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Light-weight Internal-combustion High-power, Transformative, Novel, Individual New Generator (LIGHTNING)

Description:

TECHNOLOGY AREA(S): Human Systems

OBJECTIVE: Design, develop and demonstrate a light-weight, Soldier wearable, safe, small Soldier Power Generator (SPG) system using JP-8 fuel as a minimum.

DESCRIPTION: The Soldier’s power generation capability must provide an on–the-move power to enable battery recharging.System weight including 350 Watt-Hours of fuel (inclusive refillable Bladder / canister type fuel container) shall be less than 3 Lbs.A minimum of 30 Watts continuous power shall be provided with ability to have a “LOW” setting at 20W, a “MEDIUM” setting at half way between 20 W and Maximum, and a “HIGH” setting at maximum power to allow the operator to adjust power available, noise, and fuel conservation as needed.The LIGHTNING system shall have an attachable hose (not included in system weight) to allow for indoors operation or to vent heat exhaust away from the Soldier.Fuel at a minimum will be JP-8, with objective of being multi-fuel system.The LIGHTNING System shall have a volume of less than 60 cubic inches including fuel and with a length and width not exceeding 7 inches and a depth not to exceed 3 inches in any dimension, with an objective of less than 45 cubic inches.System design and implementation shall allow for Soldier operation between -20°C to +55°C, be rugged, droppable, operate in rain and immerse able (2 hours 1 meter – shake out and able to be restarted without system damage) in Soldier use environments (iaw MIL-STD-810). The system shall have an embedded self-start function that may use power from the Soldier’s 10 to 20 VDC battery.A selector switch shall be provided to select between 10 to 20 VDC output (15-19 VDC Nominal) and 10 to 32 VDC output (28-32 VDC Nominal) power output.Full power shall be available within 5 seconds.Output power shall be interoperable with items that can scavenge power looking for Maximum Power Point Tracking (MPPT) when connected to external systems (Examples – Thales Universal Battery Charger – Lite; Revision Squad Power Manager (solar panel input); Advanced Power Electronics Corporation – Solar In-line Recharge Enabler).The system shall be relatively quiet generator < 80 dB (Threshold) / < 60 dB (Objective) at 30W output.The system shall be safe to touch (iaw MIL-STD-1472) (T); <3°C higher than ambient Temperature (O).The system shall provide Safe on-Soldier and on ground operations (T) and operate indoors (may include snorkel to outdoors) (O).The system shall be designed to operate for 2000 hours operation with minimal maintenance.At a minimum, the LIGHTNING System shall have a two pin shrouded trailer hitch and / or a 7 socket GlenAir Mighty Mouse (i.e. Glenair Part Number 8071-1472-12 / 8070-1299ZNU7-7DY - 807-663-12/807-348-01ZNU6-7SY, 8070-1675-01ZNU6-7SY or equivalent connector).The system shall be safe with minimal carbon monoxide output.Future objectives would be to output power such that it is compliant with System Management Bus (SMBus) version 1.1 or higher output to directly charge batteries as one of its output power modes, and to provide power that has an auto shut off function when the power drain is minimal.Other objectives would be to have items such as a digital readout with power out, time remaining on current cartridge/canister/bladder of fuel, and system state of health (SOH) / overall hours operated, if SMBus controlled output, - connected battery State of Charge / SOH, and time to charge complete, etc.

PHASE I: Develop an innovative approach and a detailed design of the proposed LIGHTNING System that would employ JP-8 fuel source. The design shall take into consideration the Soldier’s equipment and space claim along with appropriate placement on the Soldier, its human factors to include comfort, acoustics, emissions, etc., in order to provide a positive implementation for use on the Soldier on the move and shall not interfere with Soldier operations.Perform a tradeoff study of candidate configuration/options and identify best solution. The final report shall be a complete design of the proposed LIGHTNING System. The report shall delineate how the system will allow for proper use on the Soldier and interoperability with power scavengers and appropriate ruggedness.The report shall also provide an estimate of the cost, size, weight, system acoustics, system temperatures, system power generation, and any tradeoffs. Provide prototype of or details of proposed solution that meets the light-weight (less than 3 Lbs. at greater than 30 W output) and small on-Soldier form factor size and power requirements.A prototype system will be bench-demonstrated in form-factors relevant to the Army’s needs, with key metrics including weight of the Soldier-worn power generation device, power transfer range, peak-power, frequency, and overall system efficiency.In order to be considered for this effort, the bidding firm must also show that they are capable of performing proof-of-principle experiments.

PHASE II: Based on the selected Phase 1 design, build a minimum of two (2) fully functional, rugged prototype of the proposed SPG system, then integrate and test it with Army provided power scavengers and recharging devices (UBC-Lite; SIREN, SPM 622) as defined by the Project Manager Close Combat Squad (PM CCS) Ground Soldier Systems (GSS) – Soldier Power (SP) team and employ on and off the Soldier and verify operational performance to provide power.Demonstrate the capability of the LIGHTNING System to operate on and with existing Soldier gear and equipment (E.g. Radios and GPS systems – Government supplied) with minimal impact to Soldier or Systems performance. Submit a report detailing test and demonstration results. The report shall include the study of how the System will complement or impact Soldier operations and equipment. All software / firmware / Graphical User applications generated for the System shall be provided as open source information to the Government along with any input/output data/ICDs to / from the LIGHTNING System.Supporting data shall include analysis for LIGHTNING system’s performance throughout its lifecycle.Identify any other issues that should be addressed in Phase III like hardening the technology to survive Soldier environments (e.g. MIL-STD-810, MIL-STD-461, etc.), handling, and ease of use along with considerations for low-cost production processes for mass production.

PHASE III: In conjunction with PM CCS GSS SP, optimize the prototype fabricated in Phase II to commercialize the system and be rugged for operations in Tier 1 (most austere environments) mission operations and durable enough for Soldier fielding.Provide a transition path to DoD Program managers for use of this novel power system. The development of this LIGHTNING System also could have considerable commercialization potential for outdoor activities such as hiking and camping that do not have traditional power available.

KEYWORDS: Expeditionary Soldier Power, Internal Combustion Engine, Power Generation, DC Power, Lightening the Soldier Load, Operational Flexibility.

References:

1. Department of the Army Memorandum THRU General Robert W. Cone, Commanding General, U.S. Army Training and Doctrine Command, Fort Monroe, VA; Subject: FY12 Warfighter Outcomes (WFO) to Guide Science and Technology (S&T); Dated: 08 Jun 2011.; 2. Department of the Army Headquarters, United States Army Training and Doctrine Command Fort Monroe, VA 23651-1047 Military Operations Force Operating Capabilities dated 7 March 2008 TRADOC Pamphlet 525-66.; 3. Capability Development Document For (U) Small Unit Power (SUP) Increment: 1 dated 12 July 2013, CARDS # 16160 approved 26 SEP 13.; 4. Military Standard - Environmental Engineering Considerations and Laboratory Tests (MIL-STD-810G): http://en.wikipedia.org/wiki/MIL-STD-810.; 5. Military Standard - Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment (MIL-STD-461).; 6. Military Standard – Human Engineering (MIL-STD-1472).; 7. Military Standard - Characteristics of 28 Volt DC Electrical Systems in Military Vehicles (MIL-STD-1275).; 8. Integrated Soldier Power & Data System – Core Performance Specification (PM-SWAR-SPS-ISPDS-C Dated 27 June 2014) – Project Manager Soldier Warrior Soldier Systems & Integration, 10125 Kingman Road, Bldg 317, C18 Fort Belvoir, VA 22060-5820.Note: PM SWAR is now PM CCS located at 5966 12th Street, Bldg 1024, Fort Belvoir, VA 22060.; 9. Published Conformal Battery Specification (MIL-PRF-32383/4): Base Spec and Slash 4: http://quicksearch.dla.mil/basic_profile.cfm?ident_number=277787&method=basichttp://quicksearch.dla.mil/basic_profile.cfm?ident_number=279268&method=basic; 10. Military Operational Environments - http://www.dtic.mil/doctrine/jel/service_pubs/fm3_0a.pdf.

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