NAS_26Jul10

National Academy of Sciences Battery ConferencePanel I: The Federal Outlook for the U.S. Battery Industry

The Army Perspectives

Dr. Grace BochenekDirector, U.S. Army Tank Automotive Research, Development & Engineering Center

Dr. John PellegrinoDirector, Sensors and Electron Devices Directorate,U.S. Army Research Laboratory

NAS_26Jul10

Discussion Topics

• Army Ground Vehicle Perspective

• Vehicle Power and Energy Trends

• Warfighter Requirements

• Spectrum of Vehicle Electrification

• Systems Integration—From Component to Platform

• Energy Storage Technology Developments

• Challenges

2

NAS_26Jul10

It’s All About the Warfighter

3

NAS_26Jul10

Task Organized to Deliver Capabilities

Technology – System

Organizational Construct

Multifunctional, Multidisciplinary

Organization

Cross-cutting System Engineering

Incubating, Maturing, Transitioning

Next Generation Technology

Power & Energy

Leveraging Resources & Investments to Deliver Capabilities

4

NAS_26Jul10

TARDEC Mission and Vision

Responsible for Research, Development and Engineering Support to 2,800 Army systems and many of the Army’s and DOD’s Top Joint Warfighter Development Programs

Ground Systems Integratorfor the Department of Defense

– Provides full life-cycle engineering support and is provider-of-first-choice for all DOD ground combat and combat support vehicle systems.

– Develops and integrates the right technology solutions to improve Current Force effectiveness and provide superior capabilities for the Future Force.

5

NAS_26Jul10

Power and Energy Trends

0

20

40

60

80

100

120

1860 1880 1900 1920 1940 1960 1980 2000 2020 2040 2060

Year

Fu

el

Co

nsu

mp

tio

n p

er

So

ldie

r [g

al/

so

ldie

r/d

ay]

1944

Korean

War

Vietnam

War

Iraq

War

Desert

Storm

Future

Wars

WW I

Civil

War

Region of

Projected Fuel

Consumption

Best Case

Worst

Case

The Challenges

Battlefield consumption of energy

increasingNew C4ISR technologies

IED Defeat Systems

New weapons (EM guns, lasers)

Energy security problematicCost of fuel skyrocketing

Alternative sources sought – wind, solar, bio-

mass, waste to energy

Operational issuesBattery 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 and energy efficiency

(KPPs, low consumption components)

6

NAS_26Jul10

Power and Energy Warfighter Outcomes

• Enhance ground force effectiveness,

flexibility, protection and freedom

of movement by reducing the need to

transport fuel

• Dramatically reduce sustainment

footprint, lighten soldier load and extend

platform range/self-power endurance by

combining component functions

• Increase flexibility by expanded

capabilities to utilize alternative energy

sources, recycle energy, water and

waste, and to redistribute resources

among systems

• Reduce size and number of Soldiers &

systems required in forward areas by

deploying unmanned systems

• Integrate power & energy situational

awareness and management functions

with Mission Command to optimize

energy use and enable "energy-

informed operations"

7

NAS_26Jul10

Menu of Capability

Co

mp

lexity

an

d P

ow

er G

row

th

Onboard Power Fuel Economy

(FE) + O&E +BP

O&E + Boost

Power (BP)

Onboard & Export

Power (O&E)

Silent Mobility (SM)

+ FE+ O&E +BP

Silent Watch + (SM)

+ FE+ O&E +BP

5 kW - 30 kW 10 kW - 50 kW MPG ¼ Mi - 1 Mi 1/2 Hr - 8 Hr

Non - Mild Hybrid

Mild Hybrid – Parallel Hybrid

Parallel Hybrid - Series Hybrid

Alternator

Batteries

Motors

APU

Power Electronics

ISG

Integrated Starter

Generator (ISG)

Solid State

Silicon Carbide

(SiC) Power

Electronics

APU (Fuel Cell)

JP-8 Reformed

Fuel Cell

Advanced

Batteries

Batteries

Power Brick for

EMA

High Energy Density

Capacitors for Electric

Weapons and Armor

ESS

Elec

28V

Sta

rte

r ESS

Hull

28V

PCM3

0.8kW

PCM2

1.5kW

PCM1

1.5kW

Slip Ring

BMS2

ESS

Turret

28V

Smart

Display

(VPMS)

Dirty

Hull

Loads

Elect.

Loads

Turret

Loads

LV

610VDC

28VDC

NPS

HV/LV

LVPDB

2.24kW

HVPDB

DVDB

1.7-8.2kW

Hull

Loads

TPB

1.2-4.4kW

Gun/Turret

Drive Control

Turret

AOPET Test Control Panel

CleanHPB1

TP

EA

MP = Master Power switch

TP = Turret Power switch

EA = Engine Accy switch

oldnew

MP

AV900_CH1 (160kW)

Spare1 (30kW)

Spare2 (30kW)

AHU1

(1.4kW)

Control Line

BMS1

ECS_Compressor

(7.8kW)

ECS_Condensor_Fan

(4.4kW)

PECS_Pump

(1.7kW)

Rad_Fan1 (35kW)

AHU2

(1.4kW)Thermal

Mngmt

(VTMS)

3Ø VAC

G

D

L

S

B

A

E

M

C

5

M

C

4

HV/LV

Rad_Fan2 (35kW)

HV Enable

MC3

MC2

MC1

HPB2

HP

B3

200

80

80

80

80

80

80

80

80

500kbps

Ground Fault Detect

250kbps

PECS Loop

DCDC1

(10kW)

DCDC2

(10kW)

Coolant

Temp

Fuel

LevelEngine Accy

Master Power

Open/28V Inputs

Test Loads (Water Tank)

T

L

2

5

T

L

2

5

T

L

5

0

T

L

5

0

T

L

5

0

HEATER

18kW

700V

Engine

Status

Battle

Override

Load

Controls

Trans.

Status

Tactical

Idle

Fault

Induce

POL1

(DDC)

POL2

(DDC)

POL3

(Global ET)

AV900_CH2

(0-18kW)

DFMC

5

200

200

80

5

E-STOPNPS

Status

Load A

Gages

Bus V

Gages

Fuel

Pump

Open/Ground Outputs

Eng Clnt

Temp

Level

SwitchEngine Oil

Pressure

Trans Oil

Temp

CAN: Power

CAN: Thermal

500kbps

T

L

2

5

1000

1000

Intelligent Power

Management

Capacitors

Platform Electrification Technology

8

NAS_26Jul10

Systems Approach Applied

Subsystem Elements

High Temperature Electronics

Batteries

Component Elements

System Integration

Testing

DC/DC Converters

Motors

Engines

Platform Level

Engine Generator

High Temperature Power

Electronics

Analysis Simulation

Concepts

Systems Integration

Enabling Integration & Technology Development

Component

Parallel

Hybrid

MSV

Autonomous Platform

Demonstrator

Fuel Efficiency

ground vehicle

Demonstrator

RSTV Series HE

Ground Combat

Vehicle

Joint Light

Tactical Vehicle

Parallel hybrid UVs

9

NAS_26Jul10

Energy Storage Major Technology

Increasing Energy Density

Energy Density Improvements over time

2004

• NiMH

• 120 Wh/kg

2012

• Li-Ion Polymer

• 200 Wh/kg

Fielded

2008

• Li-Ion

• 145 Wh/kg

1860

• Pb-Acid

• ~30 Wh/kg

1980

• Nickel-Cadmium

• 60 Wh/kg

2035-2050APU + High Energy Batteries

JP 8 Reformed Fuel Cell + Batteries

Actual Growth 1985-2007

0

10

20

30

40

50

JLTV GCS Stryker HBCT HMMWV

Ele

ctr

ica

l Po

we

r (k

w)

Current

Future

Estimated Electrical Power Growth

Actual Growth 1985-2007

0

10

20

30

40

50

JLTV Stryker HBCT HMMWV

Ele

ctr

ica

l Po

we

r (k

w)

Current

Future

10

NAS_26Jul10

Vehicle Electrification Challenges

Parallel Hybrid MSV

HMMWV Series HE

RSTV Series HE

Military Duty Cycle and extreme

environments

Very high torque and power

demand

Reliability and Safety

Integration and packaging

Thermal management and high

temperature components (SiC)

Development and advanced

technology unit Cost

Logistics and supportability

Expeditionary operations

11

NAS_26Jul10

National Academy of Sciences Battery ConferencePanel I: The Federal Outlook for the U.S. Battery Industry

Army Energy and Power:Battery Research and Investments

Dr. Grace BochenekDirector, U.S. Army Tank Automotive Research, Development & Engineering Center

Dr. John PellegrinoDirector, Sensors and Electron Devices Directorate,U.S. Army Research Laboratory

NAS_26Jul10

• Defense and Army Strategic Energy

Opportunity Areas

• Army Energy Strategy and Taxonomy

• Army Battery Investment Focus

• Battery Technology Programs

• Summary

Discussion

13

NAS_26Jul10

Autonomous Platform Power

Tactical Unit Energy Independence

Adaptive Power Networks

Defense Energy Strategic Opportunity

Areas for Future Directions

Energy Optimized Platforms

Electric Weapons and High Power Sensors

EM Launch

UAV

UGS

14

NAS_26Jul10MicroWatts to 10s of Watts 100s of Watts to 100s of kW Up to 1000s of MW

DOMAINS: Soldier, C4ISR C4ISR, Air, Ground Ground, Effects

MOBILE

SOLDIER

PLATFORM &

WEAPONS

Requirement:

72 Hour Missions

Requirement: Platform Surge

Power , Weapon Pulse Power

Technologies: High Power

Switching & Conditioning;

Intelligent Power Management,

Integrated Thermal Management

Technologies: High Energy

Batteries, Hybrid Power

Sources, Photovoltaic

Requirement:

Silent Power

Technologies: Fuel Cell APUs,

Reforming, Power MEMS

Power & Energy Strategy:

Army Translation of Opportunity Areas

NAS_26Jul10

Unmanned Air and Ground Platforms

Higher Energy Power Sources for

Soldiers and Sensors

Intelligent Energy Management Coupled with

Alternative Energy Sources for Reduced

Logistical Burden (Combat Outposts)

Army Strategic Opportunity Areas

Ground Combat & Tactical Vehicles

Vehicle Auxiliary Power and Quiet Watch CapabilitiesRucksack Portable

Power System

Reformed

Methanol Hybrid

Fuel Cell

High Energy Weapons

16

NAS_26Jul10

Fuel Cells & Reforming

Electro-mechanical Generation

Alternative & Renewable Energy Conversion

Micro Power/ Actuators/Motors

FY10 Investment 6.1: 4.3% 6.2: 57.8% 6.3: 37.9% Total:100%

Heating & Cooling

Power Electronics

Sub-System Thermal Management

Primary Batteries

Rechargeable Batteries

Reserve Batteries

Capacitors

Fuel Storage

Power Switches /Electronics

Power Converters & Inverters

Power Distribution

Intelligent Power Management

Magnetics/Other

Power & Energy Taxonomy

25.6% 27.2% 16.6% 30.6%

NAS_26Jul10

Army Battery Investment Focus

Li-Air PrimarySoldier power, persistent

surveillance, sensors

Liquid Reserve

Electric fuses for artillery,

mortar, missiles, sub-munitions

Thermal ReserveElectric fuses for artillery,

missiles

Pulse Power Li-Ion

RechargeableWeapons, GCV, 600V battery

pack

Li-SO2 PrimarySoldier power, sensors

Military Unique

Chemistries

Hi Power Li-Ion

RechargeableVehicles, critical backup,

Soldier power, persistent

surveillance, sensors

Li-(CF)x PrimarySoldier power, sensors

Ni-Zn RechargeableVehicles, critical backup

Commercial Chemistry

Requiring Military

AdaptationLead Acid Rechargeable

(SLI/HEV)Vehicle, critical backup, deep

cycle applications, low cost

electrical storage

Alkaline PrimaryNon-critical applications

Ni-MH Rechargeable Soldier power, HEV

Li-MnO2 Primary

Zinc-Air Primary Soldier power, sensors

Li-FeS2 PrimarySoldier power, sensors, long

shelf life applications

Commercial Market

HighLowArmy Technology Priority

18

Low

High

Inve

stme

nt P

riority

NAS_26Jul10

19

High Voltage Li-ion Batteries

OBJECTIVE• Develop safe and higher energy-density

Li-ion batteries

CHALLENGES• Cycling capability

• Electrolyte instability at higher voltages

• Stabilized LiCoPO4 by partially

substituting Co with other metals

with low capacity loss.

• Identified electrolyte additive

that allows the cycling of high

voltage cathodes with high

capacity retention.

Cycling of structurally modified LiCoPO4 vs. Li, 3.0 – 4.9 V

LiCoPO4

ARL modified LiCoPO4

Cycling of LiNi0.5Mn1.5O4 vs. Li, 3.0 – 4.95 V

ARL electrolyte

Baseline

electrolyte

NAS_26Jul10

Bio-inspired Materials for Enhanced

Battery Performance

• Bio-inspired catalytic synthesis grows tin nanoparticles inside graphite

• Higher metal electrical capacity that better accommodates swelling and shrinking during charge-discharge cycle

• Prevents metal disintegration and capacity loss seen with other anodes

• Result is higher energy and higher power density (excellent performance at 20C); suggests applications for lightweight electric vehicles and UAVs

High-performance Anodes

For High Power, Lightweight

Li-ion Batteries

Retains High Capacity at High Rates

20

NAS_26Jul10

Improving energy capability through holistic power sharing!

Wind

Non-propulsion

Vehicle Apps

Improved

Soldier Power

Battery Technology:

Key Enabler for Networked Energy

Base/COP

Back-up Energy

Increased life/endurance

Increased Voltage

Increased Capacity

Smart Grid

Improved OperatingCharacteristics

(i.e., temperature, cycling)

Intelligent Power Usage

Energy Harvesting

EM/Reactive Armor

Energy Weapons

Future systems, ever

more power intensive!

Unattended Sensors

Safety

Less Degradation

Battery RechargingOff-peak Energy Storage

Battery Technology

21

NAS_26Jul10

It’s All About the Warfighter

22