• Provide 45kW @ 28VDC -> MIL-STD-1275E

• Provide 175kW @ 600VDC -> MIL-PRF-GCS600A.

• Silent Watch: 4 kW for 4 hours to vehicle Low Voltage loads with the main engine off

• Import/Export 30kW @ 208VAC

• Utilize the SAE-J1772 connector for exporting/importing High Voltage power

• Power electronics liquid cooling temp @ 105C

• Automated power management with anti-idling

• Meet the Abrams & Bradley environmental requirements contained within ATPD-2404

Enables Energy Weapons and >10% Fuel Savings

Page 4: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

4DISTRIBUTION A. See first page.

TEMPERATURE, COOLANT, & AIRFLOW REQUIREMENTS

Ambient Temperatures• Combat Vehicles Operate in Hot, Basic, and Cold

climates as defined in AR 70-38 & MIL-STD-810G• Vehicles without air-conditioning experience

temperatures up to 71C in the crew areas• Touch temperatures less than 60C in 29.5C

ambient• Engine compartment temperatures vary from 121C

– 260C right near the exhaustCoolant Temperatures• Using Engine Coolant or 100-105C allows a

radiator size reduction of 75% from standard 70C electronics coolant

Airflow• No natural airflow on military vehicles. Assume no

airflow. Forced air cooling approaches must be able to survive MIL-STD-810G requirements

Page 5: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

5DISTRIBUTION A. See first page.

MIL-STD-1275E & MIL-PRF-GCS600A

Page 6: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

6DISTRIBUTION A. See first page.

SAFETY FEATURES – HV INTERLOCKS

NGCVEPA High Voltage Interlocks

Page 7: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

7DISTRIBUTION A. See first page.

SAFETY FEATURES – HV DISCHARGE

High Voltage Discharge Requirements

• The voltage differential between the High Voltage Power and High Voltage Return pins of any High Voltage connection shall be less than 2 VDC within 300 microseconds upon HVIL circuit interruption, assuming external power has been removed.

• The assembly shall reduce all stored charge to less than 5 microcoulombsbefore access can be gained for repair activities.

Page 8: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

8DISTRIBUTION A. See first page.

NGCVEPA ARCHITECTURE

Page 9: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

9DISTRIBUTION A. See first page.

INTEGRATED STARTER GENERATOR CONTROLLER (ISGC)

ISGC Details:

• Power capability - 200kW High Voltage

• Three SSPC channels: 350A, 2 x 100A

• Silicon Carbide (SiC) based

• Liquid Cooled, 105oC

• Operating Temp, -45oC to +121oC

• High Power Density (181W/cu.in; 11kW/L)

• Size: 5.76” x 13.7” x 14”

• Weight: 50 lbs.

Page 10: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

10DISTRIBUTION A. See first page.

BI-DIRECTIONAL CONVERTER (BDC)

BDC Details:

• Uses Silicon Carbide (SiC) for the 600Vdc Active bridge

• Uses Gallium Nitride (GaN) for the 28Vdc Active bridge

• Designed to be rack mounted to minimize safety concerns with HV and liquid cooling

• Liquid Cooled, 105oC

• Size: 712 in3

• Weight: 39 lbs.

Page 11: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

11DISTRIBUTION A. See first page.

HIGH VOLTAGE POWER CONTROLLER (HVPC)

HVPC Details:

• 12 solid state circuit-protected channels (350/200/50/30x5/10x4)

• Configurable Pre-charge capability for each channel

• Provides central control of safety features:

• Ground Isolation Fault (GIF) Detection

• HV Interlock

• Overcurrent Protection

• Arc Flash Mitigation

• Silicon Carbide (SiC) based

• Liquid Cooled, 105oC

• Size: 6 x 12 x 15”, Weight: 48 lbs.

Page 12: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

12DISTRIBUTION A. See first page.

UNIVERSAL HIGH VOLTAGE CONVERTER (UHVC

UHVC Details:

• Non-isolated continuous transfer of 120kW

• Channel 1 – Flexible Voltage

• Lower bound 270VDC MIL-STD-704F

• Upper bound 600VDC MIL-PRF-GCS600A

• Channel 2 – Fixed Voltage

• 600VDC MIL-PRF-GCS600A

• Liquid Cooled, 105oC

• RFQ has been issued to solicit development

Universal High Voltage Converter (UHVC)

Power Conversion

Heater Circuit

Processor

J1939 CAN28Vdc

Channel 2Interlock Channel 2

Iiquid Cooling

Channel 1Interlock Channel 1

Page 13: U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – … · • Channel 2 – Fixed Voltage • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit

13DISTRIBUTION A. See first page.

Silicon Silicon Carbide

ERCA POWER DISTRIBUTION UPGRADE