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Intelligent Charge Control System w/Anti-Idle to Minimize Fuel Consumption


OBJECTIVE: Develop software to demonstrate a minimum of 10% fuel savings over a 72 hour combat mission combining power management to control battery state of charge and battery rate of charge with anti-idling technology to only run the engine when truly necessary. The strategy will be demonstrated on a military ground vehicle to validate fuel savings of at least 10% on the mission. DESCRIPTION: Currently, the vehicles'batteries, diesel engine, and power generation are not networked and intelligently controlled on today"s military ground vehicles. The technical challenge will be the system integration approach and in writing the software to connect and control these three systems together to achieve the optimal fuel consumption without changing how the soldier operates the vehicle and without reducing mission readiness. Today fuel is not consumed in the most optimal way and much energy is lost during stationary vehicle idling. All combat vehicles are required to idle for at least 50 hours of a 72 hour mission. It is during this idle time that the greatest fuel can be saved if the batteries are intelligently charged and discharged, the diesel engine is turned off and on, and the power generation power output is controlled. System will utilize a Niehoff 570amp alternator on a CAT C7 engine. Vehicle integration will be on a MRAP or Stryker. The final product will be a vehicle level software control package utilizing a networked battery monitor and an alternator whose voltage is dynamically controllable to optimize power control and battery charging. This software will likely operate on a computing resource provided by the contractor for this effort and will not be required to be fully integrated into one of the vehicle's computers. In addition a test report will be provided to document the fuel savings and the performance of the intelligent battery charge control with anti-idling algorithm. PHASE I: Identify the hardware technologies required for successful integration (batteries, battery monitoring system, control computer, etc.). Acquire CAN network interfaces for the alternator voltage regulator, battery management system, and the engine electronic control unit. Define phase II plan to develop and demonstrate/test the technology. Develop preliminary plan for vehicle integration. PHASE II: Integrate a power management system with battery monitoring with charge control and intelligent anti-idling technology on a military ground platform capable of communicating and control via CAN. Test the power management software on a vehicle to verify at least a 10% reduction in fuel consumption is realized during a 50 hour engine idle. The electrical power draw from mission loads will average 2kW during the 50 hours of engine idling on the combat mission. The contractor will deliver the power management software, CAN interfaces, interconnect drawings, and final test report detailing results as compared to the same vehicle when the anti-idling software is disabled. PHASE III: The idea would be for this software technology to be integrated onto an already existing vehicle computer or on a very small contractor supplied control box. The software will need to be continually tailored as it is applied and sold to the vehicle OEMs that have different alternators, engines, and/or battery monitoring systems. There will be multiple follow-on integration efforts in order to get this technology on to as many military ground vehicle platforms as possible. The technology will next be integrated on to an Abrams tank and Bradley vehicle, followed by any other platform with significant idling time during deployed operations, such as trucks waiting in a convoy. REFERENCES: Data from 2004 silent watch testing showing Hawker battery charge and discharge curves. Engine idling fuel consumption data from 2004 silent watch test.
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