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Novel Gun Hardened Energy Management System



OBJECTIVE: The objective is to develop a novel energy system that can meet munition power requirements for a period of 30 days and that could provide high-pulsed power on demand over this period. Candidate systems must be highly miniaturized, must integrate energy management functions to minimize energy consumption during the required 30 days power budget, must be fully compatible with currently available manufacturing processes and must be gun hardened. 

DESCRIPTION: This effort seeks proposals for the development of novel energy management systems that can provide relatively low electrical power of the order of 10mW to munitions for a period of 30 days while being capable of provide a number of pulses for no longer than 1 sec each and no more than 500ma. The power system may use appropriate electrochemistry that can provide energy at the required levels for a period of 30 days. The energy system must be capable of being gun hardened and have a minimum shelf life of 20 years. The primary application is emplaced munitions which may have to satisfy the shock survivability requirement, such as gun launch and must be capable of withstanding launch accelerations of 100,000 Gs and preferably higher during launch. The energy management system must be capable of monitoring, regulating, informing the onboard information system within the munition of the energy expanded and the energy available for the mission and the number of pulses available in the system energy management system, at any point within the 30 day mission. The Novel Energy Management System must meet all military operational and storage temperature requirements of -65 deg. F to 165 degF and safety are of great importance. The proposed energy management system concepts are expected to take full advantage of the highly developed battery and other power source technologies to develop a novel energy management system that can satisfy a wide range of military munitions, including gun-fired and emplaced munitions. The proposed energy management system must be capable of being miniaturized while the total system weight should also be considered. The system must also be highly reliable and safe for use in munitions. It is also highly desirable that in all applications the proposed energy management system concepts provide a high level of conformability to the available munitions space and its geometry. Manufacturability and the potential use of mass production processes developed for commercial applications to achieve low cost and high reliability is also of great importance. 

PHASE I: Conduct a systematic feasibility study of the proposed energy management system concepts by computer modeling and simulation as well as basic laboratory testing to determine if they have the potential of meeting the desired power and energy requirements, high shock survivability, military shelf life, military operational and storage temperature requirements. Manufacturability of the proposed concepts and compatibility with mass production technologies used in similar commercial applications to achieve low cost and highly reliable gun hardened energy management systems must also be addressed. The Phase I effort must also address shelf life and safety issues and provide a detailed plan for the development of the energy management system concepts, along with their prototyping and testing during the project Phase II period. A successful phase I needs to include a trade study on 20 year shelf life cost drivers and recommend trade-offs that may reduce shelf life but significantly reduces life cycle cost. 

PHASE II: Design and fabricate full-scale gun hardened energy management system prototypes of the selected concepts and test such prototypes in the laboratory and in relevant environments, including in shock loading machines and in air guns. Demonstrate that such prototypes can survive in operational environments while providing the designed power and voltages under simulated load conditions within the entire indicated operational temperature range. Prototypes must be subjected to laboratory tests and must include full operating cycles under simulated load conditions. The Phase II period must also include the fabrication and delivery of final prototypes of each selected design for the selected munitions applications. 

PHASE III: The proposed gun hardened energy management system concepts would apply to gun fired munitions, weapon based platforms and emplaced munitions applications. Commercial uses for such technology could include application to the electric vehicle industry and also for energy recapture in industrial settings where renewable energy sources from machinery could provide huge cost savings. 


1: Encyclopedia of Electrochemical Power Sources, C.K. Dyer et al, Elsevier Science (2010).

2:  Handbook of Batteries - Linden, McGraw-Hill, "Technology Roadmap for Power Sources: Requirements Assessment for Primary, Secondary and Reserve Batteries", dated 1 December 2007, DoD Power Sources Working Group.

3:  Macmahan, W., "RDECOM Power & Energy IPT Thermal Battery Workshop – Overview, Findings, and Recommendations," Redstone Arsenal, U.S. Army, Huntsville, AL, April 30 (2004).

4:  Linden, D., "Handbook of Batteries," 2nd Ed., McGraw-Hill, New York, NY (1998).

5:  Guidotti, R. A., Reinhardt, F. W., Reisner, J. D., and Reisner, D. E., "Preparation and Characterization of Nanostructured FeS2 and CoS2 for High-Temperature Batteries," to be published in proceedings of MRS meeting, San Francisco, CA, April 1-4, 2002.

6:  Warner, J., "The Handbook of Lithium-Ion Battery Pack Design - Chemistry, Components, Types and Terminology", Elsevier Science (2017).

KEYWORDS: Energy Management System, Electrical Power System, Electrical Power Sources, Mechanical Shock And Vibration, Low Temperature Performance 


Dr. Carlos Pereira 

(973) 724-1542 

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