ITC-Germany Visit. Chuck Coutteau, Associate Director Ground Vehicle Power and Mobility Overview 10 November 2011
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1 ITC-Germany Visit Chuck Coutteau, Associate Director Ground Vehicle Power and Mobility Overview 10 November 2011 : Distribution Statement A. Approved for public release.
2 Report Documentation Page Form Approved OMB No Public reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington VA Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. 1. REPORT DATE 10 NOV REPORT TYPE Briefing Charts 3. DATES COVERED to TITLE AND SUBTITLE Ground Vehicle Power and Mobility Overview GERMANY VISIT 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) Gary Stuber; Chuck Coutteau 5d. PROJECT NUMBER 5e. TASK NUMBER 5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) U.S. Army TARDEC,6501 E.11 Mile Rd,Warren,MI, SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) U.S. Army TARDEC, 6501 E.11 Mile Rd, Warren, MI, PERFORMING ORGANIZATION REPORT NUMBER # SPONSOR/MONITOR S ACRONYM(S) TARDEC 11. SPONSOR/MONITOR S REPORT NUMBER(S) # DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited 13. SUPPLEMENTARY NOTES Presented during Germany Visit. 14. ABSTRACT NA 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT a. REPORT unclassified b. ABSTRACT unclassified c. THIS PAGE unclassified Same as Report (SAR) 18. NUMBER OF PAGES 14 19a. NAME OF RESPONSIBLE PERSON Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18
3 Ground Vehicle Power & Mobility(GVPM) Mission & Vision Vision: GVPM will be the DoD s first choice for ground systems power and mobility solutions Survivability Transmissions Ground Systems Robotics Intelligent Systems Fuel, Water, Bridging, lubricants, mine roller Vehicle Electronics & Architecture Mission: Research, develop and deliver ground systems power and mobility technology solutions to the current and future force Unclassified 2
4 Selecting the Right Technologies to Meet the Challenges Primary Power Demand Electrical Power Demand Vehicle Agility Requirements Fuel Consumption Increasing demands, operational flexibility, and inter-relationships Requires a Systems Engineering approach and investments in key technology areas Propulsion & Thermal Management Non-Prime Power Systems Propulsion Track & Suspension Systems Level Analysis, Integration and Testing
5 S&T Vectors for Improving Operational Energy Efficiency Pursue Operational Energy Efficiency by targeting the Army s Energy Security Goals Reduced Adverse Impacts on the Environment Operational Energy: energy required for training, moving, and sustaining military forces and weapons platforms for military operations QDR Increased Use of Renewable / Alternative Energy Assured Access to Sufficient Energy Supplies Reduced Increased Energy Energy Efficiency Across Consumption Platforms and Facilities 4
6 Framework for Meeting Army Energy Security Goals ESG 1: Reduce Energy Consumption ESG 2: Increased Energy Efficiency Across Platforms and Facilities ESG 3: Increased Use of Renewable / Alternative Energy ESG 4: Assured Access to Sufficient Energy Supplies ESG 5: Reduced Adverse Impacts on the Environment Powertrain Modernization Vehicle Electrification Propulsion with On-Board Vehicle Power Develop Synthetic Fuels Lightweighting Track & Wheel Designs Increased Energy Storage Qualify Engines for Synthetic Fuels Auxiliary Power Unit Driver Assist Technologies Alternative Energy Storage Technologies Smart Grids Next Generation Engines High-temp / lowfriction materials Energy Harvesting Thermal Management Alternative Power Solutions Intelligent Power Management 5
7 Operational Energy Focus Why we need it 70-80% of convoys deliver fuel and water in a typical theater Fully burdened cost of fuel (FBCF) as high as $50 /gal in Afghanistan 18% of US casualties in OIF and OEF are related to ground resupply What needs to be done Build Operational Energy into Army requirements and funding processes What s required to enable haust 8% Exhaust 38% Characterize Engine and Vehicle Energy Usage Coolant 18% M1114 Example Charged Air 10% Friction 3% Usable Power 31% Driveline 25% Aero Drag 9% Driveline 25% Brakes 6% Accessories 27% Rolling Resistance 33% Heavy Combat 100K 140K lbs Medium Combat 40K 60K lbs Light Tactical 14K 16K lbs Incorporate Operational Energy into Fleet Modernization Requirements ECPs Existing Requirements Future Force Capabilities Efficient Power & Mobility Technologies Establish Vehicle Energy Baselines Duty cycles Basis of improvement strategy Update Vehicle Requirements to drive improvements Operational priorities ECPs based on old requirements 6
8 GVPM Technology Taxonomy Ground Vehicle Power and Energy Technology Propulsion and Thermal Management Non-Prime Power Systems Propulsion Track and Suspension Diesel Engines JP-8 Fuel Cell APU Turbine Engines Integrated Starter Generator Track Systems Transmissions Rotary Engine APU Propulsion Systems Locking Diff Suspension Systems Radiators Locking Diff Lithium Ion Batteries Traction Motor Testing Electronic Stability Control Electrified Thermal Components Lead Acid Batteries Electronics Cooling Propulsion Reliability Testing Capacitors Heat Recovery High Temperature / Power SiC Power Electronics Thermal Architectures Li-Ion / Ultracap Hybrid Energy Storage Track Elastomer Research Wide Band Gap Materials (SiC)
9 Capability Based Technology Strategy Increasing Capability Radiator Development Militarization of COTS Engines Increase Prime Power Turbocharging, Supercharging, OPOC Next Generation Combat Engine High temperature or oil cooled engine operation Power Generation Cooling Future Force Capabilities Efficient Power & Mobility Technologies Novel heat exchange recovery methods Efficient Powertrain Technologies Infinitely Variable Transmission Electrified Accessories 32-Speed Binary Logic Transmission Engine Based APU SiC Electronics Reduce Fuel Consumption Energy Harvesting Driver Assist Technologies Novel Track Material Running Gear Elastomer Improvement Program High Performance Lightweight Track Electronic Stability Control High Power Fuel Cell System Semi-active Suspension Increase Vehicle Agility Chemistry Batteries EM Armor Power Brick High-power Engine Based APU Fuel Cell APU System w/jp-8 JP-8 Reformation Improvements Lithium-Ion Battery Packs Integrated Starter Generator Increase Electrical Power Far Term 2027 Mid Term 2017 Near Term
10 GVPM Laboratory Overview Propulsion Laboratory Engine Dynamometer Test Cells Power and Inertia Simulator (PAISI) Test Cell Vehicle/transmission/drive axle Evaluation Test Cell Single-cylinder Engine Research Test Cell Engine Generator Test Lab Full Vehicle Environmental Test Cell Hybrid Electric Reconfigurable Moveable Integration Testbed (HERMIT) Electro-chemical Analysis and Research Lab (EARL) Battery Lab Air Flow/Cooling Lab Elastomer Lab Ground Systems Power & Energy Labs (GSPEL) Propulsion Lab Elastomer Lab Airflow/Cooling Lab Battery Lab HERMIT Environmental Test Cell GSPEL 9
11 Recent GVPM Accomplishments Developed methodology and tool for assessing Heavy Vehicle Road Damage Improved Stryker Air Conditioning Provided PEO GCS an independent analysis of upgrade options for Abrams Conducted PIM Full Load Cooling Tests Tested and redesigned cooling system for MRAP-ATV with Sparks II Mine Roller Evaluated & qualified 5 engines for Alternative Fuels Tested and optimized MRAP Air Conditioning Design 10
12 Recent GVPM Accomplishments Developed Abrams APU Engine Bench tested Silicon Carbide (SiC) 150 kw DC-DC Batteryto-Bus (BTB) Converter Conducted competitive runoff evaluations on Bridging Boat engine candidates Completed independent durability assessment of OEM improvements to AGT Turbine engine to support PM decision making Commissioned a new four-quadrant dynamometer for characterization and testing of electric machines, e.g. hybrid electric propulsion motors 11
13 It s all about...supporting the Warfighter 12
14 Backup Slides 13
15 Laboratory Support Throughout the Ground Platform Lifecycle Ricardo/DRS PGU M85 Traction Motors Traction Drive Inverters Satcon DC-DC Capability Gaps Concepts Platform Simulation Component Development Component Testing Vehicle Testing Vehicle Integration Integrated Component Testing Transition Enabling Warfighter Capability Through Technology Development & Integration
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