2005 Joint Service Power Expo Tampa, FL

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2005 Joint Service Power ExpoTampa, FL

• Managing Power for the
• Warfighter

May 5, 2005
Toy Dowdell, Jr - Program Manager [phone]
(x1798) tdowdell_at_custom-mfg-eng.com
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Smart Power Management for Military Vehicles and
Shelters

• Agenda
• Army Power Shelter Basics
• Problems
• Solution
• Lessons Learned
• The Future

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Smart Power Management for Military Vehicles and
Shelters
Army Power Basics
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Smart Power Management for Military Vehicles and
Shelters

• Army Shelter Basics

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The Problems

• As a standalone system, shelters cannot expand
  their capability beyond that available via
  on-board power without managing power utilization
• Present field power distribution capability is
  manually intensive and requires specialized
  expertise
• Oversized generators not running at capacity can
  cause maintenance issues as well as costing
  weight, space and fuel
• The system level solution crosses responsibility
  boundaries

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The Solution

• Standalone Systems
• SBIR, Phase I, 1998 It was recognized that with
  the digitization of the Army, the dependency on
  and quantity of electronic devices was growing.
  Since power on the battle field was limited, this
  was a concern for mobile, self-contained
  applications. The development of an intelligent
  power management system (IPMS) was sought.

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IPMS OVERVIEW
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IPMS Overview
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IPMS Overview
Notional Functionality
90-120 VAC (50/60 Hz) 15,20A 24 to 28 VDC,
35-60A 0 to 70 degrees Centigrade Size/weight
dependant on platform requirements
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IPMS Overview
Modular IPMS Design
AC/DC Module
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IPMS Overview
IPMS System
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IPMS - SICPS Platform Integration
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Integration
RWS IPMS
Before
After
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Integration
Soft-Top IPMS
Before
After
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Integration
M1068 Track Vehicle IPMS
Before
After
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Integration
Transit Case IPMS
Front
Rear
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Integration
IPMS
C4ISR OTM Capstone Demo Hummer IPMS
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IPMS Qualification Process

• HEMP/NLS/ESD
• EMI to MIL STD 461E
• Environmental to MIL STD 810F
• Munson Road/Rail Impact

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NLS/ESD/HEMP Testing
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Environmental Testing
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EMI Testing
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Munson Road/Rail Impact Testing
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Utility Assessment Demonstration

• The 1st BN 172nd FA of the New Hampshire National
  Guard (NHNG) performed an IPMS Utility Assessment
  during Sep 04.
• An IPMS PMC was installed in a 172nd Soft-Top
  platform used as a Fire Direction Center (FDC).
• Training was provided to the 172nd.
• IPMS experienced no glitches or caused any
  sporadic outages during the convoy or firing
  missions at the FDC.
• The 172nd was very impressed with IPMS
  Robustness and Training.

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IPMS Summary

• IPMS has successfully completed Compliance
  Testing
• All required Environmental, EMI, Munson Road,
  Rail Impact, HEMP, NLS, ESD (Human Body)
• A Utility Assessment Demonstration
• Received a Safety Release for Training and
  Operation by Soldiers
• IPMS is available for installation in all
  military shelters and vehicles

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Lessons Learned

• TOC Power and Distribution
• In 2002 it was recognized that, more than
  standalone shelters, a TOC with a shared
  generator could have power problems not easily
  solved by the shelter focus of IPMS. A trip into
  the field and discussions with experienced
  personnel confirmed that generator, load
  balancing and system level problems existed and a
  more general solution was sought.

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Lessons Learned

• Army TOC Basics

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Lessons Learned

• Shelter versus TOC Viewpoint
• Power within SICPS shelters were the focus of the
  original SBIR and subsequent phases
• IPMS treated each shelter independently within a
  TOC, missing opportunities for more intelligent
  management across shelters
• Trailer-mounted ECUs were not included in the
  power management strategy yet were the largest
  loads in the typical TOC

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Lessons Learned

• Shared Generator versus APU
• APUs are not typically used in TOC environments
  forcing a less intelligent IPMS control mechanism
  
• A shared generator created a different dynamic
  than could be addressed by IPMS sharing the
  available power across all shelters in real time
• An opportunity to level demand to maximize
  available power was not possible with IPMS

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Lessons Learned

• Army TOC Basics

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Lessons Learned

• Summary
• The lessons added up to a new architecture,
  features and functionality to be developed
• A strategy that kept IPMS in the shelter but
  added devices inside and outside the shelter to
  add functionality was developed
• Studying SICPS equipment loads was used to
  determine how best to manage power
• Addressing generator control and distribution was
  included in the strategy

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The Future

• Expanded Architecture
• Distributed Power Management System (DPMS)
• Inline modules for discreet load management
• Embedded modules for in-panel load management

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The Future

• Expanded Architecture
• Intelligent Power Distribution Illumination
  System Electrical (IPDISE)
• Module to generator monitoring and possibly
  control
• Module for shelter monitoring and control
• Intelligent Power Distribution Box (I200)
• Power Management Gateway (PMG)
• Module to facilitate communication among modules
  and external world

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The Future

• Expanded Architecture

Display
Shelter
IPDISE I200
LOAD
LOAD
LOAD
Shelter
Shelter
Display
Display
LOAD
LOAD
LOAD
LOAD
LOAD
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The Future

• Comparison IPDISE I200 vs. PDISE M200

PDISE M200
IPDISE I200
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The Future

• IPDISE I200
• Display features
• Phase Balance Help
• Troubleshooting Guide

OUTPUT STATUS ? ? TOTAL POWER 41.9KW
TOTAL VA 52.3KVA LINE FREQ 60.1HZ
TOTAL L1 158A 119V TOTAL L2 140A 118V
TOTAL L3 144A 120V
? INPUT STATUS ? J1 J2 REF
CON L1 78A 80A 119V L2 72A 68A 118V
L3 73A 71A 120V FREQ 60.1HZ
PHASES 3
? BALANCE STATUS ? TOTAL L1 158A
119V TOTAL L2 140A 118V TOTAL L3 144A
120V GROUP A 11A ON L1gt2 GROUP B 41A ON
L2 GROUP C 27A ON L3
?
?
?
? ALARM STATUS J2 INPUT BAD L0 OPEN CHECK
GENSET CABLE CHECK GENSET LUGS CHECK IPDISE
CONNECT
? OUTPUT STATUS ? TOTAL L1 158A
119V TOTAL L2 140A 118V TOTAL L3 144A
120V L12 209V L13 208V
L23 210V
?
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CME Overview

• CME is a small business engineering design and
  manufacturing firm serving government and
  industrial customers from Development to
  Manufacturing.
• CME
• 2904 44th Avenue North
• St. Petersburg, FL 33714
• 727-547-9799

ISO 90012000 Registered Certified WOSB, SDB, and
8(a)
May 5, 2005
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Major Product Capabilities

• Power Products
• Regulated power supplies (linear and switching)
• Integration of modern HDM technology into
  military applications
• Ruggedized, AC/DC and DC/DC power supplies and
  other internal power
• Power Monitoring, Control, and Backup Assemblies
  for standalone, rack mounted, dismounted, or
  embedded applications
• Sensors and Related Sensor Technology
• ATD/ATR and C4ISR sensor technology and mission
  needs
• Low-power sensor integration, control, data
  networking, Level 1 fusion/display, and packaging
• Visual, IR, and thermal imaging sensors
  (standalone or onboard)
• Production qualified, G-hardened,
  telemetry-capable fuse body for projectiles

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Power Products

• Power electronics and power management and
  distribution expertise in research, development,
  test, and production
• Proven power product developer and manufacturer
  to government and primes for dismounted, vehicle,
  and shipboard platforms
• Power-specific lab and test equipment
  capabilities in place
• Development, build-to-spec, and build-to-print
• Proven experience with environmental, EMI/EMC,
  EMP, near lightning, and human body ESD testing
  for power systems
• Current plant capacity to produce up to 10
  assemblies per week depending on size and
  complexity near-term capacity expansion to 25 to
  100 per week within 6 to 8 months

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Power Product Development Manufacturing
Experience
Power Distribution Cart for International Space
Station
5-Year Army AC/DC Tactical Power Supplies
Contract
Power Network Gateway Module
AC/DC Power Control Module
LM Perry Technologies UUV Battery Box
IP200 Advanced Power Distribution for Tactical
Operation Centers
Power Control Panel Assemblies for C2 Vehicles
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Sensor Related Products

• Experts in unattended ISR and force protection
  (physical security) sensor networks, protocols,
  and sensor integration
• Ruggedized visual, night vision, and thermal
  imaging sensors
• Tactical, wireless sensor subsystems and
  networking protocols
• Interface control experience with multiple
  protocols and other systems
• Electronic steering array software applications,
  search and track, and situational awareness and
  control displays based on Linux OS, Windows, Unix
• Image and signal processing algorithms
• Build-to-spec, build-to-print, and test
  capabilities
• Proven experience with lab, field, and
  operational testing including Aberdeen Proving
  Ground and Pax River
• Current plant capacity can produce up to 15
  assemblies per week with near-term capacity
  expansion of 50 to 200 per week within 4 to 6
  months

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Sensor Telemetry Product Development
Manufacturing Experience
Remote Shoreline Underwater Sensors
Track Management Rack-Mounted Assemblies
Unattended C4ISR Sensors, Wireless Network,
Fusion Displays
Tactical Sensor Transducers Cables
Hi-G Wireless NSTF Telemetry Mounted to a 120-mm
M831
Integrated, Low-PowerImagers Control
Subsystems
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How to Contact CME

• Custom Manufacturing Engineering, Inc.
• 2904 44th Avenue, North
• St. Petersburg, FL 33714
• www.custom-mfg-eng.com

• Toy Dowdell, Jr.
• Program Manager
• [phone] Ext. 1798
• FAX [phone]
• email tdowdell_at_custom-mfg-eng.com