U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND – GROUND VEHICLE SYSTEMS CENTER Power Electronics and Architecture DISTRIBUTION A. Approved for public release; distribution unlimited. George Hamilton VEA CCDC GVSC DISTRIBUTION A. See first page. 1
WHY IS TARDEC DEVELOPING POWER ARCHITECTURES? • Electrical power requirements continue to grow as more electronics are added to Military 28VDC Power (Amps) Ground Vehicles (radios, displays, computers, 1800 cameras, turret motors) 1600 1400 • Vehicle designs utilize proprietary electrical 1200 architectures to meet power requirements 1000 800 Alternator Size • The Army pays for a new power architecture 600 (Amps) 400 implementation every time a new vehicle is 200 developed. A reusable standardized 0 architecture implementation is needed to reduce development cost and schedule DISTRIBUTION A. See first page. 2
ELECTRICAL POWER ARCHITECTURE SYSTEM REQUIREMENTS • Provide 45kW @ 28VDC -> MIL-STD-1275E • Provide 175kW @ 600VDC -> MIL-PRF-GCS600A. • Silent Watch: 4 kW for 4 hours to vehicle Low Voltage loads with the main engine off • Import/Export 30kW @ 208VAC • Utilize the SAE-J1772 connector for exporting/importing High Voltage power • Power electronics liquid cooling temp @ 105C • Automated power management with anti-idling • Meet the Abrams & Bradley environmental requirements contained within ATPD-2404 Enables Energy Weapons and >10% Fuel Savings DISTRIBUTION A. See first page. 3
TEMPERATURE, COOLANT, & AIRFLOW REQUIREMENTS Ambient Temperatures • Combat Vehicles Operate in Hot, Basic, and Cold climates as defined in AR 70-38 & MIL-STD-810G • Vehicles without air-conditioning experience temperatures up to 71C in the crew areas • Touch temperatures less than 60C in 29.5C ambient • Engine compartment temperatures vary from 121C – 260C right near the exhaust Coolant Temperatures • Using Engine Coolant or 100-105C allows a radiator size reduction of 75% from standard 70C electronics coolant Airflow • No natural airflow on military vehicles. Assume no airflow. Forced air cooling approaches must be able to survive MIL-STD-810G requirements DISTRIBUTION A. See first page. 4
MIL-STD-1275E & MIL-PRF-GCS600A DISTRIBUTION A. See first page. 5
SAFETY FEATURES – HV INTERLOCKS NGCVEPA High Voltage Interlocks DISTRIBUTION A. See first page. 6
SAFETY FEATURES – HV DISCHARGE High Voltage Discharge Requirements • The voltage differential between the High Voltage Power and High Voltage Return pins of any High Voltage connection shall be less than 2 VDC within 300 microseconds upon HVIL circuit interruption, assuming external power has been removed. • The assembly shall reduce all stored charge to less than 5 microcoulombs before access can be gained for repair activities. DISTRIBUTION A. See first page. 7
NGCVEPA ARCHITECTURE DISTRIBUTION A. See first page. 8
INTEGRATED STARTER GENERATOR CONTROLLER (ISGC) ISGC Details: • Power capability - 200kW High Voltage • Three SSPC channels: 350A, 2 x 100A • Silicon Carbide (SiC) based Liquid Cooled, 105 o C • Operating Temp, -45 o C to +121 o C • • High Power Density (181W/cu.in; 11kW/L) • Size: 5.76” x 13.7” x 14” • Weight: 50 lbs. DISTRIBUTION A. See first page. 9
BI-DIRECTIONAL CONVERTER (BDC) BDC Details: • Uses Silicon Carbide (SiC) for the 600Vdc Active bridge • Uses Gallium Nitride (GaN) for the 28Vdc Active bridge • Designed to be rack mounted to minimize safety concerns with HV and liquid cooling Liquid Cooled, 105 o C • • Size: 712 in 3 • Weight: 39 lbs. DISTRIBUTION A. See first page. 10
HIGH VOLTAGE POWER CONTROLLER (HVPC) HVPC Details: • 12 solid state circuit-protected channels (350/200/50/30x5/10x4) • Configurable Pre-charge capability for each channel • Provides central control of safety features: • Ground Isolation Fault (GIF) Detection • HV Interlock • Overcurrent Protection • Arc Flash Mitigation • Silicon Carbide (SiC) based • Liquid Cooled, 105 o C • Size: 6 x 12 x 15”, Weight: 48 lbs. DISTRIBUTION A. See first page. 11
UNIVERSAL HIGH VOLTAGE CONVERTER (UHVC UHVC Details: Channel 1 Universal High Voltage Interlock Channel 1 Converter (UHVC) • Non-isolated continuous transfer of 120kW Power Channel 2 Conversion Interlock Channel 2 • Channel 1 – Flexible Voltage • Lower bound 270VDC MIL-STD-704F Heater Processor Circuit • Upper bound 600VDC MIL-PRF-GCS600A J1939 CAN 28Vdc • Channel 2 – Fixed Voltage Iiquid Cooling • 600VDC MIL-PRF-GCS600A • Liquid Cooled, 105 o C • RFQ has been issued to solicit development DISTRIBUTION A. See first page. 12
ERCA POWER DISTRIBUTION UPGRADE Silicon Carbide Silicon DISTRIBUTION A. See first page. 13
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