Company
Portfolio Data
Back to Company SearchHEPBURN AND SONS LLC
UEI: TLLAP6FKHA99
Number of Employees: 60
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
SBIR/STTR Involvement
Year of first award: 2016
16
Phase I Awards
11
Phase II Awards
68.75%
Conversion Rate
$2,683,111
Phase I Dollars
$13,822,824
Phase II Dollars
$16,505,935
Total Awarded
Awards
Medium Voltage Direct Current Disconnect Switch Design
Amount: $641,989 Topic: N221-064
Hepburn and Sons LLC, teamed with Florida State University Center for Advanced Power Systems (FSU CAPS) and Georgia Tech Research Corporation (GTRC), proposes to prototype, validate, and optimize a family of medium voltage direct current (MVDC) disconnect switches and associated switchgear based on Thomson coil topology actuator design. Shipboard MVDC distribution does not exist in the U.S. Navy fleet, but there is significant advantage. The protection of such a system is of critical importance to the feasibility of the system design as well as to the safety of personnel. The team proposes an advanced modeling and simulation approach to further develop the appropriate DC disconnect switch design selected during Phase I to meet the U.S. Navy’s needs. Existing Navy protection systems can detect and locate single line to ground faults on a given phase, but a second ground fault on a separate phase causes a line-to-line fault which trips breakers and removes power from downstream loads. Isolating an initial single ground fault can mitigate the risk of double faults and loss of power to mission critical equipment.
Tagged as:
SBIR
Phase II
2025
DOW
NAVY
Continuously Operating, Air Cooled, Ground Circuit Enabled by Advanced Magnetics with Tuned Thermal Profiles
Amount: $139,992 Topic: N25A-T009
Hepburn and Sons has teamed with the University of Pittsburgh to develop a novel air-cooled grounding circuit for medium voltage AC Shipboard Power Systems (SPS) that leverages the latest advances in magnetic materials to handle continuous fault current and DC current support with SWAP-C savings achieved through spatially tunable inductors reducing heat generation and coordinating hot spot localization. The team will evaluate passive and active solutions to best address the US Navy’s needs. Reliable SPS must operate continuously despite the existence of a single line to ground fault. This necessities a high resistance between the neutral and ground to regulate the neutral voltage to a safe and manageable level. However, continuous operation is a challenge with the resulting high-power dissipation. Novel grounding circuits can mitigate heat generation through reactance based current limiting. Further, magnetic solutions can better manage heat generation with spatial tuning of material properties to customize thermal profiles. This results in significant loss reduction in the grounding circuit which enables continuous operation with air cooling.
Tagged as:
STTR
Phase I
2025
DOW
NAVY
Predictive Methodology for Tamped Direct Laser Impulse Parameter Optimization
Amount: $199,985 Topic: DTRA243-004
Hepburn and Sons LLC (Hepburn) teamed with Applied Impulse Inc. (Aii) propose development of a novel computational toolset for the laser driven shockwave community. The team is composed of investigators with comprehensive experience in predicting, modeling, measuring, and simulating these high-pressure, high-speed events and maintain a suite of laser equipment and diagnostics to support tool validation. The team will develop a software package that determines laser parameters capable of generating user-specified plasma pressure characteristics at a target. This software is termed Predictive Impulse and Laser Optimization Toolset (PILOT) and will utilize metamodels based on a combination of physics-based calculations and machine learning (ML) algorithms to provide reliable parameter selection for laser shock experiment design and industrial process development. Uncertainty quantification in the plasma pressure prediction sources incorporated into the toolset will provide insight into sources of uncertainty, distribution, sensitivity, and potential refinement opportunities. Diagnostic outputs in the form of free surface interferometry predictions will enable comparison of expected material responses to experimentally observable data. The toolset will allow DTRA to rapidly adapt and optimize experiments to de-risk survivability of DoD materials and structures and explore the effects of high-energy lasers to counter emerging threats. This high-speed response capability will also provide insight and process optimization benefits for commercial users of laser shock processing.
Tagged as:
SBIR
Phase I
2025
DOW
DTRA
MVDC Protective Relay System with Shipboard Power System Zone Distinction
Amount: $139,993 Topic: N25A-T012
Hepburn and Sons LLC, teamed with Florida State University Center for Advanced Power Systems (FSU CAPS), is proposing to develop a machine learning (ML)-based fault protection relay system, complete with necessary sensors, for 1kV, 6 kV, and 12 kV zonal Medium Voltage Direct Current (MVDC) shipboard power systems (SPS) with the objective to implement overcurrent and differential/directional protection in both breaker and breakerless architectures. MVDC SPS architectures present unique challenges and opportunities for protection due to the low system inertia, high probability of backfeeding through low impedance buswork, and imprecise zonal definitions due to the lack of transformers. It is critical for the maintaining of SPS integrity to quickly isolate a faulted piece of Navy equipment, and the use of advanced methods that identify the electrical zone and shipboard compartment containing the fault will facilitate rapid repair responses and enable safe and continuous operation of the system for the warfighter. Our proposed relay system will leverage emerging machine learning technology to quickly characterize fault signatures in zonal architectures of interest. This solution will provide the benefit of simplified, high speed, fault identification and localization to then coordinate and trigger appropriate protection responses in a proper sequence upon fault initiation.
Tagged as:
STTR
Phase I
2025
DOW
NAVY
Ground Fault Detection System
Amount: $1,699,926 Topic: N21A-T005
Hepburn and Sons LLC proposes a ground fault detection system design for 440VAC three phase radial Navy shipboard power distribution, while teaming with their partner Florida State University, Center for Advanced Power Systems (FSU CAPS). Existing Navy ground fault detection systems can detect and locate single line to ground faults on a given phase, but a second ground fault on a separate phase causes a line-to-line fault which trips breakers and removes power from downstream loads. Quickly detecting, locating, and resolving an initial single ground fault can mitigate the risk of double faults and loss of power to mission critical equipment. The ground fault detection and localization system design will function for both permanent and non-permanent fault cases, particularly for USN Shipboard 440VAC three phase radial power distribution either grounded or ungrounded. The low voltage alternating current interface standard, MIL-STD-1399-300-1, provides further characteristics. For ungrounded and high resistance grounded power systems, a single line to ground fault is permissible on one of the three phases enabling continued operation. Without the benefit of simplified fault localization of a solidly grounded power system which trips upon a single ground fault, it is critical to quickly identify the faulted piece of Navy equipment or at least identify the shipboard compartment containing the fault. The Hepburn and CAPS team proposes a noise pattern analysis approach to ground fault protection which utilizes machine learning techniques and yields the benefit of passive localization. This approach mitigates an interference issue that comes with conventional protection strategies involving disruptive signal injection as well as manual disconnect hunting of fault localization by trial and error. The methodology is based upon a patent presenting an autonomous fault location approach differentiating fault location by signal oscillatory characteristics (US Patent 8067942 B2, “Method for locating phase to ground faults in DC distribution systems”). In the presence of power electronic switching devices (converter, etc.), this noise pattern analysis-based fault localization does not necessarily require signal injection, but passively monitors a naturally occurring ringing circuit which is altered by a given fault case location. In the absence of such sources of continually occurring switching transients, separate injection of a small amount of signal noise may be required. The team is building upon extensive previous work and intellectual property. The Phase I design approach has been validated for the LVAC radial system of this topic. Phase II will involve prototyping, validating, and demonstrating the approach with plans for shipboard application.
Tagged as:
STTR
Phase II
2025
DOW
NAVY
USV Modular Power Generator System: Design for Reliability using MBSE achieving Graceful Degradation through Supervisory Control
Amount: $139,993 Topic: N241-060
Hepburn and Sons LLC teamed with General Electric (GE) Vernova Advanced Research proposes to design a supervisory control methodology that enable graceful degradation of an Unmanned Surface Vessel (USV) modular generator system. The design will be optimized for system reliability, efficiency, and extended maintenance intervals. Key challenge facing USVs is the maintenance interval and autonomous fault management. Among other maintenance requirements, generator systems require oil changes every 700 hours. In order to reach a 2000-hour maintenance interval and 4000-hour mean time between failure (MTBF), USV power generation systems necessitates an innovative maintenance solution and graceful degradation from full mission capacity down to “limp home” mode. The design approach will include an extensive failure modes, effects, and criticality analysis (FMECA), incorporating the Hepburn team’s hull, mechanical, and electrical (HM&E) expertise into a model-based systems engineering (MBSE) approach to achieve an Authoritative Source of Truth (ASoT) model that follows the design lifecycle. The GE Research team brings supervisory control and energy conversion system expertise for an innovative and automatic maintenance solution for system graceful degradation. The team will assess the mission concept of operations (CONOPS) alongside the TPOC and extended Navy network in support of an effective MBSE design approach.
Tagged as:
SBIR
Phase I
2024
DOW
NAVY
Analysis of MELD Additive Friction Stir Deposition Applications to Improve the Production of Low-Cost Attritable UAVs
Amount: $749,752 Topic: AF212-CSO2
During Phase I, the Hepburn - MELD Manufacturing Corporation (MELD) team successfully down selected four components from different UAVs presented by AFRL as possible ideal options for applying their signature additive friction stir deposition (AFSD) proc
Tagged as:
SBIR
Phase II
2024
DOW
USAF
In-situ Solid State Repair of Damaged Aircraft Structures Utilizing Impact Welding Technologies
Amount: $1,799,989 Topic: AF242-D020
Hepburn and Sons LLC teamed with Applied Impulse Inc. to incorporate novel manufacturing capabilities of impulse welding to provide crack repairs on damaged aircraft structural components. The solid-state joining process enables immediate restoration of component structural integrity through the bonding of wrought plate materials including alloys of aluminum, steel, and titanium. Utilizing wrought plate materials for joining in combination with impact welds preserves the initial microstructures and enables high strength repairs without post-processing or heat treating. In addition, the widely commercially available plate products improve supply chain capabilities, support cost reduction, and provide a more streamlined path to repair certification than experimental materials. The ability to apply the process in open environments and confined spaces makes the technology uniquely positioned to perform repairs in the ground support equipment environment. This research effort will demonstrate the effectiveness of impact weld crack repairs on a coupon level basis and provide evaluation articles of repaired aircraft structural elements. A final demonstration that provides evidence that the technology is deployable to the point of need will be held.
Tagged as:
SBIR
Phase II
2024
DOW
USAF
Digital Engineering Applied to the Boeing B-52H Stratofortress for Integration Risk Reduction
Amount: $179,957 Topic: AF242-0001
Hepburn and Sons LLC (Hepburn) proposes to leverage our teamÆs expertise in Model Based Systems Engineering (MBSE) and Digital Engineering (DE) to provide the Air Force with a digital ecosystem and framework for the B-52H legacy aircraft digital twin. HepburnÆs proposed approach is to use MBSE and DE principles to improve the Air Force Global Strike CommandÆs (AFGSC) cost-effectiveness in design and manufacturing of new systems and reduce risk for integration of equipment into the legacy B-52H legacy aircraft system through the 2050s. Rolls-Royce Corporation and its subsidiary Rolls-Royce North American Technologies, Inc. (LibertyWorks«) provided a letter of support, ōRolls Royce is very interested in Hepburn and SonsÆ proposed digital effort especially because of potential applicability to an Air Force digital pathfinder project such as the B-52 re-engine program.ö The purpose of this project in developing a B-52H digital twin is not simply to replicate the physical twin. Rather, the purpose of the proposed approach is to create a digital framework that enables AFGSC with the ability to increase mission assurance confidence while reducing risk (integration of new systems and equipment) over the life cycle of the aircraft to improve maintenance forecasting and training. Applying the latest policies and directives from DoD, Hepburn will model the legacy aircraft using Cameo Enterprise Architecture (Cameo) as the foundational model and as needed will use other software such as, but not limited to: OpenMBEE, AutoCAD, CATIA, SysML 1.6, and Python. The AFGSC will provide the style guide for this work and Hepburn will strictly align to that style guide. The final deliverable of Phase I will include the system concept, a completed feasibility study including a risk assessment, and HepburnÆs solution for creating a digital twin of the B-52H legacy system as part of the Phase II initial proposal. The system concept will be a digital framework that will be an evolving digital twin of the B-52H ready to accept and integrate virtual environments and other system models and simulations. The final deliverable(s) will be Cameo files that integrate the provided style guide. During Phase II, Hepburn will fully construct the approved concept into a prototype.ĀThe process involves a detailed review of the aircraft design, identification of mission critical systems (MCS), building a model that captures the aircraft features and systems as best as possible, updating the parameters through targeted testing, and iteratively simulating this model to better inform design decisions. The Hepburn process is referred to as a Model-Test-Model-Inform (MTMI) framework which is thoroughly reviewed.Ā
Tagged as:
SBIR
Phase I
2024
DOW
USAF
Binder Jet based Additive Manufacturing of Ni-Zn Ferrite Composites Enabling High Power Microwave (HPM) Directed Energy Weapons (DEW)
Amount: $139,997 Topic: N24A-T024
Hepburn and Sons LLC teamed with the University of Pittsburgh proposes a binder jet 3D printing (BJ3DP) additive manufacturing process with Ni-Zn Ferrite Composites and BaTiO3 batch infiltration to produce ferromagnetic and ferroelectric composite components that are power dense, cost-effective, high-resolution, and high-performance to enable High Power Microwave (HPM) Directed Energy Weapons (DEW) for Navy use. HPM generator technology has received increased attention corresponding with the emergence of non-lethal DEW as well as with improved wireless radar technologies. Priority is placed on minimizing size, weight, power, and cost (SWAP-C) for HPM sub-systems and optimizing its energy density at electronic targets of different sizes. HPM systems will benefit from BJ3DP capabilities as alternative to conventional, more costly fabrication and prototyping, sintering, and machining.
Tagged as:
STTR
Phase I
2024
DOW
NAVY