N102-153 TITLE: Innovative materials/manufacturing for a prototype 600-1000VDC DC/DC Converter for Shipboard Radar

TECHNOLOGY AREAS: Materials/Processes, Sensors, Electronics

ACQUISITION PROGRAM: NA, IWS 2.0 will transition technology into developing high power radars.

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted." The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: The objective of this topic is to develop a prototype, high efficiency, high power density, low noise, 2.5KW DC/DC converter for insertion into developing Air and Missile Defense Radar (AMDR) systems. Future Navy Active Electronically Steered Array (AESA) radar systems will demand higher peak and average power levels requiring development of high power density, isolated DC/DC converters for pulsed current loads. This effort will require research and development of advanced materials, technologies, and manufacturing processes that will provide reliable, high performance power conversion while minimizing cost, weight, volume, and thermal management infrastructure.

DESCRIPTION: This topic seeks an advanced DC/DC converter design compatible with Transmit/Receive Modules utilized in Navy AESA radar systems and compatible with shipboard power requirements. The power systems within AESA radar systems consume significant power, space and thermal management resources. The power converters are designed to minimize cost, volume, thermal management infrastructure while maximizing efficiency, power density, and electrical performance. Goals for this prototype 2.5KW DC/DC converter will be 650 volt input, 28V output, efficiency greater than 90 percent%, power density greater than 200W per cubic inch, output regulation less than 0.1 percent, output ripple less than 0.25 percent, output stored energy less than 1 joule, and response time less than 10 microseconds, settling time less than 10 microseconds, overshoot less than 4 percent, output voltage droop less than .5 percent, and baseplate temperature typically at 50C. Key areas of interest are innovative designs for low loss switching topologies, low loss magnetic components, high common-mode isolation, advanced control loops, power factor correction, and enhanced thermal performance.

Power converters are a key enabling technology for fielding reliable and cost effective future AMDRs. The prototype converter within this topic shall support developing AMDR radars in terms of system performance and component reliability. Testing of the power converters will be conducted in a manner consistent with the operational requirements for the T/R modules (i.e. pulsed load conditions). Additionally testing should include a 1000-Hr life test and other long term life tests performed to demonstrate power supply maturity.

PHASE I: Identify, model, and develop an innovative converter design incorporating materials, technologies and manufacturing processes that significantly improve performance and reliability.

PHASE II: Using the design in Phase I and any improvements in materials, technologies, and manufacturing processes developed in this phase, build and test a prototype DC/DC converter focusing on a Navy transition. The prototype design, materials, and processes developed will address the issues described in the description of this topic (e.g., performance, cost, size, weight, etc.)

PHASE III: The Small Business will team with the Navy to transition the phase II developed DC/DC converter design into first articles and pilot production for integration into a Navy systems.

Private Sector Commercial Potential/Dual-Use Applications: Reliable, high performance DC/DC converters are needed to support a number of emerging applications within the military and industry.


REFERENCES:
1. NAVMAT P-4855-1A Navy Power Supply Reliability, Design and Manufacturing Guidelines, 1989.

2. NAVSO P-3641A More Power For The Dollar, 1999.

3. Next Generation Integrated Power Systems (NGIPS) Roadmap:
https://www.neco.navy.mil/synopsis_file/N00024NGIPS_Technology_Dev_Roadmap_final_Distro_A.pdf

KEYWORDS: Power,Converter,Radar,EW,AESA,AMDR, DC

** TOPIC AUTHOR (TPOC) **

DoD Notice:   Between April 21 and May 19, 2010, you may talk directly with the Topic Authors to ask technical questions about the topics. For reasons of competitive fairness, direct communication between proposers and topic authors is not allowed starting May 19, 2010, when DoD begins accepting proposals for this solicitation.

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