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UNCLAS: Dist A. Approved for public release The 5 th International IEEE Vehicle Power and Propulsion Conference Gus Khalil US Army TARDEC Hybrid Electric program
UNCLAS: Dist A. Approved for public release
The 5th International IEEE Vehicle Power and Propulsion Conference Gus Khalil
US Army TARDECHybrid Electric program
Background
1900 Lohner-Porsche4x4 Hybrid Vehicle
1943 T-23 Electric Drive 1943 Elephant TankElectric Drive
2008 NLOS-C hybrid electric MGV1995 Hybrid HMMWV
Power & Energy Trends
25 September 2009 3
• Battlefield consumption of energy increasing– New C4ISR technologies– IED Defeat Systems– New weapons (EM guns, lasers)
• Energy security problematic– Increasing dependence on foreign oil– Alternative sources sought – wind, solar,
bio-mass, 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 (KPPs, low consumption components)
The Challenges
0
20
40
60
80
100
120
1860 1880 1900 1920 1940 1960 1980 2000 2020 2040 2060
Year
Fuel
Con
sum
ptio
n pe
r Sol
dier
[gal
/sol
dier
/day
]
1944
Korean War
Vietnam War
Iraq War
Desert Storm
Future Wars
WW I
CivilWar
Region of Projected Fuel Consumption
Best Case
Worst Case
Vehicle Speed
0.6
0.9Per side
Vehicle driven by one track.0.9 te/wt transient
PERFORMANCE SPECS
60% slope te/wt=0.6 continuous
Military Environment
CRTCCRTC
YumaYuma
AberdeenAberdeen
Field Testing
Robust
Environment
Hybrid Electric Payoffs
• Onboard and Export Power• Fuel Economy• Flexibility and Packaging Efficiency• Synergy with Pulsed Power Loads• Silent Operations
Hybrid HMMWV powering a Tactical Operations Center
Hybrid HMMWV Hybrid HMMWV powering a Tactical powering a Tactical Operations CenterOperations Center
Onboard and Export Power
Onboard power from ISG Onboard power from ISG
Fuel Economy
Optimized Engine Performance
1.
Brake Energy Recovery
2.
Based on the given statistical models of the test data over the range of speeds, the Hybrid HMMWV showed the following % improvement in Mean Fuel Economy over the Conventional HMMWV:
Munson: 4.2% [Common interval 5.1-30.7 mph]
Churchville B: 10.9% [Common interval 5.1-25.0 mph]
KEYHybrid: Conventional:
XM1124Munson
M1113Munson XM1124
Churchville B
M1113Churchville BXM1124
charging battery
Fuel Economy Measurements
Design Flexibility
• Most of the connections are wire• Minimum rigidity • Modular architecture
• Most of the connections are wire• Minimum rigidity • Modular architecture
Silent Operations
Challenges
• Thermal Management• Cooling System Size and Complexity• Power Density and Specific Power • Energy Storage• Reliability• Cost
Temperature Impact on Cooling System
Approximate Northrop Grumman calculations for 600 shaft hp (about 500-550 kW Inverter)
For One 400 kW Traction Inverter• 70 ºC to 95 ºC => 56% reduction• 95 ºC to 130 ºC => 44% reduction
50 70 90 110 130 150 170 190 210 230 250 270 290 3100
1
2
3
4
5
6
7
8
9
10
1111
0.385
vol ΔT( )
31060 Tcool ΔT( )
Radiator Volume vs. Coolant Temperature
Approximate calculation assuming fixed 50ºC ambient
Silicon Carbide(100ºC coolant)
StandardInverters
(65ºC coolant)
Volu
me
(cub
ic fe
et)
Coolant Inlet Temperature (ºC)
SiC Motor Inverter
Hybrid Si/SiC Converter
Current SiC Converters(APEI)
• High junction temperature operation ≥ 1750C• High frequency ≥ 50 kHz• High efficiency
• Lower on-state resistance• Faster reverse recovery
• More robust and higher reliability
Silicon Carbide Development
RAGONE CHARTRechargeable Batteries
(Cell Level)
1
10
100
1000
10000
100000
0 20 40 60 80 100 120 140 160 180 200
Specific Energy, Wh/kg
Spec
ific
Pow
er, W
/kg
1CRATE
10CRATE
100CRATE
0.1CRATE
0.01CRATE
Pb-Acid
Pb-AcidSpiral Wound
Ni-Cd Ni-MH Li-Polymer
Ni-H2
Li-ion
ASDS
JSF 270V
16 TON MCV6 TON ARV
RSTV
GLOBALHAWK
SSHCL
ACTIVE DENIAL
Energy Storage
Prime Prime PowerPower
Energy Energy StorageStorage
MotorsMotors
Power Power ConditioningConditioning
Pulse Pulse PowerPower
Technology Goals
Capacitors
Traction In-Hub
Li-Ion Batteries
Engine
Si DC-DC Converters
SiC DC-DC Converter
kW/kg
1.5
0.3
W-hr/kg
45
200
kW/l
3
10
kW/l
0.75
6
J/cc
2.5
0.67
3X
4X
3X
6X
4X
1.5
200
10
6
2.5
Field Weakened PM Motor
Solid State Output Switch
Lead AcidLead Acid
MTU 1 kW/kgMTU 1 kW/kg
Thank you!
