AUV Power and Endurance 24 April 2002

Transcription

1 ARL AUV Power and Endurance 24 April 2002 Presented by: Dr. Thomas G. Hughes Head, Energy Systems Division Presented to: Fifth International Symposium Technology and the Mine Problem Applied Research Laboratory P. O. Box 30 State College, PA

2 Representative AUVs 26.5 Diameter 21 Diameter 38 Diameter

3 Volume To Surface Area Ratio CUBIC FEET PER SQUARE FOOT P d 7 d d UUV DIAMETER [IN]

4 Representative Propulsors Weed Guard Rotor Inlet Guide Vane (IGV) Shroud Control Fin Fwd Hull Aft Hull Inlet Guide Vanes Actuator Stator Shroud TVPJ Control Fin Load Button Motor NC Interface nnnector and lkhead (not pictured) PCIU (7x7x7) Rotor Motor Ring Mounts A Cable Hull Connector Drive Train With Shaft, Bearings and Seawater Seal

5 Power vs Speed (38" dia. UUV) POWER [KW] Propulsion 4 2 Hotel UUV SPEED [KTS]

6 Range versus Speed (38" dia. UUV with 500 W Hotel Load) RANGE [NM] UUV SPEED [KTS]

7 The Optimum AUV Power System Range Simple to Refuel Speed Stealth Exerciseability Easy Turnaround Weight Volume Environmentally Benign Direct Costs Performance to Complete Mission Batteries Fuel cells Affordable Cost Heat engines Thermoelectrics

8 Molecular Structure Defines the Available Energy s' Hydrogen 3 H Li Al s' 2s' 2.70 Lithium [Ne] 3s 2 p 1 Aluminum s 2 2s 2 p 4 Oxygen O s 2 2s 2 p 5 Fluorine F

9 hp hr per ft^3 or 100 lbm JP5/LOX Li/SF6 Al/H2O LH2/LOX Li/H2O JP5/atm Reactant Energy Density and Specific Energy Reactants hp hr/100 lb hp hr/ft^3

10 Nuclear versus Chemical ~10 hp hr lbm 7 Fission U 235 ~10 hp hr lbm JP5 in air (free)

11 Batteries Active Materials 36.00% Grids 21.50% Top Lead 4.70% Container, lid, ventplugs, separators 10.30% Electrolyte 27.50% Single Cell

12 Theoretical and Actual Capacity of Batteries Watthours/kilogram Handbook of Batteries & Fuel Cells, David Linden, ed., McGrawHill, Inc. 1984

13 NOO Vehicle Batteries Batteries mounted in 12 aluminum cylinders. Batteries arranged in pucks of 48 Dcells, 8 pucks in parallel per group, 4 groups per series (2 groups per can). Room for 9 pucks per group, all pucks individually fused. With new batteries, open circuit voltage ~288V; 230V under load. Intelligent interface board monitors temperature, group current, puck voltages, leak. Testing indicates battery capacity is well above requirement for 300 nmi.

14 ARL Texeco Ovonic GMO Ahr Nickel Metal Hydride Battery Configurable Can be ordered with different number of cells Fairly quick delivery Reasonable packaging effort required Relatively cost effective Weight: lbs for 11 cell battery Volume: 453 cu. In for 11 cell battery Estimate: 35.6 lbs for 10 cell battery 17.8 lbs for 5 cell battery

15 ARL GMO0900 Battery Specifications Quoted from manufacturer s manual Nominal Capacity 1 85 Ahr Nominal Energy Kwhr Specific Energy 1 67 Whr/kg Energy Density Whr/l Peak Specific Power W/kg Peak Power Density W/l Cycle Life >500 Discharge Rate 0 to 200A 1 Based on a 30 A rate discharge to 1 volt/cell at 70 F and a 90% manufacturing conformance level of initially achieving at least 90% of specified value 2 Based on calculation from 30 second constant current discharge of 300 amps at 70 F

16 LELFAS NiMH Battery Module Configuration: 10 Rows of batteries Each row: 2Ten cell & 2Five cell batteries Total: 20 Ten cell batteries (12V) 20 Five cell batteries (6V) Battery configurations allow for fine tuning the total voltage and weight. 300 cells at nominal 1.2V = 360V Total Battery Weight: 1070 lbs Batteries will be operated and charged in the ventup orientation ARL Total energy: ~ 35kWhr Usable energy will be less due to voltage and current limitations

17 ARL Battery Charging: Prerun top off is needed, NiMH batteries are expected to lose up to 2% per day at 70 F; 4% per day at 100 F. (Back of a truck or deck of a ship in summer) Low rate charging will be implemented through the umbilical. It will be isolated before launch. Cyclic charging between runs accomplished with external power supply. Control TBD. Shells will be vertically oriented for charging.

18 Fuel Cells Load H 2 O (u), N 2, O 2 e Excess Hydrogen Stack H Air Hydrogen (fuel) Cathode Anode Proton Exchange Membrane (PEM) Schematic System Testing

19 Fuel Cell System Schematic Fuel Storage Excess Water and CO 2 Reformer or H 2 Storage Hydrogen Separator/ Conditioner Heat Exchanger Pump Fuel Cell Stack Oxygen Storage/ Generator Oxygen Conditioner

20 Site Performance Summary Table Through January 31, 2002 SITE NAME SERVICE START DATE OPER. HOURS MWHRS OUTPUT AVG KW ELEC. EFF. AVAIL. MODEL B UNITS Naval Station Newport Navy 1/23/ ,375 6, % 76.1% U.S. Army Soldier Systems Center Army 1/27/ ,608 6, % 61.2% Picatinny Arsenal Army 10/11/ ,053 5, % 62.4% Watervliet Arsenal Army 10/29/ ,875 4, % 77.3% US Military Academy Army 11/17/ ,393 4, % 63.0% Fort Eustis Army 9/12/ ,075 4, % 50.7% Naval Hospital MCB Camp Marines 10/6/ ,859 4, % 55.1% 934 th Airlift Air Force 2/1/ ,777 4, % 48.2%

21 Site Performance Summary Table Data through February, 2002 SITE NAME FUEL CELL STARTUP Oper. Hours kwh Output Input Fuel (MMBTU) Electri Efficiency Avail. Sierra Army Depot May 2002* Brooks AFB Dec 2002* MCB Kaneohe Bay Dec 2002* Ft. Bragg Dec 2002* Ft. Jackson Dec 2002* Barksdale AFB Dec 2002* Patuxent River NAS Oct 2002* Patuxent River NAS Oct 2002* Geiger Field Mar 6, 2002 Watervliet Arsenal/ Officer s Quarters 1/15/2002 3,921 9, % 95% Watervliet Arsenal/Research Facility 1/18/2002 2,852 7, % 98% Watervliet Arsenal/ Manufacturing Facility 1/18/2002 2,860 7, % 98% * Projected Fuel Cell Installation Date

22 Oxygen Storage lbm/ft^ O2(3000psia gas) H2O2(70%) O2(6000psia gas) Source H2O2(90%) NaClO3 O2(liquid) LiClO4 lbm sub/ft^3 lbm O2/ft^3

23 Hydrogen Storage lbm/ft^ H2(3000 psia) FeTiHx Source H2 Liquid Carbon SWNT's Reforming Al(H2O) lbm sub/ft^3 lbm H2/ft^3

24 ARL Heat Engine Systems Balancer lternator Stirling Engine ck ombustor Status: 3 kw Design, 2.2 kw 44% Efficiency Design, 35% Prototype Engine Operated 100hours Fuel Tank

25 ARL Stirling Engine REGENERATOR Cold End Gas Alternator Mover Gas Displacer Piston Gas Hot End Schematic

26 ARL Wick Combustor 8Li SF 6 6LiF Li 2 S Stirling Heater Tubes Enhanced Surface Area Flame Porous Combustor Structure Oxidant Injector Start / Restart Module Trap / Heat Shield Differential Pressure Membrane Fuel Feed Arteries Fuel Products

27 ARL Compact Turbine/Alternators 1 ST Generation 2 ND Generation 3 RD Generation

28 ARL Combustors C 10 H O 2 70 H 2 O Æ 10 CO H 2 O 70 H 2 O Diluent Oxygen Fuel Mixed Products Oxygen Diluent Max power Max depth Temperature Isosurface is 12% liquid water Contours are diluent mass fraction

29 Thermophotovoltaics/Thermoelectrics Thermal Radiator (ARL) (from Scientific American) TPV Assembly (KAPL)

30 Converter Weights and Volumes 350 Hp Turbine _ Hp Stirling 1 Hp Fuel Cell 30 lbs.5 ft 3 55 lbs.25 ft 3 16 lbs.15 ft 3

31 Generating Electricity.35 Kw Alternator.8 Kw Fuel Cell 3 Kw Alternator 3 Kw Alternator 3 lbs 17 in 3 6 lbs 38 in 3 24lbs 137 in 3 16 lbs 248 in 3

32 Range vs Speed for SEAHORSE UUV (with various power systems) Range [nm] Wick/Stirling Wick/Rankine Lithium Battery (Primary) Fuel Cell (Cryo) JP5 H 2 O 2 (Rankine) JP53000 psi O 2 (Rankine) Lithium Battery (Secondary) Silver Zinc Battery (Seconda Speed [knots]

33 Summary No energy system is optimum for all applications; most are for some. Performance varies by an orderofmagnitude among the candidates. Cost and performance tend to vary inversely. Expect about a twofold improvement in emerging technologies in the next decade.