Unclassified – Approved for Public Release

Integrated Starter Generator “More than a 24V Vehicle Power Supply” Integrated Starter GeneratorIntegrated Starter Generator

““More than a 24V Vehicle Power SupplyMore than a 24V Vehicle Power Supply””

L-3 Combat Propulsion SystemsMuskegon, MI 49442

LL--3 Combat Propulsion Systems3 Combat Propulsion SystemsMuskegon, MI 49442Muskegon, MI 49442

1

Presented byDonald Underwood – VP, Engineering

Presented byPresented byDonald Underwood Donald Underwood –– VP, EngineeringVP, Engineering

Unclassified Unclassified -- Approved for Public ReleaseApproved for Public Release

Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

Talking PointsTalking Points

Power & Energy Power & Energy ––

Critical Combat EnablersCritical Combat Enablers

ISG System ArchitectureISG System Architecture

Performance CapabilitiesPerformance Capabilities

RetrospectiveRetrospective

2

Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

OverOver--Arching Technology RequirementsArching Technology Requirements

Build Lighter and Smaller (Weight, Volume)Build Lighter and Smaller (Weight, Volume)

Build to Last (RAM)Build to Last (RAM)

Build UserBuild User‐‐Friendly (Interfaces, displays, and Friendly (Interfaces, displays, and  automation to manage operator workload)automation to manage operator workload)

Reduce/Manage Required Network BandwidthReduce/Manage Required Network Bandwidth

Build Affordably (Production Cost Reduction)Build Affordably (Production Cost Reduction)

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Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

Terms of ReferenceTerms of ReferenceHigh Energy Systems (High Value) will dominate the High Energy Systems (High Value) will dominate the ““Future Future BattlespaceBattlespace””

Tactical Vehicle designs impose severe limitations on volume Tactical Vehicle designs impose severe limitations on volume and weightand weight

Fuel Economy is Combat Power Fuel Economy is Combat Power …… a key performance parametera key performance parameterEnergy Density is the primary figure of merit for mobility solutEnergy Density is the primary figure of merit for mobility solutionsionsLong term commitment to manufactured liquid hydrocarbon fuels Long term commitment to manufactured liquid hydrocarbon fuels from domestically abundant feedstocks (Biofrom domestically abundant feedstocks (Bio--diesel, methanol, diesel, methanol, ethanol)ethanol)Hydrogen presently unsuitable for tactical mobility fuel but is Hydrogen presently unsuitable for tactical mobility fuel but is feasible for hotel powerfeasible for hotel power

Network Centric Operations and increasing bandwidth are Network Centric Operations and increasing bandwidth are driving electrical power requirements exponentially driving electrical power requirements exponentially

U.S. Defense has committed to hybridU.S. Defense has committed to hybrid--electric architecture for electric architecture for FCS and future Tactical Wheeled Vehicles (e.g. JLTV)FCS and future Tactical Wheeled Vehicles (e.g. JLTV)

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Power and Energy are Critical Transformation Enablers

Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

The Power IssueThe Power Issue

NOW FY14

Powe

rNe

eds Bandwidth

Power Density

Transportability

10 MW

1 MW

500 KW

Pow

er

5Years

High EnergyLasers

Active Denial

Sensors

Hybrid Drive Vehicles and Platforms

C4ISR Systems

Objective Warrior

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Total System Energy Total System Energy Management:Management: is a critical is a critical resource for future economiesresource for future economies

Stability/instabilityStability/instability of World of World regionsregionsEnergy Energy ““independenceindependence”” should be should be based on based on diversitydiversity

Scaleable Options:Scaleable Options: Concepts Concepts must include methods for must include methods for supporting and facilitating supporting and facilitating natural resources and natural resources and alternative energy sourcesalternative energy sources

Highest Possible Packing Density Highest Possible Packing Density and Utility and Utility to maximize systemto maximize system’’s s useuseS&T funding is supporting S&T funding is supporting fuels/synfuels/bio-diesel researchresearch

“Power”… Critical Resource on Tomorrow’s Battlefield

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Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

Adv Mobile Electric Tactical Power SourcesAdv Mobile Electric Tactical Power SourcesAddresses Power Addresses Power Generation Mission Generation Mission Capabilities Gaps (5Capabilities Gaps (5-- 75kW) to support Future 75kW) to support Future Force and dismounted Force and dismounted warfighterwarfighter

Development of high Development of high power density (>1kW/kg) power density (>1kW/kg) systems (generators and systems (generators and fuel cells)fuel cells)

Development of Hybrid Development of Hybrid Intelligent Power Mgmt Intelligent Power Mgmt architecture using node architecture using node control switchgearcontrol switchgear

6

30 kWModern Tactical

Quiet Generator

OPOC-FL1.5kW

Hybrid Smart Grid

Unclassified – Approved for Public ReleaseJoint Power Exposition 20097

Proven Exportable Power Systems: TRL 6Proven Exportable Power Systems: TRL 6--7 7

Unclassified – Approved for Public ReleaseJoint Power Exposition 20098

LL--3 Commitment to Hybrid Architectures3 Commitment to Hybrid Architectures

101 102 103 104 105 106 107 108

COMMERCIAL

Power, Watts

Soldier Power

MILITARY

Residential

Automotive

Electronics

Ship Service

Heavy Vehicle

Locomotive

Industrial

Marine

Sensors, Unmanned

Vehicles

Vehicles,Mobile GeneratorsFCS

OPOC 560kW

Wankel 200 kW

10 kW PEM

Fuel Cell

epc™

1.5 kW Electric Power Cell

M54 1050 kW

Grid

M57

200kW

ShipPropulsion

MCFC

300-1000 kW

30kW APU

Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

ISG System ArchitectureISG System ArchitectureDesign based on military application prototypesDesign based on military application prototypesModular capability with incremental power  20Modular capability with incremental power  20‐‐110kW110kW

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ISG

Transmission

Power Management

Controller

DC/DC Power Converter28 VDC Output Power

DC/AC  PowerConverterAC Output Power

DC/DC Power ConverterHigh Voltage Energy Storage

Motor/Generator Controller

3 Phase AC

750 VDC

Engine/Transmission Signals

OperatorInterface

Not shown:

•Mounting

•Cooling

•Interconnect box

•AC Distribution Interface

Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

Nominal ISG Performance Capabilities Nominal ISG Performance Capabilities

1

0

10

20

30

40

50

60

70

80

90

100

0

50

100

150

200

250

300

350

400

450

500

550

600

0 1000 2000 3000 4000 5000

Power (kW) Torque (N-m)

Torq

ue(N

-m)

Speed (rpm)

G36 and G37 + S31 Continuous Generator Power(@750V)

G36 Torque (N-m)

G37 Torque (N-m)

G36 DC power (kW)

G37 DC power (kW)

Power (kW

)

Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

ISG AC Output vs. TemperatureISG AC Output vs. Temperature

•AC-Power = Power at 3-Phase between Generator and PE

•Cont = Continuous = Thermal Limit

•Peak = Possible Power due to DC-Voltage, BEMF

and Inductance of Coils

How to use:

1)Choose rpm + chose Inlet temp ‐> get possible cont. Power

2) 

Choose DC‐Voltage ‐> get possible Peak Power

3) 

Power that can be used = Minimum of 1) and 2)

•DC‐Voltage‐dependency  indicates that lower temp does not always mean 

higher power.

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Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

G37 G37 -- ISG Motor /Starter EfficiencyISG Motor /Starter Efficiency

1

Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

HMPT 600/675/800 with ISGHMPT 600/675/800 with ISG

1

Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

Open Systems TechnologyOpen Systems Technology

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HEV modular power control design provides continuous upgrade/modernization during the life of the system

Leverages Hybrid and energy Leverages Hybrid and energy management validated legacy management validated legacy

Combat Vehicle Concepts & Combat Vehicle Concepts & IterationsIterationsWheelWheel--hub drive product hub drive product applicationapplicationHigh energy / Power DensityHigh energy / Power Density

Seamless Horizontal Seamless Horizontal Technology Insertion into Technology Insertion into current and future platformscurrent and future platformsDual use COTS / NDI Dual use COTS / NDI components maximizes components maximizes affordabilityaffordability

ATDATD EMDEMD LRIPLRIP PRODPROD OBSOBSEENNDD

Time

Program Synthesis

Unclassified – Approved for Public ReleaseJoint Power Exposition 2009

RetrospectiveRetrospective LL--3 CPS is meeting emergent 3 CPS is meeting emergent challenges with innovative applications challenges with innovative applications of leading technology and extensive of leading technology and extensive expertise in engineering and analysisexpertise in engineering and analysisThe Presence of Hybrid Powered The Presence of Hybrid Powered Vehicles and Energy Generation Vehicles and Energy Generation Systems permits the utilization of Systems permits the utilization of broad ranging concepts for energy broad ranging concepts for energy management that will revolutionize the management that will revolutionize the makeup of future economies and makeup of future economies and infrastructuresinfrastructuresEnergy Management Architectures and Energy Management Architectures and Power Distribution Products are Power Distribution Products are modular and scalable to provide modular and scalable to provide maximum system flexibility maximum system flexibility SpinSpin--Out technologies (FCS/JLTV) Out technologies (FCS/JLTV) applications provides current and applications provides current and future force systems growth margins future force systems growth margins to meet emerging requirementsto meet emerging requirements

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Evolutionary acquisition focused on spiral development

New technology that gives conventional systems more capability

New technology that provides unconventional capabilities

Multi-dimensional options Logistics transformation

enabler

Builds, generates and sustains combat power

Pathway to energy “independence”