Auxiliary Pwer Units Kevin Centek Nn-Primary Systems Team Leader
Reprt Dcumentatin Page Frm Apprved OMB N. 0704-0188 Public reprting burden fr the cllectin f infrmatin is estimated t average 1 hur per respnse, including the time fr reviewing instructins, searching existing data surces, gathering and maintaining the data needed, and cmpleting and reviewing the cllectin f infrmatin. Send cmments regarding this burden estimate r any ther aspect f this cllectin f infrmatin, including suggestins fr reducing this burden, t Washingtn Headquarters Services, Directrate fr Infrmatin Operatins and Reprts, 1215 Jeffersn Davis Highway, Suite 1204, Arlingtn VA 22202-4302. Respndents shuld be aware that ntwithstanding any ther prvisin f law, n persn shall be subject t a penalty fr failing t cmply with a cllectin f infrmatin if it des nt display a currently valid OMB cntrl number. 1. REPORT DATE 17 NOV 2010 4. TITLE AND SUBTITLE Auxiliary Pwer Units 6. AUTHOR(S) Kevin Centek 2. REPORT TYPE N/A 3. DATES COVERED - 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 5d. PROJECT NUMBER 5e. TASK NUMBER 5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) US Army RDECOM-TARDEC 6501 E 11 Mile Rd Warren, MI 48397-5000, USA 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) US Army RDECOM-TARDEC 6501 E 11 Mile Rd Warren, MI 48397-5000, USA 8. PERFORMING ORGANIZATION REPORT NUMBER 21345RC 10. SPONSOR/MONITOR S ACRONYM(S) TACOM/TARDEC 11. SPONSOR/MONITOR S REPORT NUMBER(S) 21345RC 12. DISTRIBUTION/AVAILABILITY STATEMENT Apprved fr public release, distributin unlimited 13. SUPPLEMENTARY NOTES The riginal dcument cntains clr images. 14. ABSTRACT 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT SAR a. REPORT unclassified b. ABSTRACT unclassified c. THIS PAGE unclassified 18. NUMBER OF PAGES 9 19a. NAME OF RESPONSIBLE PERSON Standard Frm 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18
NPS Technlgy Fcus Areas Small Engines -Achieve increased pwer density fr existing vehicle APU space claims -Optimize injectrs fr heavy fuels -Minimize acustic signature Refrmatin/Fuel Cells -Achieve increased pwer density fr existing vehicle APU space claims -Optimize system integratin and cntrls Rbtic Pwer -Achieve increased range (vs. current batteries) with small engine and fuel cell-based pwer surces -Minimize acustic signature f small engine-based rbtic platfrms -Increase fuel cell reliability and shck and vibratin perfrmance Missin Gals fr each Fcus Area: High Pwer Density Engine APU that can prvide up t 45 kwe auxiliary pwer t meet increasing nbard vehicle pwer demands withut reducing mbility. Silent Watch (undetectable at 50m) thrugh the use f a fuel cell based APU that pwer missin equipment with main engine ff while the vehicle is statinary with reduced acustic and thermal signature. Small UGV pwer thrugh small engine and fuel cell based slutins that can extend the missin duratin and range f UGVs, reducing risk t sldiers. 2
Prject Purpse & Gal: Develp, integrate, test and demnstrate a 9kW rtary engine APU in Abrams M1A2 SEP V1 tank Ruggedize design t meet vibratin requirements f tank Optimize cmpnent placement fr ease f maintenance Prduce 6 units fr testing at varius gvernment test facilities Challenges: Cnsumes il: 1 qt. every 12hrs. Requires cnstant use f glw plug Maintenance required every 75hrs Minimal nise mitigatin wrk dne 9kW JP-8 Rtary APU: Integrated, Demnstrated, Tested Prgram Status: Cmpleted 200+ hurs (2000 miles) f in-vehicle peratinal cnditins at Yuma Cmpleted tw 100 hur high temperature (125F) tests at TARDEC Prpulsin Lab Cmpleted M1A2 SEP V1 Integratin Test f 300+ tank cmmands Delivered perfrmance specificatin t PM HBCT, which may be used fr pen cmpetitin Delivered test reprt f all testing cmpleted Generatin 1 Prf f Cncept Generatin 2 Test Prttype Generatin 3-9 kw APU - TARDEC Testing - Aberdeen Prving Grunds Tests - Yuma Prving Grunds Test FY06 FY07 FY08 FY09 FY10 FY11 3
17 kw Rtary JP-8 APU: Current Prgram Prject Purpse & Gals: Design, mdel, build & deliver Rtary Diesel APU Utilize lessns learned frm previus Rtary APU wrk Prduce APU fr Abrams space claim Increase pwer by utilizing mdern rtary engine technlgy Minimize dependence n glwplug Decrease il cnsumptin Challenges Cnsumes il, but at lwer rate than previus generatin Requires use f glwplug fr cmbustin New engine design: limited evaluatin dne Technlgy Descriptin: Rtary engine, cntinuus glwplug ignitin 17kW electrical utput Imprved fuel ecnmy 350 lbs Fits in Abrams space Reduced cling burden Lwer fuel cnsumptin (kg/kw) Cmpnent Design Cmpnent Fabricatin Engine Assembly FY09 FY10 FY11 Q1 Q3 Q1 Q3 Q1 Q3 Engine Perfrmance Testing Cmpnent Testing Engine Endurance Testing APU Fabricatin APU Testing 4
Reciprcating Pistn APU: Current Prgram Prject Purpse & Gals: Prduce APU fr Abrams space claim Utilize COTS Direct Injectin (DI) cmpressin ignitin engine State f the art in reducing fuel cnsumptin and ptimizing fuel cntrl Integrate muffler inside space claim Challenges Cnsumes il: 1 qt. every 24hrs. Reservir needs refill every 40 hrs N ballistic prtectin in unit design Nt a drp-in design Minimal nise mitigatin wrk dne Technlgy Descriptin: 10kW electrical utput (360A) Single Cylinder 4-strke Diesel engine Liquid Cled In-cylinder fuel injectin 420 lbs Fits in Abrams space (including muffler) True cmpressin ignitin Cmpnent Design Cmpnent Testing Air Cled Unit Fabricatin Air Cled Unit Testing Liquid Cled Unit Design Liquid Cled Unit Fabricatin Liquid Cled Unit Testing TARDEC Test & Evaluatin FY08 FY09 FY10 FY11 5
Turbcharged Rtary JP-8 Engine: Current Prgram Prject Purpse & Gals: Build, test, mature & deliver Rtary Diesel Engine Utilize state f the art high pressure fuel system, direct injectin, and turbcharger system Prduce 25kW APU fr Abrams in 3 yrs. Cllabrate with AMRDEC UAV Shadw prgram t use same technlgy fr multiple applicatins Minimize il cnsumptin, use il fr cling t minimize lgistical burden Challenges New engine design: limited evaluatin dne Optimizing il cnsumptin, while prviding enugh lubricatin fr side seals Spark plug lng term durability Use f multiple injectrs have nt been fully determined Technlgy Descriptin: 25kW shaft utput, spark ignitin Lw nise & vibratin design Extremely lightweight and pwer dense Fits in Abrams APU space Optimized fuel cntrl and lw fuel cnsumptin Reduced lgistic burden Engine Build, Turb Selectin Engine Reliability Testing Engine Delivery & Dem APU Build APU Delivery & Dem APU Test & Evaluatin (TRL 5) APU Redesign & Optimizatin FY11 FY12 FY13 FY14 FY15 FY16 6
JP-8 Fuel Cell APU: Current Prgram Prject Purpse & Gals: Prvide quiet, cntinuus, nn-primary electrical pwer fr extended engine-ff peratin with reduced acustic and thermal signatures in a fuel cell based APU. Design and develp tw APUs that deliver 5 kw (T), 10 kw (O) f vehicle electrical pwer Design systems t fit int the existing Abrams APU space claim Challenges: Sulfur tlerant systems Immature technlgies; Limited reliability data available High cst cmpared t cnventinal APUs Technlgy Descriptins: High Temperature PEM APU Regenerable Desulfurizatin System Steam Refrmer Water Gas Shift Reactr Slid Oxide Fuel Cell APU Regenerable Desulfurizatin System Autthermal Refrmer Sulfur Tlerant Stack MILESTONES FY10 FY11 FY12 FY13 FY14 FY15 System M&S System Refinement Prttype Develpment Breadbard test Field Hardening Increase Pwer Density Preliminary TTA APU Demnstratin 5 6 7
Unmanned Rbtic System Utilizing Hydrcarbn Fueled Oxide Fuel Cell Current Prgram Prject Purpse & Gals: T integrate a 250 Watt Slid Oxide Fuel Cell system nt an existing Unmanned Grund Vehicle (UGV) Analyze current manufacturing prcess and perfrm a lw rate initial prductin f 20 units Analyze prductin cst and unit variability Test 5 units at cntractr facility fr 2000 hurs r failure Technlgy Descriptin: 250 Watt Slid Oxide Fuel Cell System Uses cmmercially available prpane Fits int existing battery cmpartment Pwer system can be used as stand alne pwer surce Increases missin duratin ver batteries Challenges: Limited shck and vibratin testing Meeting limited space cnstraints Manufacturability 250 Watt Sub-system analysis UGV SOFC system cnfiguratin FY10 FY11 FY12 Envirnmental testing shck/vib Design fr Manufacture Study LRIP Mfg plan and executin User/safety assessment Delivery f SOFC pwer systems 8
Nn-Primary Pwer Systems Technical Challenges Obtain 45kW in current r smaller space claim 2.5 galln/hr fr 25kW utput Undetectable at 50 meters Mean time between failure 1140 hurs 9