Department of the navy (don) 18. 1 Small Business Innovation Research (sbir) Proposal Submission Instructions introduction

KEYWORDS: Submarine Escape; Pressure Reduction; DISSUB; High Pressure Survival; Low Power Emergency on Submarines; Oxygen Toxicity

TECHNOLOGY AREA(S): Battlespace, Electronics, Sensors

ACQUISITION PROGRAM: POM-15 Multi-Function Energy Storage Module FNC

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 5.4.c.(8) of the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.

OBJECTIVE: Develop innovative high-bandwidth, tunable, compact, high-efficiency battery chargers providing significantly reduced voltage and current ripple for high-power battery systems.

DESCRIPTION: The Navy is seeking an Ultra-Low Ripple 1000 Volt Direct Current (1kV DC) battery charging system capable of maintaining high-density 1kV battery banks. The Navy has requirements for a charger to maintain a high-power, energy-dense storage battery capable of supporting pulse-type loads. The ability to provide sustained and maintenance type battery charging of electric weapon systems, with batteries that are in continuous use is a key enabler to the future of electric weapons and high energy loads in the fleet. Typical power conversion systems are either very large, and/or have high power ripple and poor power quality under various modes of use. Battery chargers that reduce battery degradation due to low/no ripple, while providing a smaller footprint by innovatively leveraging recent commercial advances in high-bandwidth power for conversion components and topologies are needed. This innovation will ensure highly compact and efficient power supplies offering significantly reduced voltage and current ripple ensuring longer battery life and better performance. The product of this effort should allow real-time tuning and optimized charging in a manner that best aligns to large battery systems for high-energy weapons such as lasers and railguns.

Battery systems have an intrinsic sensitivity to current and voltage ripple under charging and float-type maintenance. Variations in the charging power create scenarios where higher levels of heating can occur within the cells due to the ripple induced current flow, as well as higher than desired voltage spikes, which can facilitate oxidation and other degrading conditions. Present-day silicon devices are large, inefficient, and do not offer sufficiently fast switching frequencies to minimize ripple and DC artifacts when charging batteries. New commercial innovations in high-bandwidth materials are enabling significantly smaller consumer electronics. This topic seeks technologies for charging much larger battery systems in a military setting. These innovations need to be tunable, compact, and highly efficient battery charging power supplies that can be common to multiple uses. By utilizing advanced charging methodologies, there will be less stress on the batteries, which will require less operational maintenance and provide longer battery life, reducing cost. By leveraging high-bandwidth materials (silicon carbide (SiC), gallium nitride (GaN)) as an enabling technology applied to efficiently charging large battery systems, the Navy expects to optimize Space, Weight, Power, and Cooling (SWaP-C).

The Navy desires research to leverage recent advancements in commercial power electronic switching technologies such as the use of solid state switching and advanced materials in power electronics in order to create a unidirectional charging converter. The charger controls, programming, components, and input/output must hold to available IEEE and NEC 2017 design standards while maintaining the highest levels of safety and efficiency. The design should also include the self-diagnosis of anomalous behaviors and potential damaging conditions such under or over voltages, overcurrent conditions, out-of-range temperature readings, or changes in the response characteristics of the target battery system.

Designs should produce options that have minimal losses and require minimal thermal management as a result. They should provide clean power at all output conditions, and ensure that no irregular power quality issues are caused for the sourcing power system.

Operational requirements include:

PHASE I: Develop a concept for a 1kV battery charging system capable of maintaining high-density 1kV battery banks. Demonstrate the viability of the concept in meeting Navy requirements described above, and establish that the system can be feasibly developed into a useful product for the Navy. Feasibility will be established by modeling and simulation of a battery system of appropriate scale and technology. The Phase I Option, if awarded, will address technical risk reduction and provide performance goals and key technical milestones. Phase I will include creating plans for prototype development during Phase II.

PHASE II: Based on the results of Phase I and the Phase II Statement of Work (SOW), develop and deliver a prototype to the Navy for evaluation in a relevant environment. Demonstrate system performance through evaluation in a laboratory environment and modeling or analytical methods over the required range of parameters to demonstrate ability to meet the performance goals defined in the Phase II SOW and the Navy requirements for a charger to maintain a high-power, energy-dense storage battery capable of supporting pulse-type loads. Use evaluation results to refine the prototype into a design that will meet Navy requirements as cited in the Phase II SOW. Conduct performance integration and risk assessments, and develop a cost-benefit analysis and cost estimate for a Naval shipboard unit. Prepare a Phase III development plan to transition the technology to Navy and potential commercial use.

PHASE III DUAL USE APPLICATIONS: Support the Navy in evaluating the system delivered in Phase II. Based on analysis performed during Phase II, recommend test fixtures and methodologies to support environmental, shock (MIL-S-901D), and vibration (MIL-STD-167-1A) testing and qualification. The company and the Navy will jointly determine appropriate systems for replacement of current battery charger with the SBIR-developed system for operational evaluation, including required safety testing and certification. Working with the Navy, demonstrate the battery charger on a relevant system to support directed energy weapons and electronic warfare. Provide detailed drawings, code, and specifications in defined format.

Transition opportunities for this technology include charging and charge maintenance of high-power battery systems in ship-wide stable backup power systems and energy storage systems that are widely used in large industrial applications, utilities, and back-up systems.

REFERENCES:

1. Uddin, Kotub, Moore, Andrew D., Barai, Anup, and Marco, James. “The effects of high frequency current ripple on electric vehicle battery performance.” Applied Energy, Volume 178, 15 September 2016, p. 142-154, ISSN 0306-2619. http://dx.doi.org/10.1016/j.apenergy.2016.06.033

2. "Charger Output AC Ripple Voltage and the effect on VRLA batteries.” C&D Technologies Inc, C&D Technical Bulletin 41-2131. http://www.cdtechno.com/pdf/ref/41_2131_0212.pdf

3. De Breucker, Sven. "Impact of DC-DC Converters on Li-ion Batteries.” Kathoieke Univeriteit Leuven, December 2012. https://www.researchgate.net/publication/260819365_Impact_of_Dc-dc_converters_on_Li-ion_batteries

KEYWORDS: 1000V Direct Current Battery Charger; High Switching Frequency; Galvanically Isolated; Advanced Battery Chargers; Silicon Carbide (SiC) Electronics; High Power Ripple

TECHNOLOGY AREA(S): Battlespace, Electronics, Sensors

ACQUISITION PROGRAM: PMS 397, COLUMBIA Class Submarine Program Office

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 5.4.c.(8) of the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.

OBJECTIVE: Develop advanced analyzer technology to improve performance and reduce maintenance costs of current atmosphere monitoring systems.

DESCRIPTION: Many spectrometry tools are commercially available for analyzing gas constituents, including ion mobility, optical, and mass spectrometry, with many variations in each technique. Advances have been made in all spectrometry technologies, with great improvements in optical spectrometry versatility and select ability, thanks to mid-infrared (IR) laser and other material developments. U.S. Navy submarine atmosphere monitoring has remained largely unchanged since the 1970’s with magnetic sector mass spectrometry and IR spectrophotometry the primary techniques employed. Listed below are the five common gases that are monitored at the percent level (partial pressure measured in torr), and the 14 contaminants that are measured at the parts per million (PPM) level (partial pressure measured in millitorr). While trace contaminants are continuously reviewed, and monitoring requirements are subject to change, the five gases measured in torr are unlikely to change. The Central Atmosphere Monitoring System (CAMS) IIA mass spectrometer is capable of measuring ions between 2 and 210 atomic mass units (AMU). The IR spectrophotometer identifies carbon monoxide because it cannot be detected by mass spectrometry in a nitrogen-rich atmosphere, due to the two gases having the same atomic mass. Although the combination of mass spectrometry and IR spectrophotometry have provided reliable service to the Navy for 40 years, the system is costly to maintain, and not flexible enough to meet all future capabilities. The Navy is looking to identify advanced analyzer technologies that have emerged since the development of CAMS, such as long-life, solid-state lasers or energy detectors, in order to improve performance and reduce maintenance costs of current atmosphere monitoring systems.

Gases measured by CAMS IIA:

GASES MEASURED IN PERCENT (torr):

GASES MEASURED IN PPM (millitorr):

Cost to maintain: The high vacuum and sophisticated tuning required of mass spectrometry are the main factors in the current system’s high maintenance costs. Many common failures require entering the vacuum boundary of the mass spectrometer for repair, and are outside of the operators’ technical capabilities. The cost to repair the mass spectrometer averages $145,000 per unit, not including ancillary costs such as packaging, shipping, and administration. Assuming there are no premature failures, policy requires overhaul of each system every three years at the same cost as repair. The goal of this research effort is to halve the frequency of factory overhauls, and reduce annual maintenance costs to under $20,000, including amortized factory overhaul and operator maintenance costs. This effort seeks a technology that minimizes the number of moving mechanical parts, unless those parts can be shown to require no more frequent maintenance than the factory overhaul (at least six years).

Capabilities: The naval engineering directorate promulgates atmosphere-monitoring requirements based on recommendations from the naval medical community, as well as engineering concerns. Mass spectrometry meets existing submarine atmosphere monitoring requirements; however, these requirements are not static. As submarine atmospheres are surveyed continuously, and as the medical and engineering communities’ interest in atmospheric contaminants evolves, measuring new gases—such as acrolein, formaldehyde, and ozone—will become required. These new gases might provide transport challenges, in addition to detection challenges. This research effort seeks a technology that can be tuned to new gases through software upgrades, or minimal component changes (e.g., replacing laser wavelength) that do not affect overall system configuration or footprint. The initial start time from a cold condition should not exceed the current threshold for CAMS IIA, eight hours, and ideally is under one hour. Individual reading response time should not exceed 120 seconds, but ideally should be under one minute.

Integration: The incumbent system includes sample control, power, and data distribution systems. The technology sought by this effort must be capable of integration in the incumbent cabinet or as a standalone system. The enclosure should be a rectangular prism, with dimensions designed to fit in a space with a 16-inch by 16-inch footprint and a height of 8 inches, and be capable of mounting in different orientations. Input power is 115VAC whether integrated in incumbent cabinet or operated independently. Sample flow is continuous 1-6 SCFH in the incumbent cabinet. The technology can modulate flow, but must vent to the same type of connection as used for inlet from, for rejection by the incumbent system. If mounted standalone, the technology must have a sample system that requires no more frequent than annual material maintenance (flow adjustment no more than weekly). The technology must have local display for operation, analysis results, fault isolation, maintenance, and troubleshooting, and be capable of providing the same data as well as historical data through an external data connection.

PHASE I: Investigate processes to analyze gases required on U.S. Navy submarines; then develop a concept to determine the capability of the technology to perform its function within the conditions specified. Demonstrate, through analysis and/or simulation, the feasibility of the concept in meeting Navy needs and establish that the material can be reasonably developed into a useful system for the Navy. The Phase I Option, if awarded, should include the initial layout and capabilities description to build a prototype in Phase II. Develop a Phase II plan.

PHASE II: Based on the results of Phase I and the Phase II Statement of Work (SOW), develop and deliver a prototype for testing on a lab scale under the appropriate conditions to simulate a submarine environment. Evaluate the prototype to determine its capability in meeting the performance goals defined in Phase II SOW and the Navy requirements for monitoring gases and contaminants. Using evaluation results, finalize a system configuration that will meet Navy requirements. Prepare a Phase III development plan to transition the technology to Navy use.

PHASE III DUAL USE APPLICATIONS: Support the Navy in transitioning the technology to Columbia Class submarines. The final product will be capable of operation in an existing atmosphere monitoring system cabinet or as a standalone system. The system will be capable of measuring required gases, and meet maintenance requirements. The product will meet all relevant incumbent qualification testing, including shock, vibration, electromagnetic interference (EMI), humidity, and noise, per references (6) through (10), respectively; ship’s motion (demonstration of operation with inclination up to 45 degrees from vertical in any direction), temperature (operation over the temperature range from 10°C to 46°C), humidity (operation in ambient pressure ranging from 450 torr to 900 torr, absolute) cross-sensitivity (demonstration of operation within specification when a mix of all gases analyzed is applied to the system), stability (demonstration that once full value readings are indicated, drift of readings must not exceed half of limits during three hours of continuous application of the mix of all gases analyzed),and endurance (continuous unattended operation for 720 hours). Power, dimensions, and weight limits will be determined by a trade study that includes the number of gases that the system is capable of indicating.

Atmosphere monitoring requirements are continuously evolving in the private sector. Atmosphere quality is regulated in workplaces, industrial effluent (such as smokestacks), and outdoors. Many contaminants of interest to the U.S. Navy submarine force are shared with private sector employers. Technology meeting the requirement for flexibility described in the description will be capable of meeting private sector requirements. Some examples of private sector applications include monitoring of combustion gasses in pre- and post- fire applications, monitoring of CO2 and other emissions from factories, power plants, cars, or other private industry applications, and detection of gas levels and leakages in various industrial environments.

REFERENCES:

1. Watson, J. Throck & Sparkman, O. David. “Introduction to Mass Spectrometry: Instrumentation, Applications, and Strategies for Data Interpretation, 4th Ed.” Chichester: Jonh Wiley & Sons, 2007.

2. Werle, P., Slemr, F., Maurer, K., Kormann, R., Mucke, R. and Janker, B. "Near- and Mid-Infrared Laser-Optical Sensors for Gas Analysis." Opt. Las. Eng. 37(2–3), 101–114 (2002). https://www.researchgate.net/profile/Franz_Slemr/publication/228543356_Near-and_mid-infrared_laser-optical_sensors_for_gas_analysis/links/5681672208ae1975838f86d4.pdf

3. “Emergency and Continuous Exposure Guidance Levels for Selected Submarine Contaminants.” Washington, DC: The National Academies Press, 2007. https://www.nap.edu/catalog/11170/emergency-and-continuous-exposure-guidance-levels-for-selected-submarine-contaminants

4. “Emergency and Continuous Exposure Guidance Levels for Selected Submarine Contaminants: Volume 2.” Washington, DC: The National Academies Press, 2008. https://www.nap.edu/catalog/12032/emergency-and-continuous-exposure-guidance-levels-for-selected-submarine-contaminants

5. “Emergency and Continuous Exposure Guidance Levels for Selected Submarine Contaminants: Volume 3.” Washington, DC: The National Academies Press, 2009. https://www.nap.edu/catalog/12741/emergency-and-continuous-exposure-guidance-levels-for-selected-submarine-contaminants

6. MIL-S-901D, Amended with Interim Change #2, Shock Test, H.I. (High Impact); Shipboard Machinery, Equipment and Systems, Requirements for

7. MIL-STD-167-1, Mechanical Vibration for Shipboard Equipment (Type I - Environmental and Type II - Internally Excited)

8. MIL-STD-461F, Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

9. MIL-HDBK-2036, Preparation of Electronic Equipment Specifications

10. MIL-STD-740-2, Structure-borne Vibration Acceleration Measurements and Acceptance Criteria of Shipboard Equipment

KEYWORDS: Atmosphere Analysis; Laser Spectroscopy; Analytical Chemistry; Atmosphere Monitoring on Submarines; CAMS IIA; Submarine Atmosphere

TECHNOLOGY AREA(S): Battlespace, Electronics, Sensors

ACQUISITION PROGRAM: PMS 435 - Submarine Electromagnetic Systems

OBJECTIVE: Develop high performance ultra-narrow band tunable filters for Radio Frequency (RF) photonic systems that will be utilized by the submarine electronic warfare next generation architecture.

DESCRIPTION: The Navy seeks development of ultra-narrow optical band pass filters that would enable the utilization of RF photonic signal distribution systems for next generation electronic warfare (EW) platforms. A narrow band optical filter featuring ultra-steep roll off, size (150mm x 30mm x 15mm), weight (< 16oz), and power (< 3W) comparable to commercially available technology, and wide tunability is desired to advance the current technology and improve performance metrics for military RF photonic signal distribution systems. The filters should operate with center wavelength in the c-band (1525-1565nm) as a first step, but should have a means to scale to other wavelength regimes. Tuning range should exceed 40GHz with tuning speed less than 25ms, and tuning resolution less than 0.10GHz. The rejection at 4GHz from the 3dB point should be greater than 45dB, with bandwidth scalable from 1-10GHz, and insertion loss less than 3dB. These narrow band optical filters should be compatible with standard single mode optical fiber including polarization maintaining single mode fiber. State of the art commercial off the shelf (COTS) filters utilize thermally tuned fiber Bragg grating (FBG) filter solutions, but improvement is required for faster tuning and higher spectral rejection of signals located just GHz from the passband.

Improved RF signal distribution performance enhances tactical EW, situational awareness, and electronic maneuver warfare capabilities for the Navy. The submarine EW next generation architecture is considering Radio Frequency over Fiber (RFoF) technology to improve its signal distribution architecture to transport high fidelity RF signals inboard and distribute them to the appropriate receivers. The benefits of intensity modulated direct detection (IMDD) RFoF links are well documented, as are their deficiencies. However, there have been substantial improvements in areas traditionally detrimental to the proliferation of RFoF technology in the EW/Intelligence, Surveillance, and Reconnaissance (ISR)/Signals Intelligence (SIGINT) applications. Recent improvements in size, weight, and power (SWaP), manufacturability, and RF performance (Noise Figure, Gain, and Spur-free Dynamic Range) is beginning to better align RFoF technology with these mission sets.