D-STAR Engineering Corporation, All Rights Reserved Approved for Public Release, Distribution Unlimited 2005.05.02 Logistics-Fueled, Man-Portable Generator Sets for Soldier Power, Battery Charging and APU.

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Transcript D-STAR Engineering Corporation, All Rights Reserved Approved for Public Release, Distribution Unlimited 2005.05.02 Logistics-Fueled, Man-Portable Generator Sets for Soldier Power, Battery Charging and APU.

Logistics-Fueled, Man-Portable Generator Sets for Soldier Power, Battery Charging and APU Needs

A Presentation to the

NDIA Tri-Service Power Expo

May 02, 2005 Tampa Convention Center, Tampa, Florida by S. Paul Dev, President D-STAR Engineering Corporation

4 Armstrong Road, Shelton, CT 06484 Phone : (203) 925 7630, Fax : (203) 925 7631 E-Mail : [email protected]

Approved for Public Release, Distribution Unlimited;

Outline

1.

2.

3.

2005.05.02

50 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 0.1 hp Diesel Engine Goals, Current Status, Residual Challenges, Future Plans

700 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 1.3 hp Diesel Engine Current Work in Process for DARPA + SOCOM Future Plans : 2-Cylinder Engine, 4-Stroke Engine

Future Plans : 2-Cyl. Engine, 4-Stroke Engine

Portable Power, Hybrid-Electric Drive, APUs

System Overview

2005.05.02

Regulator:

Allows for minimum efficiency hit Addressing heat sink & packaging issues

Control Panel Interface:

Allows for Regulated Voltage or Full Voltage for Maximum Efficiency

D-STAR 50-Watt Personal Power Unit

Goals 2005.05.02

Warm Air & Clean Gases Out 5½” Stowed / Storage Mode Includes onboard JP-8 Fuel Tank for 3 – 5 days of continuous operation Operational Mode Air In Air In 5½” 5½” Approximately equal in volume & weight to two BA-5590 batteries

D-STAR 50-Watt Personal Power Unit

Interior Layout

2005.05.02

Exhaust System Fuel Tank Micro Diesel Engine Beta Prototype Hardware Buffer Batteries Cooling Fan Starter-Generator Long-Life Back-Up Batteries Power & Control Electronics D-STAR Engineering Corporation, All Rights Reserved Approved for Public Release, Distribution Unlimited 2005.05.02

D-STAR MGS-50 : Diesel Fueled Micro Generator Set System efficiency calculations Peak

Unit output (W) FADEC power draw (W) 5V regulator efficiency (%) Power electronics power draw (W) Regulated electrical output (W) Power conversion electronics efficiency (%) Generator unregulated electrical output (W) Generator efficiency (%) Fan mechanical power (W) Engine mechanical power required (W)

Efficiency : engine mech. to net elect. (%)

SFC (lb/HP/hr) Fuel flow (g/min) Fuel energy, Lower Heating Value (MJ/kg) Engine mech output energy (MJ/kg)

Efficiency : fuel LHV to engine (%) Overall efficiency - Fuel to DC Output (%) Today

40 2.5

85% 1 44

83%

75%

7 78

52% 1.5

1.2

42.8

3.95

9% 5% Goal

50 2.5

85% 1 54 93% 58 85% 3 71

70%

1.2

0.87

42.8

4.93

12% 8% Continuous Today

Goal

45 2.5

85% 1 44

83%

75%

7 78

52% 1.5

1.2

42.8

3.95

9% 5%

2.5

85% 1 49 93% 53 85% 3 65

69%

1.0

0.66

42.8

5.92

14% 10%

D-STAR MGS-50 : System Performance Comparison for 3-day and 10-Day Missions Current Actual Goal Mission Length Power Output, Average Energy Requirement Days Hours Watts W-hr 3 72 20 1440 10 240 20 4800 3 72 20 1440 10 240 20 4800 Number of Batteries (BB-2590) Energy / Battery (BB-2590) 0 181 0 181 Weight / Battery (BB-2590) Fuel Flow, When Running Round Trip Efficiency Fuel Flow, Mission Average Fuel Needed Unit Empty Weight Total System Mass, Average Specific Energy, Average Equivalent BB-2590 (125 W-hr / kg) Batteries Wh / Batt.

kg / Batt.

g/min % g / min kg kg kg W-hr / kg # Batt.

kg 1.20

81% 0.66

2.8

1.9

3 438 8 12 1.45

1.20

81% 0.66

9.5

1.9

7 727 27 39 0.66

81% 0.36

1.6

1.0

2 808 8 12 1.45

0.66

81% 0.36

5.2

1.0

4 1331 27 39 MGS Weight Advantage (Ratio) 3.5

5.9

6.5

10.9

D-STAR MGS-50 : System Performance Comparison for 3-day and 10-Day Missions Current Actual Goal Mission Length Power Output, Average Energy Requirement Days Hours Watts W-hr 3 72 20 1440 10 240 20 4800 3 72 20 1440 10 240 20 4800 Number of Batteries (BB-2590) Energy / Battery (BB-2590) Weight / Battery (BB-2590) Fuel Flow, When Running Round Trip Efficiency Fuel Flow, Mission Average Fuel Needed Unit Empty Weight Total System Mass, Average Specific Energy, Average Equivalent BB-2590 (125 W-hr / kg) Batteries Wh / Batt.

kg / Batt.

g/min % g / min kg kg kg W-hr / kg # Batt.

kg 1.20

81% 0.66

2.8

1.9

6 233 8 12 2 181 1.45

1.20

81% 0.66

9.5

1.9

10 505 27 39 0.66

81% 0.36

1.6

1.0

5 307 8 12 2 181 1.45

0.66

81% 0.36

5.2

1.0

7 737 27 39 MGS Weight Advantage (Ratio) 1.9

4.1

2.5

6.0

D-STAR MGS-50 : System Performance Comparison for 3-day and 10-Day Missions Current Actual Goal Mission Length Power Output, Average Energy Requirement Days Hours Watts W-hr 3 72 20 1440 10 240 20 4800 3 72 20 1440 10 240 20 4800 Number of Batteries (BB-2590) Energy / Battery (BB-2590) Weight / Battery (BB-2590) Fuel Flow, When Running Round Trip Efficiency Fuel Flow, Mission Average Fuel Needed Unit Empty Weight Total System Mass, Starting Specific Energy, Starting Equivalent BA-5590 (169 W-hr / kg) Batteries Cost of BA-5590 Batteries , @ MGS Weight Advantage (Ratio) Wh / Batt.

kg / Batt.

g/min % g / min kg kg kg W-hr / kg # Batt.

kg $70 1.20

81% 0.66

2.8

1.9

4.7

306 8 8 $ 1.7

1.45

560 0 181 1.20

81% 0.66

9.5

1.9

11.3

423 28 29 $ 1,960 2.5

0.66

81% 0.36

1.6

1.0

2.6

562 8 8 $ 3.2

560 0 181 1.45

0.66

81% 0.36

5.2

1.0

6.2

772 $ 28 29 1,960 4.6

D-STAR MGS-50 : System Performance Comparison for 3-day and 10-Day Missions Current Actual Goal Mission Length Power Output, Average Energy Requirement Days Hours Watts W-hr 3 72 20 1440 10 240 20 4800 3 72 20 1440 10 240 20 4800 Number of Batteries (BB-2590) Energy / Battery (BB-2590) 2 181 2 181 Weight / Battery (BB-2590) Fuel Flow, When Running Round Trip Efficiency Fuel Flow, Mission Average Fuel Needed Unit Empty Weight Total System Mass, Starting Specific Energy, Starting Equivalent BA-5590 (169 W-hr / kg) Batteries Cost of BA-5590 Batteries , @ MGS Weight Advantage (Ratio) Wh / Batt.

kg / Batt.

g/min % g / min kg kg kg W-hr / kg # Batt.

kg $70 1.20

81% 0.66

2.8

1.9

7.6

189 8 8 $ 1.1

1.45

560 1.20

81% 0.66

9.5

1.9

14.2

337 28 29 $ 1,960 2.0

0.66

81% 0.36

1.6

1.0

5.5

263 8 8 $ 1.5

1.45

560 0.66

81% 0.36

5.2

1.0

9.1

526 $ 28 29 1,960 3.1

Integration / Packaging

Fuel Tank Air Intake Tract 2005.05.02

MGS-50 : Current Status

2005.05.02

Engine + Starter / Generator (Upside Down) Engine Assy.

Power Electronics + Control Electronics Buffer Batteries (Hybrid Power) Assembled Prototype

MGS-50 Next Steps

2005.05.02

1. Revise Engine from Alpha to Beta Configuration 2. Incorporate Variable-Cooling Scheme for All Ambient Temps.

3. Optimize Encapsulation and Packaging 4. Deliver Several Units for Field Testing 5. Transition to LRIP / Full-Scale Productions

Outline

1.

2.

3.

2005.05.02

50 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 0.1 hp Diesel Engine Goals, Current Status, Residual Challenges, Future Plans

700 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 1.3 hp Diesel Engine Current Work in Process for DARPA + SOCOM Future Plans : 2-Cylinder Engine, 4-Stroke Engine

Future Plans : 2-Cyl. Engine, 4-Stroke Engine

Portable Power, Hybrid-Electric Drive, APUs

Basis of D-STAR 700 Watt Micro Generator Set DARPA-Funded 1.3 hp Micro-Diesel Engine



Successful Operation on JP8 + Oil, No Volatile Additives



Beat SFC Goal by 20%



Beat Life Goal by > 600%

Life Goal : 10 hours.

One Engine : 70 Hrs (Living) Total Time : 250+ Hours

D-STAR 0.54 cu. in.

Micro-Diesel Engine

1.4 hp 1.4 lb Wt.



Performance Verified by Army @ Redstone Goal 1.3 hp, Made 1.5 + hp

2005.05.02

D-STAR Mini-FADEC

MGS-700 : Goals Honda 700W Unit Gasoline 26 lbs.

2005.05.02

D-STAR 700 W Unit Diesel 15 lbs.

D-STAR Diesel Gen Set is Half-the-Size, Half-the-Weight of Honda Gasoline Gen-Set

MGS-700 : Work in Progress 1.

Core Power Unit : Breadboard Testing in Process

2005.05.02

Packaging : Under Design

MGS-700 : Engine + Starter/Generator on Test Stand

2005.05.02

MGS-700 : Engine + Starter/Generator on Test Stand : Max. Pwr.

D-STAR GenSet GS-700 1/5/2005 16,000 800 Power 14,000 700 Speed 12,000 600 10,000 8,000 500 400 Speed Watts 6,000 4,000 2,000 300 200 100 0 4:12:00 PM 4:19:12 PM 4:26:24 PM 4:33:36 PM 4:40:48 PM Time (Clock hh:mm:ss) 4:48:00 PM D-STAR Engineering Corporation, All Rights Reserved Approved for Public Release, Distribution Unlimited 0 4:55:12 PM 2005.05.02

MGS-700 : Engine + Starter/Generator on Test Stand : Max. Pwr.

MGS-700 : Engine + Starter/Generator on Test Stand : MC Power D-STAR GenSet GS-700 1/6/2005 14000 1400 12000 1200 10000 8000 6000 4000 2000 200 Speed Watts 0 0 4:03:22 PM 4:13:26 PM 4:23:31 PM 4:33:36 PM 4:43:41 PM 4:53:46 PM 5:03:50 PM 5:13:55 PM Time (Clock hh:mm:ss) D-STAR Engineering Corporation, All Rights Reserved Approved for Public Release, Distribution Unlimited 2005.05.02

1000 800 600 400

MGS-700 : Engine + Starter/Generator on Test Stand : MC Power D-STAR GenSet GS-700 1/7/2005 1.20

1,200 1.00

1,000 0.80

800 0.60

600 0.40

1-Hour Run at Max. Cont. Power Average Power = 709 W (28 V DC) 400 Average Engine-SFC = 0.81 lb/bhp-hr 0.20

200 SFC Watts 0.00

0 2:57:07 PM 3:07:12 PM 3:17:17 PM 3:27:22 PM 3:37:26 PM 3:47:31 PM 3:57:36 PM 4:07:41 PM Time (Clock hh:mm:ss) D-STAR Engineering Corporation, All Rights Reserved Approved for Public Release, Distribution Unlimited 2005.05.02

D-STAR MGS-50 : Diesel Fueled Micro Generator Set System efficiency calculations Peak

Efficiency : engine mech. to net elect. (%)

SFC (lb/HP/hr) Fuel flow (g/min) Fuel energy, Lower Heating Value (MJ/kg) Engine mech output energy (MJ/kg)

Efficiency : fuel LHV to engine (%) Overall efficiency - Fuel to DC Output (%) Today

700 2.5

85% 1 704

93%

757

85%

99 990

71% 0.82

8.2

42.8

7.22

17% 12% Goal

700 2.5

85% 1 704 93% 757 85% 99 990

71%

0.82

8.23

42.8

7.22

17% 12% Continuous Today

600

Goal

600 2.5

85% 1 604

93%

649

85%

85 849

71% 0.82

7.1

42.8

7.22

17% 12%

2.5

85% 1 604 93% 649 85% 85 849

71%

0.82

7.06

42.8

7.22

17% 12%

D-STAR MGS-50 : System Performance Comparison for 3-day and 10-Day Missions Current Actual Goal Mission Length Power Needs, Average, 12 Soldiers Energy Requirement Days Hours Watts W-hr 3 72 240 17280 10 240 240 57600 3 72 240 17280 10 240 240 57600 Number of Batteries (BB-2590) Energy / Battery (BB-2590) 0 181 0 181 Weight / Battery (BB-2590) Fuel Flow, When Running Round Trip Efficiency Fuel Flow, Mission Average Fuel Needed Unit Empty Weight Total System Mass, Average Specific Energy, Average Equivalent BB-2590 (125 W-hr / kg) Batteries Wh / Batt.

kg / Batt.

g/min % g/min kg kg kg W-hr / kg # Batt.

kg 7.10

86% 3.28

14.2

10.0

17 1011 95 138 1.45

7.10

86% 3.28

47.3

10.0

34 1712 318 461 7.10

86% 3.28

14.2

7.0

14 1226 95 138 1.45

7.10

86% 3.28

47.3

7.0

31 1880 318 461 MGS Weight Advantage (Ratio) 8 14 10 15

D-STAR MGS-50 : System Performance Comparison for 3-day and 10-Day Missions Current Actual Goal Mission Length Power Needs, Average, 12 Soldiers Energy Requirement Days Hours Watts W-hr 3 72 240 17280 10 240 240 57600 3 72 240 17280 10 240 240 57600 Number of Batteries (BB-2590) Energy / Battery (BB-2590) Weight / Battery (BB-2590) Fuel Flow, When Running Round Trip Efficiency Fuel Flow, Mission Average Fuel Needed Unit Empty Weight Total System Mass, Average Specific Energy, Average Equivalent BB-2590 (125 W-hr / kg) Batteries MGS Weight Advantage (Ratio) Wh / Batt.

kg / Batt.

g/min % g/min kg kg kg W-hr / kg # Batt.

kg 7.10

86% 3.28

14.2

10.0

52 333 95 138 3 24 181 1.45

7.10

86% 3.28

47.3

10.0

68 841 318 461 7 7.10

86% 3.28

14.2

7.0

49 353 95 138 3 24 181 1.45

7.10

86% 3.28

47.3

7.0

65 880 318 461 7

D-STAR MGS-50 : System Performance Comparison for 3-day and 10-Day Missions Current Actual Goal Mission Length Power Needs, Average, 12 Soldiers Energy Requirement Days Hours Watts W-hr 3 72 240 17280 10 240 240 57600 3 72 240 17280 10 240 240 57600 Number of Batteries (BB-2590) Energy / Battery (BB-2590) Weight / Battery (BB-2590) Fuel Flow, When Running Round Trip Efficiency Fuel Flow, Mission Average Fuel Needed Unit Empty Weight Total System Mass, Starting Specific Energy, Starting Equivalent BA-5590 (169 W-hr / kg) Batteries Cost of BA-5590 Batteries , @ MGS Weight Advantage (Ratio) Wh / Batt.

kg / Batt.

g/min % g/min kg kg kg W-hr / kg # Batt.

kg $70 7.10

86% 3.28

14.2

10.0

24.2

714 100 102 $ 7,000 4 0 181 1.45

$ 7.10

86% 3.28

47.3

10.0

57.3

1006 335 342 23,450 6 7.10

86% 3.28

14.2

7.0

21.2

816 100 102 $ 7,000 5 0 181 1.45

$ 7.10

86% 3.28

47.3

7.0

54.3

1061 335 342 23,450 6

D-STAR MGS-50 : System Performance Comparison for 3-day and 10-Day Missions Current Actual Goal Mission Length Power Needs, Average, 12 Soldiers Energy Requirement Days Hours Watts W-hr 3 72 240 17280 10 240 240 57600 3 72 240 17280 10 240 240 57600 Number of Batteries (BB-2590) Energy / Battery (BB-2590) 24 181 24 181 Weight / Battery (BB-2590) Fuel Flow, When Running Round Trip Efficiency Fuel Flow, Mission Average Fuel Needed Unit Empty Weight Total System Mass, Starting Specific Energy, Starting Equivalent BA-5590 (169 W-hr / kg) Batteries Cost of BA-5590 Batteries , @ MGS Weight Advantage (Ratio) Wh / Batt.

kg / Batt.

g/min % g/min kg kg kg W-hr / kg # Batt.

kg $70 7.10

86% 3.28

14.2

10.0

59.0

293 100 102 $ 7,000 2 1.45

$ 7.10

86% 3.28

47.3

10.0

92.1

625 335 342 23,450 4 7.10

86% 3.28

14.2

7.0

56.0

308 100 102 $ 1.45

7,000 2 $ 7.10

86% 3.28

47.3

7.0

89.1

646 335 342 23,450 4

MGS-700 : Stand-Alone Test Unit (Semi-Packaged Prototype)

MGS-700 : Stand-Alone Test Unit : Front View

2005.05.02

Exhaust Pipe

MGS-700 : Stand-Alone Test Unit : Rear View

2005.05.02

Aux. Blower (Interim Prototype Only) Internal Batteries

Outline

1.

2.

3.

2005.05.02

50 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 0.1 hp Diesel Engine Goals, Current Status, Residual Challenges, Future Plans

700 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 1.3 hp Diesel Engine Current Work in Process for DARPA + SOCOM Future Plans : 2-Cylinder Engine, 4-Stroke Engine

Future Plans : 2-Cyl. Engine, 4-Stroke Engine

Portable Power, Hybrid-Electric Drive, APUs

MGS-700 : Future Plans 1.

MGS-1500 : 1.5 kW Unit Based on 2-Cylinder Engine

2005.05.02

Long-Endurance Unit Based on 4-Stroke Engine for Greater Fuel Economy

Current Marine Corps Program Hybrid Power System for Small UGVs

2005.05.02

Objectives :

Replace Current Low-Speed Engine with Hydro-Static Drive by Compact, Light-Weight Hybrid-Electric Power System

D-STAR Concept

High-Speed Mini-Diesel Engine and Starter-Generator Remote Wheel Motors with Plug-and-Play Modular Architecture Hybrid-Electric Operation with Batteries, Super-Capacitors, Electro-Turbo-Compounding D-STAR Engineering Corporation, All Rights Reserved Approved for Public Release, Distribution Unlimited 2005.05.02

Current Marine Corps Program Hybrid Power System for Small UGVs

72” 2005.05.02

Conclusions

2005.05.02

D-STAR Micro-Diesel Engines are Logistics Fueled Source of Power.

Compared to Batteries, D-STAR Micro Gen Sets Offer : An Order of Magnitude Greater Energy Density An Order of Magnitude Lower Costs.

3. D-STAR Micro Gen Sets are Close to Transitioning to Production.

D-STAR Engineering Corporation, All Rights Reserved Approved for Public Release, Distribution Unlimited 2005.05.02 Logistics-Fueled, Man-Portable Generator Sets for Soldier Power, Battery Charging and APU.

Transcript D-STAR Engineering Corporation, All Rights Reserved Approved for Public Release, Distribution Unlimited 2005.05.02 Logistics-Fueled, Man-Portable Generator Sets for Soldier Power, Battery Charging and APU.

Logistics-Fueled, Man-Portable Generator Sets for Soldier Power, Battery Charging and APU Needs

A Presentation to the

NDIA Tri-Service Power Expo

May 02, 2005 Tampa Convention Center, Tampa, Florida by S. Paul Dev, President D-STAR Engineering Corporation

Outline

1.

2.

3.

50 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 0.1 hp Diesel Engine Goals, Current Status, Residual Challenges, Future Plans

700 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 1.3 hp Diesel Engine Current Work in Process for DARPA + SOCOM Future Plans : 2-Cylinder Engine, 4-Stroke Engine

Future Plans : 2-Cyl. Engine, 4-Stroke Engine

Portable Power, Hybrid-Electric Drive, APUs

System Overview

Regulator:

Control Panel Interface:

D-STAR 50-Watt Personal Power Unit

D-STAR 50-Watt Personal Power Unit

Integration / Packaging

MGS-50 Next Steps

1. Revise Engine from Alpha to Beta Configuration 2. Incorporate Variable-Cooling Scheme for All Ambient Temps.

3. Optimize Encapsulation and Packaging 4. Deliver Several Units for Field Testing 5. Transition to LRIP / Full-Scale Productions

Outline

1.

2.

3.

50 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 0.1 hp Diesel Engine Goals, Current Status, Residual Challenges, Future Plans

700 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 1.3 hp Diesel Engine Current Work in Process for DARPA + SOCOM Future Plans : 2-Cylinder Engine, 4-Stroke Engine

Future Plans : 2-Cyl. Engine, 4-Stroke Engine

Portable Power, Hybrid-Electric Drive, APUs

Outline

1.

2.

3.

50 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 0.1 hp Diesel Engine Goals, Current Status, Residual Challenges, Future Plans

700 Watt Heavy-Fueled Micro-Generator Set

Basis : Successful DARPA-Funded 1.3 hp Diesel Engine Current Work in Process for DARPA + SOCOM Future Plans : 2-Cylinder Engine, 4-Stroke Engine

Future Plans : 2-Cyl. Engine, 4-Stroke Engine

Portable Power, Hybrid-Electric Drive, APUs

Current Marine Corps Program Hybrid Power System for Small UGVs

Objectives :

D-STAR Concept

Current Marine Corps Program Hybrid Power System for Small UGVs

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