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!