National Academy of Sciences Battery Conference Panel I: The Federal Outlook for the U.S. Battery Industry The Army Perspectives Dr. Grace Bochenek Director, U.S. Army Tank Automotive Research, Development & Engineering Center Dr. John Pellegrino Director, Sensors and Electron Devices Directorate, U.S. Army Research Laboratory
Discussion Topics Army Ground Vehicle Perspective Vehicle Power and Energy Trends Warfighter Requirements Spectrum of Vehicle Electrification Systems Integration From Component to Platform Energy Storage Technology Developments Challenges 2
It s All About the Warfighter 3
Task Organized to Deliver Capabilities Technology System Organizational Construct Multifunctional, Multidisciplinary Organization Cross-cutting System Engineering Incubating, Maturing, Transitioning Next Generation Technology Power & Energy Leveraging Resources & Investments to Deliver Capabilities 4
TARDEC Mission and Vision Provides full life-cycle engineering support and is provider-of-first-choice for all DOD ground combat and combat support vehicle systems. Develops and integrates the right technology solutions to improve Current Force effectiveness and provide superior capabilities for the Future Force. Ground Systems Integrator for the Department of Defense 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 5
Fuel Consumption per Soldier [gal/soldier/day] Power and Energy Trends The Challenges Battlefield consumption of energy increasing New C4ISR technologies IED Defeat Systems New weapons (EM guns, lasers) Energy security problematic Cost of fuel skyrocketing Alternative sources sought wind, solar, biomass, waste to energy Operational issues Battery usage & limitations energy & power density Demand for auxiliary power on-board vehicles Emphasis on silent ( quiet ) watch Unmanned vehicles (air/ground) Unattended sensors Inefficient management/ distribution of power Demand for soldier-wearable power Increased emphasis on system power metrics and energy efficiency (KPPs, low consumption components) 120 100 80 60 40 20 Civil War 1944 WW I Korean War Vietnam War 0 1860 1880 1900 1920 1940 1960 1980 2000 2020 2040 2060 Year Desert Storm Iraq War Worst Case Best Case Future Wars Region of Projected Fuel Consumption 6
Power and Energy Warfighter Outcomes Enhance ground force effectiveness, flexibility, protection and freedom of movement by reducing the need to transport fuel Dramatically reduce sustainment footprint, lighten soldier load and extend platform range/self-power endurance by combining component functions Increase flexibility by expanded capabilities to utilize alternative energy sources, recycle energy, water and waste, and to redistribute resources among systems Reduce size and number of Soldiers & systems required in forward areas by deploying unmanned systems Integrate power & energy situational awareness and management functions with Mission Command to optimize energy use and enable "energyinformed operations" 7
Starter B A E G D L S DVDB 1.7-8.2kW Hull Loads MP ESS Hull 28V PECS Loop 3Ø VAC AV900_CH1 (160kW) 610VDC old new 28VDC Spare1 (30kW) CAN: Power Spare2 (30kW) CAN: Thermal Control Line MP = Master Power switch TP = Turret Power switch EA = Engine Accy switch 1000 BMS1 Dirty TPB 1.2-4.4kW Gun/Turret Drive Control DCDC1 (10kW) HPB1 200 HV/LV Slip Ring ESS Turret 28V EA TP 80 80 80 PCM1 1.5kW Elect. Loads BMS2 ESS Elec 28V Smart Display (VPMS) 1000 Clean 500kbps Turret PCM2 1.5kW Turret Loads 250kbps HVPDB DCDC2 (10kW) PCM3 0.8kW HV/LV Hull Loads T L 5 0 POL1 (DDC) Fuel Level Fault Induce Bus V Gages AOPET Test Control Panel T L 5 0 Coolant Temp Tactical Idle Load A Gages T L 5 0 T L 2 5 POL2 (DDC) 80 80 80 Engine Status Trans. Status NPS Status T L Test Loads (Water Tank) 2 5 T L 2 5 MC1 MC2 MC3 Thermal Mngmt (VTMS) 200 DFMC NPS LV POL3 (Global ET) HPB3 Battle Override Load Controls E-STOP Level Switch 5 HEATER 18kW 700V 500kbps HPB2 200 LVPDB 2.24kW Open/Ground Outputs Open/28V Inputs Rad_Fan1 (35kW) Rad_Fan2 (35kW) PECS_Pump (1.7kW) ECS_Compressor (7.8kW) ECS_Condensor_Fan (4.4kW) 80 80 AV900_CH2 (0-18kW) 80 5 AHU1 AHU2 (1.4kW) (1.4kW) Eng Clnt Temp M C 4 M C 5 Engine Accy Master Power Ground Fault Detect Trans Oil Temp Fuel Pump Engine Oil Pressure HV Enable Platform Electrification Technology Complexity and Power Growth Capacitors Batteries Non - Mild Hybrid Integrated Starter Generator (ISG) Intelligent Power Management Solid State Silicon Carbide (SiC) Power Electronics Advanced Batteries Mild Hybrid Parallel Hybrid High Energy Density Capacitors for Electric Weapons and Armor Power Brick for EMA Parallel Hybrid - Series Hybrid 5 kw - 30 kw 10 kw - 50 kw MPG ¼ Mi - 1 Mi 1/2 Hr - 8 Hr JP-8 Reformed Fuel Cell APU (Fuel Cell) Alternator Batteries Motors APU Power Electronics ISG Onboard Power Onboard & Export Power (O&E) O&E + Boost Power (BP) Fuel Economy (FE) + O&E +BP Silent Mobility (SM) + FE+ O&E +BP Silent Watch + (SM) + FE+ O&E +BP Menu of Capability 8
Systems Approach Applied Component System Integration Platform Level Component Elements DC/DC Converters Concepts Fuel Efficiency ground vehicle Demonstrator Autonomous Platform Demonstrator Motors Batteries Analysis Simulation Subsystem Elements Ground Combat Vehicle Joint Light Tactical Vehicle Engines Engine Generator Testing High Temperature Electronics Parallel hybrid UVs RSTV Series HE High Temperature Power Electronics Systems Integration Parallel Hybrid MSV 9 Enabling Integration & Technology Development
Energy Storage Major Technology Increasing Energy Density Electrical Power ( kw) Energy Density Improvements over time 2035-2050 APU + High Energy Batteries JP 8 Reformed Fuel Cell + Batteries 2012 Li-Ion Polymer 200 Wh/kg 2008 Li-Ion 145 Wh/kg Fielded 2004 NiMH 120 Wh/kg 50 Estimated Electrical Power Growth 1980 Nickel-Cadmium 60 Wh/kg 40 30 Current Future 1860 Pb-Acid ~30 Wh/kg 10 20 10 0 Actual Growth 1985-2007 JLTV GCS Stryker HBCT HMMWV
Vehicle Electrification Challenges Parallel Hybrid MSV HMMWV Series HE Military Duty Cycle and extreme environments Very high torque and power demand Reliability and Safety Integration and packaging RSTV Series HE Thermal management and high temperature components (SiC) Development and advanced technology unit Cost Logistics and supportability Expeditionary operations 11
National Academy of Sciences Battery Conference Panel I: The Federal Outlook for the U.S. Battery Industry Army Energy and Power: Battery Research and Investments Dr. John Pellegrino Director, Sensors and Electron Devices Directorate, U.S. Army Research Laboratory Dr. Grace Bochenek Director, U.S. Army Tank Automotive Research, Development & Engineering Center
Discussion Defense and Army Strategic Energy Opportunity Areas Army Energy Strategy and Taxonomy Army Battery Investment Focus Battery Technology Programs Summary 13
Defense Energy Strategic Opportunity Areas for Future Directions Tactical Unit Energy Independence UAV Autonomous Platform Power UGS Adaptive Power Networks Energy Optimized Platforms Electric Weapons and High Power Sensors 14 EM Launch
Power & Energy Strategy: Army Translation of Opportunity Areas SOLDIER Requirement: Silent Power Requirement: Platform Surge Power, Weapon Pulse Power Requirement: 72 Hour Missions MOBILE Technologies: Fuel Cell APUs, Reforming, Power MEMS Technologies: High Power Switching & Conditioning; Intelligent Power Management, Integrated Thermal Management Technologies: High Energy Batteries, Hybrid Power Sources, Photovoltaic PLATFORM & WEAPONS DOMAINS: Soldier, C4ISR C4ISR, Air, Ground Ground, Effects MicroWatts to 10s of Watts 100s of Watts to 100s of kw Up to 1000s of MW
Army Strategic Opportunity Areas Higher Energy Power Sources for Soldiers and Sensors Unmanned Air and Ground Platforms Intelligent Energy Management Coupled with Alternative Energy Sources for Reduced Logistical Burden (Combat Outposts) Reformed Methanol Hybrid Fuel Cell Rucksack Portable Power System Ground Combat & Tactical Vehicles Vehicle Auxiliary Power and Quiet Watch Capabilities High Energy Weapons 16
Power & Energy Taxonomy Fuel Cells & Reforming Electro-mechanical Generation Alternative & Renewable Energy Conversion Micro Power/ Actuators/Motors Primary Batteries Rechargeable Batteries Reserve Batteries Capacitors Fuel Storage Power Switches /Electronics Power Converters & Inverters Power Distribution Intelligent Power Management Heating & Cooling Power Electronics Sub-System Thermal Management Magnetics/Other 25.6% 27.2% 16.6% 30.6% FY10 Investment 6.1: 4.3% 6.2: 57.8% 6.3: 37.9% Total:100%
Army Battery Investment Focus Low Army Technology Priority High Investment Priority High Low Commercial Market Lead Acid Rechargeable (SLI/HEV) Vehicle, critical backup, deep cycle applications, low cost electrical storage Alkaline Primary Non-critical applications Ni-MH Rechargeable Soldier power, HEV Li-MnO 2 Primary Zinc-Air Primary Soldier power, sensors Li-FeS2 Primary Soldier power, sensors, long shelf life applications Commercial Chemistry Requiring Military Adaptation Hi Power Li-Ion Rechargeable Vehicles, critical backup, Soldier power, persistent surveillance, sensors Li-(CF)x Primary Soldier power, sensors Ni-Zn Rechargeable Vehicles, critical backup Military Unique Chemistries Li-Air Primary Soldier power, persistent surveillance, sensors Liquid Reserve Electric fuses for artillery, mortar, missiles, sub-munitions Thermal Reserve Electric fuses for artillery, missiles Pulse Power Li-Ion Rechargeable Weapons, GCV, 600V battery pack Li-SO2 Primary Soldier power, sensors 18
High Voltage Li-ion Batteries OBJECTIVE Develop safe and higher energy-density Li-ion batteries CHALLENGES Cycling capability Electrolyte instability at higher voltages LiCoPO 4 ARL modified LiCoPO 4 ARL electrolyte Cycling of structurally modified LiCoPO 4 vs. Li, 3.0 4.9 V Baseline electrolyte Cycling of LiNi 0.5 Mn 1.5 O 4 vs. Li, 3.0 4.95 V Stabilized LiCoPO 4 by partially substituting Co with other metals with low capacity loss. Identified electrolyte additive that allows the cycling of high voltage cathodes with high capacity retention. 19
Bio-inspired Materials for Enhanced Battery Performance High-performance Anodes For High Power, Lightweight Li-ion Batteries Bio-inspired catalytic synthesis grows tin nanoparticles inside graphite Higher metal electrical capacity that better accommodates swelling and shrinking during charge-discharge cycle Retains High Capacity at High Rates Prevents metal disintegration and capacity loss seen with other anodes Result is higher energy and higher power density (excellent performance at 20C); suggests applications for lightweight electric vehicles and UAVs 20
Battery Technology: Key Enabler for Networked Energy Energy Weapons Improved Soldier Power Wind Non-propulsion Vehicle Apps Increased life/ endurance Increased Voltage Battery Technology EM/Reactive Armor Increased Capacity Unattended Sensors Base/COP Back-up Energy Safety Less Degradation Improved Operating Characteristics (i.e., temperature, cycling) Intelligent Power Usage Smart Grid Future systems, ever more power intensive! Battery Recharging Off-peak Energy Storage Energy Harvesting Improving energy capability through holistic power sharing! 21
It s All About the Warfighter 22