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High Voltage Wide-Bandgap Motor Controller

Description:

TECHNOLOGY AREA(S): Ground Sea 

OBJECTIVE: Design a high voltage wide bandgap motor controller (HVMC) capable of operating across on all military ground vehicles. The use of wide bandgap should reduce size, weight and cooling requirements. 

DESCRIPTION: With the growing vehicle electrical power requirements in military vehicle systems the use of wide bandgap semiconductor technology is necessary for the future. The motor controller must account for safety, efficiency, scalability, configurability, CAN control, and integration. The solution will have the processing power necessary for fault detection and handling capabilities, built-in diagnostics, and stand alone and remote control in a compact device suitable for use in military ground vehicle applications. The proposed unit must use wide bandgap technology capable of operating at high voltages as specified by MIL-PRF-GCS600A. Topic proposals should focus on units capable of operating up to 18kW at 30A DC. The use of wide bandgap power electronics that can operate in a 71C ambient environment using 105C coolant is required. The unit should be able to communicate using J1939 CAN interface to accept commands from the “host”, and provide diagnostic status on command, or in the event of a “fault”. The motor controller should demonstrate High Voltage Interlock capabilities. The proposal should address thermal management plan for the HVMC, while also meeting military standards. 

PHASE I: Develop a proof of concept circuit for a high voltage wide bandgap motor controller that addresses the features and functionality described above. This preliminary design will include a packaging plan with SWaP, thermal analysis and considerations for meeting MIL-STD-1275E, MIL-PRF-GCS600A, MIL-STD-810G, MIL-STD-461G supported by modeling, analysis, and/or brass board proofs of concept, all to be provided. 

PHASE II: Electrical, thermal, mechanical, and functional aspects of a high voltage wide bandgap motor controller solution will be designed, developed, and built. Demonstration and technology evaluation will take place in a relevant laboratory environment or on a military ground vehicle system. Phase II will reach at least TRL 5 and commercial viability will be quantified. 

PHASE III: Mechanical packaging and integration of the HVMC (high voltage motor controller) into a vehicle that will achieve TRL 6 and a technology transition will occur so the device can be used in military ground vehicle applications. Applications include MRAP CS13 vehicles, Stryker, Bradley, Abrams, and AMPV. 

REFERENCES: 

1: MIL-STD-1275E

2:  MIL-STD-810G

3:  MIL-STD-461G

4:  MIL-PRF-GCS600A

CONTACT(S): 

Eric Szczesny 

(586) 282-4889 

eric.a.szczesny2.civ@mail.mil 

Paul Hillebrand 

(586) 282-8756 

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