2011 Joint Service Power Expo
Office of Naval Research Maneuver Science and Technology Programs in
Fuel Efficiency and Battlefield Power
Michael Mimnagh
Maneuver Thrust Area
Expeditionary Maneuver Warfare and
Combating Terrorism Dept (Code 30)
Office of Naval Research
2011 Joint Service Power Expo
• Exportable Power Program Overview
• Transmission Integral Motor/Generator – HMMWV On-Board Vehicle Power System (OBVP) Overview
– 3000 Series Transmission Integral Generator (“3TIG”)
– Electric Torque Assist
• Medium Tactical Vehicle Replacement (MTVR) OBVP
• MTVR “Hybrid” OBVP
• Medium Electromechanical Infinitely Variable Transmission
• Summary & Link to ONR Long Range BAA
2011 Joint Service Power Expo
Exportable Power Program Overview
• DRS HMMWV – PM Generator Integrated Into
HMMWV Mechanical Transmission
– Power Electronics Converter For Fixed Frequency (60 Hz) Export And Mobile Power Over Range Of Engine Speed
– 30kW Of Static Exportable Power, 35kW Of Static Power Surge, 10.5kw Of Mobile Power
• Oshkosh MTVR – Implements ProPulse Electric
Propulsion System
– 280 kW Generator, Configurable For 208/480 VAC
– 120kW Static Exportable Power, 21 kW Of Mobile Power
Electronics
Cooling
Energy Storage
Power
Distribution &
System Control
Programmable
Rectifier 208 VAC
3PH
Conversions
OBVP
Generator
Output
Connector
Relocated
Transmission
controller
Engine
Generator
Cooling System
Traction Motor Drive
High Voltage Box
Multi-Motor Gearbox
2011 Joint Service Power Expo
Cooling Upgrades
Relocated Original HMMVW Electronics
Power Conditioning
System Control
Transmission Integrated Generator
HMMWV On-Board Vehicle Power System Overview
•Transmission
Integral Generator
(TIG) exportable
power approach
•Up to 30kW
stationary
exportable power
•10 kW mobile
exportable power
•Retrofit “Kit”
Approach
2011 Joint Service Power Expo
30 kW
30 kW
Significant logistics savings achieved using HMMWV OBVP
Existing Configuration to Deliver 30 kW with HMMWV Class Vehicle
USMC OBVP Equipped HMMWV Configuration to Deliver 30 kW
HMMWVs 15 Kilowatt Generators Soldiers
HMMWV OBVP Soldier
2 2 2
1
1
HMMWV On-Board Vehicle Power Logistics Savings
•Weight Reduction •Volume Reduction •Manning Reduction
2011 Joint Service Power Expo
No Impact to Drive Line
Space Claim
3200TIG Transmission
3200SP Transmission
Scalability of Transmission Integral Generator Concept
• Installs at factory or depot using standard tools and
mounts
• More than 125 kW of continuous electric power
while stationary
• No impact to the vehicle driveline
• High voltage output available (300 VDC to 600 VDC)
•120/208 VAC at 50/60 Hz
2011 Joint Service Power Expo
Electric Torque Assist
• Load Split Algorithm
– System uses the electric machine as generator to charge the battery when drive system is operating at high efficiency
– System uses the battery and electric machine as motor to assist when drive system is operating at low efficiency
• Additional Efficiency Through Regenerative Braking
• Improve Efficiency of Exportable Power Transient Performance
Energy Storage
Power
Distribution &
System Control
Programmable
Rectifier 208 VAC
3PH
Conversions
OBVP
Generator
Output
Connector
Relocated
Transmission
controller
• Electric Assist Components
– Base HMMWV OBVP Kit
– Accelerator Pedal and Other Sensors
– Motor/Generator Controller (bi-directional power converter)
– Battery System
– Hybrid Electric Vehicle Controller
Exportable Power System Components Leveraged for Vehicle Fuel Efficiency Gain
Approach Applicable for other Transmission Integral Motor/Generator Systems
2011 Joint Service Power Expo
Engine
Traction Motor
Traction Motor
Controller
Traction Motor
Traction Motor
Controller
Traction Motor
Traction Motor
Controller
Multi Motor Gearbox
21 kW Load
21 kW Converter
120 kW Load
Distribution Panel
Generator
• Diesel electric Propulsion
• 120kW stationary
exportable power
• 20kW mobile exportable
power
Oshkosh MTVR OBVP System Overview
Engine
Generator
Cooling System
Traction Motor Drive
High Voltage Box
Multi-Motor Gearbox
2011 Joint Service Power Expo
9
Oshkosh MTVR Hybrid-OBVP High Level Control Schematic
Engine
Throttle Input
Electrical Power Link
Accessory Load Control
Shifter RND
Vehicle Powerflow Control
Engine Speed is independent of Vehicle Speed
Mechanical Link
Traction Motors
Generator Energy Storage Device
Energy Storage enables Regenerative Braking
2011 Joint Service Power Expo
10
• Technical Approach
– Build on MTVR OBVP ProPulse® Drive System, capitalizing
on continuously variable nature of series electric drive
through the addition of regenerative braking and
selecting a power dense (vs. torque dense) engine.
– “Hybridize” with Regenerative Braking Subsystem
– Capacitor based energy storage modules
– Develop charge/discharge control algorithms to optimize
regenerative braking
– “Repower” with power dense engine
– Continuously variable nature of series electric drive
allows prime mover to make requisite mobility power at
any optimum efficiency speed
– No low end torque requirement allows lighter weight
options.
– Decrease in engine weight achievable Repower with power dense engine
Hybridize with Energy Storage and ProPulse® Drive System
Oshkosh MTVR Hybrid-OBVP
2011 Joint Service Power Expo
Oshkosh Electromechanical
Infinitely Variable Transmission
•Alternative powertrain for medium vehicles •Transfers weight from front axle •Improves weight distribution for Air Transportability •Enables Exportable Power
2011 Joint Service Power Expo
Engine Sub-System
Throttle Input
‘Max Power’ Combined
System Map
Engine Commands
Status
Electrical Power Link
Accessory Loads
EMIVT Powerflow Control
Max Available Power Vs Eng Speed Map
Vo
ltag
e Fe
ed
bac
k
Shifter RND
Commands
Transmission Output Speed
Desired EMCVT Mode
Engi
ne
Fee
db
ack
EM1
Co
mm
and
EM2
Fee
db
ack
EM2
Co
mm
and
EM1
Fee
db
ack
EM1 EM2
Clutches
•Electronically controlled engine / electric machines •System architecture yields efficient, redundant operation •Power management algorithms optimize efficiency
System Controlled to Minimize Combined System Losses
Oshkosh EMIVT
Control Schematic
2011 Joint Service Power Expo
Oshkosh EMIVT Fuel Economy
Simulation
• Preliminary comparison between conventional powertrain and and EMIVT • Simulation of cruising “steady state, flat road” operation - no energy storage • Addition of energy storage can further improve mpg by 10-15% depending on drive
cycle
•EMIVT shows an overall improvement in mpg on MTVR •Sawtooth pattern on the six speed conventional transmission due to discrete gear shift points •Only one shift needed on EMIVT
Estimated Fuel Economy
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0
Speed (MPH)
Fu
el
Ec
on
om
y (
MP
G)
Allison 4700SP Allison 4700 SP (aggressive shift) EMiVTConventional Conventional (aggressive shift)
No
rma
lize
d F
uel
Ec
on
om
y
0.0
0
.3
0.6
0
.9
2011 Joint Service Power Expo
Energy Storage
Export Power Inverter
•Regenerative Braking with the addition of Energy Storage option for Improved Fuel Economy
Both electromagnetic machines may be operated as generators
Future Options
•Export Power capability with addition of DC to AC inverter
•150kW stationary power
•30kW mobile power
Oshkosh EMIVT
Control Schematic
2011 Joint Service Power Expo
ONR Fuel Efficiency and Battlefield Power Program Summary
• Marine Corps Expeditionary Energy Strategy
– “By 2025… the only liquid fuel needed (by Marine Expeditionary Forces) will be for mobility systems, which will be more energy efficient than systems are today.”
– Mobility systems will also provide exportable power for battlefield needs.
• Integration of electromechanical power systems (generation, storage, conversion, and control) with vehicle drive systems enables fuel efficient mobility and exportable power.
– Series Electric Drive – High Power Applications
– Transmission Integral Motor/Generators – Small/Medium Applications
– EM IVT – Alternative Mobility/Exportable Power System
– Future Capability Enabler – Directed Energy, Energy Based Survivability
• Other Applicable Approaches
– Fuel Cells, Auxiliary Power Units
• Science and Technology Needs – High Temp, Power Dense Components
• COST - Acquisition Cost as Important as Lifecycle Cost Savings
• ONR Long Range BAA – http://www.onr.navy.mil/en/Contracts-Grants/Funding-Opportunities/Broad-Agency-Announcements.aspx
