d-star engineering corporation, all rights reserved approved for public release, distribution...

D-STAR Engineering Corporation, All Rights Reserved Approved for Public Release, Distribution Unlimited 2005.05.02


Logistics-Fueled, Man-Portable Generator Sets

for Soldier Power, Battery Charging and APU Needs

A Presentation to the NDIA Tri-Service Power Expo

May 02, 2005 Tampa Convention Center, Tampa, Florida

by

S. Paul Dev, PresidentD-STAR Engineering Corporation

4 Armstrong Road, Shelton, CT 06484Phone : (203) 925 7630, Fax : (203) 925 7631

E-Mail : [email protected]

Approved for Public Release, Distribution Unlimited; All Rights Reserved



Outline

1. 50 Watt Heavy-Fueled Micro-Generator SetBasis : Successful DARPA-Funded 0.1 hp Diesel

EngineGoals, Current Status, Residual Challenges, Future Plans

2. 700 Watt Heavy-Fueled Micro-Generator SetBasis : Successful DARPA-Funded 1.3 hp Diesel EngineCurrent Work in Process for DARPA + SOCOMFuture Plans : 2-Cylinder Engine, 4-Stroke Engine

3. Future Plans : 2-Cyl. Engine, 4-Stroke EnginePortable Power, Hybrid-Electric Drive, APUs



System Overview

Regulator:Allows for minimum efficiency hitAddressing heat sink & packaging issues

Control Panel Interface:Allows for Regulated Voltage or Full Voltage for Maximum Efficiency



D-STAR 50-Watt Personal Power Unit

Goals

Approximately equal in volume & weight to two BA-5590 batteries

5½”

Includesonboard JP-8

Fuel Tankfor 3 – 5 days of continuous

operation

Warm Air &Clean Gases Out

5½”5½”

Operational Mode

Air In Air In

Stowed / Storage Mode



D-STAR 50-Watt Personal Power UnitInterior Layout

Beta Prototype Hardware

Long-Life Back-Up Batteries

Power & Control Electronics

Fuel Tank

Micro-Diesel Engine

Cooling Fan

Starter-Generator

Buffer Batteries

Exhaust System



System efficiency calculations

Today Goal Today Goal

Unit output (W) 40 50 40 45

FADEC power draw (W) 2.5 2.5 2.5 2.5

5V regulator efficiency (%) 85% 85% 85% 85%

Power electronics power draw (W) 1 1 1 1

Regulated electrical output (W) 44 54 44 49

Power conversion electronics efficiency (%) 83% 93% 83% 93%

Generator unregulated electrical output (W) 53 58 53 53

Generator efficiency (%) 75% 85% 75% 85%

Fan mechanical power (W) 7 3 7 3

Engine mechanical power required (W) 78 71 78 65

Efficiency : engine mech. to net elect. (%) 52% 70% 52% 69%

SFC (lb/HP/hr) 1.5 1.2 1.5 1.0

Fuel flow (g/min) 1.2 0.87 1.2 0.66

Fuel energy, Lower Heating Value (MJ/kg) 42.8 42.8 42.8 42.8

Engine mech output energy (MJ/kg) 3.95 4.93 3.95 5.92

Efficiency : fuel LHV to engine (%) 9% 12% 9% 14%

Overall efficiency - Fuel to DC Output (%) 5% 8% 5% 10%

Peak Continuous

D-STAR MGS-50 : Diesel Fueled Micro Generator Set



Days 3 10 3 10

Hours 72 240 72 240

Power Output, Average Watts 20 20 20 20

Energy Requirement W-hr 1440 4800 1440 4800

Number of Batteries (BB-2590)

Energy / Battery (BB-2590) Wh / Batt.

Weight / Battery (BB-2590) kg / Batt.

Fuel Flow, When Running g/min 1.20 1.20 0.66 0.66

Round Trip Efficiency % 81% 81% 81% 81%

Fuel Flow, Mission Average g / min 0.66 0.66 0.36 0.36

Fuel Needed kg 2.8 9.5 1.6 5.2

Unit Empty Weight kg 1.9 1.9 1.0 1.0

Total System Mass, Average kg 3 7 2 4

Specific Energy, Average W-hr / kg 438 727 808 1331

# Batt. 8 27 8 27

kg 12 39 12 39

MGS Weight Advantage (Ratio) 3.5 5.9 6.5 10.9

D-STAR MGS-50 : System Performance Comparison for 3-day and 10-Day Missions

0 0

GoalCurrent Actual

Mission Length

Equivalent BB-2590 Batteries(125 W-hr / kg)

181

1.45

181

1.45



Days 3 10 3 10

Hours 72 240 72 240













# Batt. 8 27 8 27

kg 12 39 12 39



181

1.45

181

1.45


2 2

GoalCurrent Actual

Mission Length



Days 3 10 3 10

Hours 72 240 72 240











Total System Mass, Starting kg 4.7 11.3 2.6 6.2

Specific Energy, Starting W-hr / kg 306 423 562 772

# Batt. 8 28 8 28

kg 8 29 8 29

Cost of BA-5590 Batteries, @ $70 560$ 1,960$ 560$ 1,960$


Equivalent BA-5590 Batteries(169 W-hr / kg)

181

1.45

181

1.45


0 0

GoalCurrent Actual

Mission Length



Days 3 10 3 10

Hours 72 240 72 240













# Batt. 8 28 8 28

kg 8 29 8 29

Cost of BA-5590 Batteries, @ $70 560$ 1,960$ 560$ 1,960$



2 2

GoalCurrent Actual

Mission Length


181

1.45

181

1.45



Integration / Packaging

User InterfaceFan / Flywheel Output Regulator

Fuel Tank

Casing

Air Intake Tract



MGS-50 : Current Status

Engine + Starter / Generator(Upside Down)

Power Electronics +Control Electronics

Buffer Batteries(Hybrid Power)Engine Assy.

AssembledPrototype



MGS-50 Next Steps

1. Revise Engine from Alpha to Beta Configuration

2. Incorporate Variable-Cooling Scheme for All Ambient Temps.

3. Optimize Encapsulation and Packaging

4. Deliver Several Units for Field Testing

5. Transition to LRIP / Full-Scale Productions



Outline







Basis of D-STAR 700 Watt Micro Generator Set

DARPA-Funded 1.3 hp Micro-Diesel Engine

Successful Operation on JP8 + Oil, No Volatile Additives

Beat SFC Goal by 20%

Beat Life Goal by > 600%

Life Goal : 10 hours.

One Engine : 70 Hrs (Living)

Total Time : 250+ Hours

Performance Verified

by Army @ Redstone

Goal 1.3 hp, Made 1.5 + hp

D-STAR

0.54 cu. in.

Micro-Diesel

Engine

1.4 hp

1.4 lb Wt.

D-STAR Mini-FADEC



MGS-700 : Goals

Honda700W Unit

Gasoline

26 lbs.

D-STAR700 W

Unit

Diesel

15 lbs.

D-STAR Diesel Gen Set

is Half-the-Size, Half-the-Weight

of Honda Gasoline Gen-Set



MGS-700 : Work in Progress

1. Core Power Unit :

Breadboard Testing

in Process

2. Packaging :

Under Design



MGS-700 : Engine + Starter/Generator on Test Stand

D-STAR1.3 hpMicro-Diesel Engine

Starter / Generator



MGS-700 : Engine + Starter/Generator on Test Stand : Max. Pwr.D-STAR GenSet GS-700 1/5/2005

0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

16,000

4:12:00 PM 4:19:12 PM 4:26:24 PM 4:33:36 PM 4:40:48 PM 4:48:00 PM 4:55:12 PM

Time (Clock hh:mm:ss)

Spe

ed (

RP

M)

0

100

200

300

400

500

600

700

800

Wat

ts (

Ful

ly C

ondi

tione

d D

C O

utpu

t)

Speed

Watts

Speed

Power



MGS-700 : Engine + Starter/Generator on Test Stand : Max. Pwr.



MGS-700 : Engine + Starter/Generator on Test Stand : MC Power

D-STAR GenSet GS-700 1/6/2005

0

2000

4000

6000

8000

10000

12000

14000

4:03:22 PM 4:13:26 PM 4:23:31 PM 4:33:36 PM 4:43:41 PM 4:53:46 PM 5:03:50 PM 5:13:55 PMTime (Clock hh:mm:ss)

Spee

d (R

PM)

0

200

400

600

800

1000

1200

1400

Wat

ts (

Fully

Con

ditio

ned

DC

Out

put)

Speed

Watts



MGS-700 : Engine + Starter/Generator on Test Stand : MC Power



MGS-700 : Engine + Starter/Generator on Test Stand : MC Power D-STAR GenSet GS-700 1/7/2005

0.00

0.20

0.40

0.60

0.80

1.00

1.20

2:57:07 PM 3:07:12 PM 3:17:17 PM 3:27:22 PM 3:37:26 PM 3:47:31 PM 3:57:36 PM 4:07:41 PM

Time (Clock hh:mm:ss)

SF

C, l

b/hr

per

hp

( Ass

umes

80%

Ele

ctri

cal C

onve

rsio

n E

ffic

ienc

y)

0

200

400

600

800

1,000

1,200

Wat

ts (

Ful

ly C

ondi

tione

d D

C O

utpu

t)

SFC

Watts

1-Hour Run at Max. Cont. Power

Average Power = 709 W (28 V DC)

Average Engine-SFC = 0.81 lb/bhp-hr



System efficiency calculations

Today Goal Today Goal

Unit output (W) 700 700 600 600

FADEC power draw (W) 2.5 2.5 2.5 2.5

5V regulator efficiency (%) 85% 85% 85% 85%

Power electronics power draw (W) 1 1 1 1

Regulated electrical output (W) 704 704 604 604

Power conversion electronics efficiency (%) 93% 93% 93% 93%

Generator unregulated electrical output (W) 757 757 649 649

Generator efficiency (%) 85% 85% 85% 85%

Fan mechanical power (W) 99 99 85 85

Engine mechanical power required (W) 990 990 849 849

Efficiency : engine mech. to net elect. (%) 71% 71% 71% 71%

SFC (lb/HP/hr) 0.82 0.82 0.82 0.82

Fuel flow (g/min) 8.2 8.23 7.1 7.06

Fuel energy, Lower Heating Value (MJ/kg) 42.8 42.8 42.8 42.8

Engine mech output energy (MJ/kg) 7.22 7.22 7.22 7.22

Efficiency : fuel LHV to engine (%) 17% 17% 17% 17%

Overall efficiency - Fuel to DC Output (%) 12% 12% 12% 12%

Peak Continuous

D-STAR MGS-50 : Diesel Fueled Micro Generator Set



Days 3 10 3 10

Hours 72 240 72 240

Power Needs, Average, 12 Soldiers Watts 240 240 240 240







Fuel Flow, Mission Average g/min 3.28 3.28 3.28 3.28

Fuel Needed kg 14.2 47.3 14.2 47.3




# Batt. 95 318 95 318

kg 138 461 138 461

MGS Weight Advantage (Ratio) 8 14 10 15


0 0

GoalCurrent Actual

Mission Length


181

1.45

181

1.45



Days 3 10 3 10

Hours 72 240 72 240









Fuel Needed kg 14.2 47.3 14.2 47.3




# Batt. 95 318 95 318

kg 138 461 138 461



24 24

GoalCurrent Actual

Mission Length


181

1.45

181

1.45



Days 3 10 3 10

Hours 72 240 72 240









Fuel Needed kg 14.2 47.3 14.2 47.3




# Batt. 100 335 100 335

kg 102 342 102 342

Cost of BA-5590 Batteries, @ $70 7,000$ 23,450$ 7,000$ 23,450$



181

1.45

181

1.45


0 0

GoalCurrent Actual

Mission Length



Days 3 10 3 10

Hours 72 240 72 240









Fuel Needed kg 14.2 47.3 14.2 47.3




# Batt. 100 335 100 335

kg 102 342 102 342

Cost of BA-5590 Batteries, @ $70 7,000$ 23,450$ 7,000$ 23,450$



24 24

GoalCurrent Actual

Mission Length


181

1.45

181

1.45



MGS-700 : Stand-Alone Test Unit (Semi-Packaged Prototype)

ControlPanel

OutputPanel



MGS-700 : Stand-Alone Test Unit : Front View

Exhaust Pipe



MGS-700 : Stand-Alone Test Unit : Rear View

Internal Batteries

Aux. Blower(Interim

Prototype Only)



Outline







MGS-700 : Future Plans

1. MGS-1500 : 1.5 kW Unit

Based on 2-Cylinder Engine

2. Long-Endurance Unit

Based on 4-Stroke Engine

for Greater Fuel Economy



Current Marine Corps Program

Hybrid Power System for Small UGVs

Objectives :

Replace Current Low-Speed Engine with Hydro-Static Drive

by Compact, Light-Weight Hybrid-Electric Power System

D-STAR Concept

High-Speed Mini-Diesel Engine and Starter-Generator

Remote Wheel Motors with Plug-and-Play Modular Architecture

Hybrid-Electric Operation with

Batteries, Super-Capacitors, Electro-Turbo-Compounding



Current Marine Corps Program

Hybrid Power System for Small UGVs

24” 24” 24”

72”

28” 40” 19” Dsl. 15”,

10 hp



Conclusions

1. D-STAR Micro-Diesel Engines are Logistics Fueled Source of Power.

2. Compared to Batteries, D-STAR Micro Gen Sets Offer :

An Order of Magnitude Greater Energy Density

An Order of Magnitude Lower Costs.

3. D-STAR Micro Gen Sets are Close to Transitioning to Production.

d-star engineering corporation, all rights reserved approved for public release, distribution...

Documents

rights reserved slide

public release

distribution unlimited

apus slide

assembled prototype

maximum efficiency slide

stroke engine portable

cylinder engine