N221-002 TITLE: Ultra Lightweight Tactical Vehicle Power Generation

OUSD (R&E) MODERNIZATION PRIORITY: General Warfighting Requirements (GWR)

TECHNOLOGY AREA(S): Ground / Sea Vehicles

OBJECTIVE: Develop a compact, lightweight, and engine driven power generation system for energy export power with high specific power (kilowatts per kilogram) that fits within the confines of the chassis of recreational off-highway vehicles (ROVs) to meet expected power and energy demands and allow for future mission growth.

DESCRIPTION: Currently available vehicles capable of being internally transported in rotary wing aircraft have insufficient export power capabilities to meet power and energy demands of current Counter-Unmanned Aerial Systems (C-UASs) and allow for future mission growth. The current Light Marine Air Defense Integrated System (LMADIS) uses a 5 kilowatts (kW) diesel generator weighing 300 lbs. that results in the vehicle weighing 15 lbs. over the maximum gross vehicle weight (GVW) of the current Ultra Lightweight Tactical Vehicle (ULTV). Future mission growth to add additional communications equipment to LMADIS is expected to increase the power demands to 10 kW. Currently available diesel generators that meet the higher power requirements weigh close to 500 lbs. and would result in the vehicle weighing 100 to 150 lbs. over maximum Gross Vehicle Weight (GVW). Compact and lightweight power generation systems are needed to power C-UAS and C2 systems and keep the vehicle safely within its allowable GVW. System requirements are:

• Integrated system using the existing Polaris MRZR-ALPHA 118hp 1.5L Ford diesel engine
• Export power output of 10 kW at idle Threshold (T); 15 kW at idle Objective (O) at 28 volts direct current (VDC)
• Reduced physical size of export power system (same approximate size as an alternator, 8 inches wide x 10 inches long x 8 inches high)
• Physical weight of export power system less than 125 lbs.
• Compatible with typical 28VDC tactical electrical systems and 14VDC vehicle electrical systems while conforming to the necessary requirements within MIL-STD-1275E, MIL-STD-1332B, and MIL-STD-705D
• Electrical component and connections with an ingress protection rating of Ingress Protection (IP67) or higher in accordance with (IAW) American National Standards Institute (ANSI) / International Electrotechnical Commission (IEC) 60529-2004
• Modular design that can be inspected, serviced, and repaired in the field
• Full power output across the range of engine speeds, ~750-4,500 Revolutions Per Minute (RPM)
• Operate at temperatures between 0�F to 125�F (T); -25�F to 125�F (O)

PHASE I: Develop concept(s) for a generator technology and its supporting control equipment that can meet the requirements described above. Demonstrate the feasibility of the concept(s) in meeting the Marine Corps needs and establish that the concepts can be developed into a useful product for the Marine Corps. Feasibility will be established by material testing and/or analytical modeling, as appropriate. Provide a Phase II development plan with performance goals, key technical milestones, and address technical risk reduction.

PHASE II: Develop a full-scale prototype for evaluation. The prototype shall be evaluated through bench or lab testing to determine its capability in meeting the performance goals defined in the Phase II development plan and the Marine Corps requirement for the integrated power generation system. System performance shall be demonstrated through prototype evaluation and modeling or analytical methods over the required range of parameters including numerous deployment cycles. Evaluate the results and refine the design as necessary. Conduct on-vehicle testing in a relevant environment. Evaluate and compare the results to Marine Corps requirements. Prepare a Phase III development plan to transition the technology for Marine Corps and commercial use.

PHASE III DUAL USE APPLICATIONS: Provide support to the Marine Corps in transitioning the technology for Marine Corps use. Refine a power generation system for further evaluation and determine its effectiveness in an operationally relevant environment. Support the Marine Corps test and evaluation program to qualify the system for the Marine Corps use.

Commercial applications include law enforcement vehicles, search and rescue vehicles, tractor trailers, and general automotive platforms to provide integrated power capability reducing both weight and space claim supporting a more demanding future mobile power environment.

REFERENCES:

1. "MIL-STD-1275E Characteristics of 28 Volt DC Input Power to Utilization Equipment in Military Vehicles." U.S. Army Tank automotive and Armaments Command, March 22, 2013. https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=36186.
2. "MIL-STD-1332B Tactical, Prime. Precise, and Utility Terminologies For Classification of the DoD Mobile Electric Power Engine Generator Set Family." Naval Facilities Engineering Command, Naval Construction Battalion Center, March 13, 1973. https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=36687.
3. "MIL-STD-705D Mobile Electric Power Systems." Communications Electronics Research Development Engineering Center (CERDEC) Product Realization Directorate (PRD), November 22, 2016. https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=35902.
4. "ANSI/IEC 60529-2004 Degrees of Protection Provided by Enclosures (IP Code)." https://www.nema.org/Standards/ComplimentaryDocuments/ANSI-IEC-60529.pdf.

KEYWORDS: Tactical vehicle; power generation; weight reduction; size reduction; ultra lightweight tactical vehicle; ULTV; Light Marine Air Defense Integrated System; LMADIS; Exportable power; Power