TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: Project Manager for Mobile Electric Power (PM-MEP)

OBJECTIVE: Two objectives are targeted: 1) Development of a catalytic fuel ignition technology that enables efficient combustion of diesel fuels in low-compression engines. 2) Apply hybrid-electric technologies (power electronics, energy storage, controls) to enable periodic silent watch capability and to pursue benchmark system reliability improvements.

DESCRIPTION: There is an emerging military need for man-portable (<60 lbs.) power in the 1 kW range with periodic silent operating capability as demonstrated by AMC-FAST (Army Materiel Command- Field Assistance in Science/Technology) inquiries to the CECOM RDEC (Communications-Electronics Command Research, Development & Engineering Center) and PM-MEP (Project Manager-Mobile Electric Power). This emerging need is envisioned as a critical capability for the Objective Force for a multitude of tactical missions. The ability to operate in a silent mode periodically can be addressed through application of emerging hybrid-electric power technologies. The difficult technical issue is man-portability. This cannot be achieved today through the use of off-the-shelf products. There are no compression ignition engines small enough to provide 1 kW and support man-portability. There are, however, many low compression, spark ignition, gasoline engines on the market in the power range of interest. One emerging research area that offers the potential for efficient combustion of diesel fuels in these low compression engines is catalytic fuel ignition. Catalytic fuel ignition involves the use of a heated catalyst material that ignites diesel fuels in a prechamber approximately the same size/form factor as a traditional spark plug. The EPA (Environmental Protection Agency), NASA (National Aeronautics and Space Administration), and DOE (Department of Energy) have funded low levels of basic research in this area.

Catalytic fuel ignition research is extremely important to the military’s efforts to reduce the size and weight of the force, reduce costs through better fuel consumption, and provide the power necessary for critical missions.

The advancement of Hybrid-electric technology and its application to military gensets is critical to achieving soldier and system survivability, and reliability goals. The hybrid approach allows for periodic silent operation as needed, and allows for short term power supply in the event of a mechanical failure.

Successful execution of this SBIR effort will result in benchmark mobility (portability), reliability, and survivability (periodic silent mode operation) characteristics critical to the Objective Force dismounted soldier and Objective Force battlefield tactical power systems.

PHASE I: Identify the critical technology barriers associated with catalytic fuel ignition, specifically associated with the efficient combustion of logistics fuels in low compression engines. Also investigate high density energy storage technologies and devices to determine feasibility of the hybrid-electric approach. Develop concepts for mission scenarios to include period of silent mode operation. Define a path for future research to develop the fuel catalyst and hybrid technologies necessary for success. Develop conceptual 1 kW hybrid-electric power system designs that leverage the benefits of catalytic fuel ignition, and capitalize on the reliability & survivability benefits of hybrid-electric technology application.

PHASE II: Execute the research path from Phase I to advance catalytic fuel technology to the demonstration phase. Conduct detailed design of a laboratory breadboard hybrid-electric power system utilizing catalytic fuel ignition. Incorporate permanent magnet or other high power density alternators, power electronics, and controls necessary to achieve on-demand silent mode power capability, and default silent mode operation in the event of an engine/mechanical failure.

PHASE III: The commercial market potential is extremely high. Currently, there is a large consumer, construction, and recreational market demand for power in this range that is being addressed by gasoline generators from a variety of manufacturers. The military market potential is also very promising. We have recently worked on programs with PM-Howitzer, JBREWS (Joint Biological Remote Early Warning System), and others with low level power needs, and survivability needs. Man-portable 1 kW hybrid-electric power systems can significantly impact these market segments, providing advantages over current products in many performance and cost areas.

REFERENCES:

http://www.smartplugs.com