fuels and power at us army tardec - nc military … (nac) chartered by secretary of the army 21 june...
TRANSCRIPT
Fuels and Power at US Army TARDECPaul F. SkalnyDirector, U.S. Army TARDEC – National Automotive Center
North Carolina Military Foundation - Fuels and Power Event
28 Jan 2010 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
2UNCLASSIFIED
Agenda
• Introduction
• Ground Vehicle Power and Energy
• End-to-End Energy
• Fuels Qualification / Certification
• Closing
3UNCLASSIFIED
– Provides full life-cycle engineering support and is provider-of-first-choice for all DODground combat and combat support weapons and vehicle systems.
– Develops and integrates the right technology solutions to improve Current Force effectiveness and provide superior capabilities for the Future Force.
Responsible for Research, Development and Engineering Support to 2,800 Army systems and many of the Army’s and DOD’s Top Joint Warfighter Development Programs
Tank Automotive Research, Development & Engineering Center (TARDEC)
Ground Systems Integrator for the Department of Defense
UNCLASSIFIED
4UNCLASSIFIED
Portfolio
Combat Vehicles • Heavy Brigade Combat Teams• Strykers• MRAPs• Ground Combat Vehicles (Future)
Tactical Vehicles• HMMWVs • Trailers• Heavy, Medium and Light
Tactical Vehicles
Force Projection• Fuel & Water Distribution • Force Sustainment • Construction Equipment • Bridging • Assured Mobility Systems
Robotics• Technology Components• Demonstrators• Military Relevant Test & Experimentation• Transition and Requirements Development
4UNCLASSIFIED
5UNCLASSIFIED
Technology Thrust Areas
Ground Vehicle Power & Mobility• Prime Power (Powertrain)• Non Primary Power• Power & Thermal Management• Energy Storage• Track & Suspension• Alternative Energy
Ground Systems Survivability• Integrated Vehicle Protection Systems• Active Defense• Signature Management• Laser Vision Protection• Ballistic Protection• Crew Survivability
Force Projection Technology • Water Generation, Purification, Storage, Distribution & Quality Surveillance (QS)
• Petroleum Storage, Distribution & QS• Material Handling Equipment• Petroleum, Oils & Lubricants Technology• Mechanical Countermine Equipment• Tactical Bridging•Alternative Fuels
Intelligent Ground Systems • Autonomous Robotics Systems•Safe Operations Technologies • Indirect Vision Technologies • Unmanned Systems Technology Development
• 360°Situational Awareness Technologies • Soldier Machine Interfaces• Connected Vehicles
Vehicle Electronics & Architecture
• Electronics Integration• Data Architecture• Condition-Based Maintenance (CBM+)• Power Architecture/Management
Systems Engineering
5UNCLASSIFIED
6UNCLASSIFIED
Mission: “The Center will serve as the Army focal point for the
development of dual-use automotive technologies and their application to
military ground vehicles. It will focus on facilitating joint efforts between
industry, government and academia in basic research, collaboration,
technology, industrial base development and professional development.”
U.S. Army National Automotive Center (NAC)
Chartered by Secretary of the Army 21 June 1993
“Leveraging Opportunities to Fill Technology Gaps.”
“Accelerating the infusion of commercially viable technology into military land warfare systems”
7UNCLASSIFIED
Increases Heat Rejection LoadsLow-grade Heat, Heat Sensitive Electronics
Army Ground Vehicle Power and Energy Drivers
NET-CENTRIC WARFAREWFO#1: Battle Command NetworkNet-Centric KPP
SURVIVABILITYWFO #2: Counter IED and MineSystem Survivability KPP
ENVIRONMENTAL CONTROLWFO #4: Human Dimension
INCREASING POWER DEMANDWFO #3: Power and EnergyEnergy Efficiency KPP
Air Conditioning Thermal Condenser Heat Load
Power for Air ConditioningCompressor, Fan
Vehicle Weight Growth
Additional Armor, Mine Kits
Low-Grade HeatSilicon based Power Electronics
Continuous Power for C4ISRNode on Network, High Bandwidth
Power for APS, IED DefeatElectric Armor, Electric Warfare
REQUIREMENTS DRIVERS FOR POWER AND ENERGY GROWTH ON MILITARY GROUND VEHICLES:
Power for Mobility
Hybrid Electric Drivetrain, Increase Dash/ Top Speed
Future ground vehicle will demand more electric powerThermal loads and rising vehicleweights compound power issuesEfficiency critical to reducing system power demands
Electrical BurdenThermal BurdenWeight Burden
LEGEND:
Increasing power demand, heat rejection difficulties, and vehicle weight gain are all interrelated problems that require a coordinated response across RDECOM.
8UNCLASSIFIED
Ground Vehicle Power and Energy Technology Taxonomy
Gro
und
Vehi
cle
Pow
er a
nd E
nerg
y Te
chno
logy
Pow
er
Gen
erat
ion
Ener
gy S
tora
geTh
erm
al
Tran
spor
t &
Dis
trib
utio
n
Pow
er C
ontr
ol &
D
istr
ibut
ion
Trac
k &
Su
spen
sion
JP-8 Fuel Cells
Rotary Engines Alternators
Integrated Starter Generator
Turbine Engines
Diesel Engines
Transmissions Traction Motors
Drivelines
Li-Ion / Ultracap Hybrid Energy Storage Capacitors Advanced Batteries
Fuels
RadiatorsHeat Recovery
Thermal Interface Materials Phase Change CoolingAdvanced Electronics
CoolingThermal
Architectures
High Temp Inductors
High Temperature Capacitors
Power Controllers for Power Management Power Converters/Inverters
Wide Band Gap Materials (SiC)
High Temperature SiC Modules Pulse Power
Switching
Track Systems
SuspensionSystems
Elastomer Research
Electronic Stability Control
8
10UNCLASSIFIED
End-to-End Energy Initiatives
Alternative Fuel Vehicles & Infrastructure
Domestic Manufacturing Capability
CellsModules Packs
Dual-Use Applications
Advanced Automotive Batteries Enabler of Alternative Energy
Alternative Fuels Program
Fuel EvaluationsChemical CompositionPhysical propertiesFuel system impacts
Engine EvaluationsFuel ignitabilityFuel combustionPerformance / durability
System EvaluationsFuel-system interactionsSystem performance and durabilityFuel specification inputsSuitability of fuel for use in Army
equipment
SANGB HydrogenFilling Station
Advanced Mobile
Microgrid
11UNCLASSIFIED
Electronic Power Conditioning & Control – Distributed Generation
Mobile Encampment Waste to Electrical Power (MEWEPS)
Plug-in Hybrid Electric Vehicles (PHEV)
Vehicle Inputs
Renewable Inputs
Generator Inputs
Tactical Quiet Generator (TQG)
Electric Power Control and Conditioning (EPCC)
Solar
Supply – Infrastructure - Demand
12UNCLASSIFIED
Alternative Source Liquid Hydrocarbons for DoD Ground Systems (Tactical/Combat)
Fossil Energy Feedstock(large U.S. resource)
coal
petcokeoil shale
• Various conversion processes dependent on feedstock• Product meeting military or commercial fuel specifications
tallow, fats, lard
wood waste &by-products
agri-wastenon-foodcrops
algae
Biomass Feedstock(renewables)
Petroleum Crude Oil
(declining discovery and production)
Jet Fuels / JP-8
• Blending Stock (FT SPK, HRJ)• “Drop in”• Single Fuel in the Battlefield*
Diesel Fuel / Commercial
• Blending Stock (B100)• “Drop-in” (HRD?, FTD?)• Fuel most Army ground engines designed to operate on *Diesel fuel in ground equip. allowed when supplying
jet fuel not practicable or cost effective
13UNCLASSIFIED
Qualification / Certification Pipeline
Systems Engineering
RDT&E / Qualification
??
TRL 1 TRL 5-6
CertificationTRL 9
100% FT
100% bio
Fuels may travel along conveyor at different rates!
HRJ moving fast, “drafting” FT SPK
DARPA
**Approved Fuels, ASTM D7566Specification for Aviation Turbine Fuels Containing Synthesized Hydrocarbons
non-HRJ bio
Courtesy Dr. Tim Edwards, AFRL (modified)
• Issued September 2009• Criteria for production, distribution, and use of FT jet fuels made from coal, natural gas, or biomass. • Future versions may allow synthetic jet fuels produced using other processes once they are qualified.
Jet A/A-1
JP-8/5
Fischer-Tropsch Synthetic Paraffinic Kerosene (FT SPK)Hydroprocessed Renewable Jet (HRJ)Semi-Synthetic Jet Fuel (SSJF)Fully Synthetic Jet Fuel (FSJF)
HRJ“50/50” blends
Civil Aviation HRJ“50/50” blends
USAF
Potential Alternative
Fuels
Incubator
14UNCLASSIFIED
RDT&E of Alternative Ground Fuels
Systems Engineering
Market ConnectionManufacturing technologyFuel data, samplesMarket drivers
EMERGINGALTERNATIVE FUELS MARKET
DODDOEIndustryAcademiaFuel ProducersEquipment OEMsOther Government AgenciesStandards Development Organizations
Fuel / Component EvaluationsChemical compositionPhysical propertiesComponent performance / durability
Engine EvaluationsFuel ignitabilityFuel combustionPerformance / durability
System EvaluationsOperabilityPerformanceDemonstrations
Approval and acceptability of alternative fuels for use in
DOD ground equipment.
Poor lubricity fuel may cause increased wear rates in fuel injectors and injection pumps.
Fuel with low cetane ratings may cause cold-starting problems, and misfire and combustion instability, esp. for lt-med load operation.
Low fuel viscosity may result in fuel pump internal leakage and associated loss of power.
Fuel Qualification
15UNCLASSIFIED
Alternative Fuels Qualification
Systems Engineering
Laboratory Evaluations
Component Evaluations
System Evaluations Demonstrations
Build user knowledge of and confidence in use of fuel.
• Completed– Fuel chemical composition and properties– Materials compatibility evaluations– Fuel blends studies– Limited component/engine/system testing (ground equipment)– Test track evaluation (HMMWV)– Tactical Wheeled Vehicle pilot field demo
• In Progress – Some engine testing (NATO test cycle)– Fuel injection test rig testing (rotary pump, high pressure common rail) – Cetane - Volatility window studies
• Planning– Tactical generator sets testing– Additional component/engine/system testing and demos (including Army Aviation)
Develop data needed to assess fuel’s suitability for use.
Blends of FT SPK and JP-8 undergoing qualification; based on similarity of HRJ with FT SPK, blends of HRJ and JP-8 will be integrated to conduct a concurrent qualification.
Timelines for evaluations and demos dependant on the availability of test fuel volumes required.
16UNCLASSIFIED
Beyond Traditional BoundariesNew Partnership Strategies…
Memorandum of Agreement with DOE, Energy Efficiencyand Renewable Energy, Office of Vehicle Technologies
Department of Energy (DOE) $25B Loan GuaranteeTARDEC supported review of proposals that leveraged expertise in Ground Vehicle Power & Mobility and Lightweight Materials
Alliance(s) with MEDC, DOE, Oakridge National LaboratoryAdvanced BatteriesAdvanced Lightweight MaterialsAlternative Fuels
Advanced Automotive Battery InitiativeIndustry, Government and Academia vetted White Paper
Advanced Vehicle & Power InitiativeIndustry, Government and Academia vetted White Paper
Michigan Economic Development Corporation (MEDC)Cooperative Research and Development Agreement (Centers of Energy Excellence)Michigan Automotive Robotics Cluster (MARC)
User Forums: Hybrid Truck Users Forum (HTUF); Commercial Construction Equipment Users Forum (CCEUF); Class 8 Truck Users Forum (Class8TUF)
Fuel Efficiency ground vehicle Demonstrator (FED)