Submission of proposals
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U.S. and International patents: 1) PCT/US 99/05632 (Baker) 17 March 1999 2) US 4,553,385 A (Lamont) 19 November 1935 3) US 4,015,424 A (Shinohara) 05 April 1977 4) US 4,513,568 A (Bajulaz) 30 April 1985 5) US 5,526,780 A (Wallis) 18 June 1996 6) US 4,010,727 A (Cross et al) 08 March 1977 7) US 3,959,971 (Mekari) 01 June, 1976
A03-228 TITLE: Passive Thermal Management for Next Generation Vehicles TECHNOLOGY AREAS: Ground/Sea Vehicles ACQUISITION PROGRAM: PM Future Combat System OBJECTIVE: Develop, demonstrate, and integrate advanced, lightweight, passive Thermal Management hardware for cooling mission critical technologies in next generation vehicles. The next generation of vehicles, tactical and commercial, may incorporate fuel cells, electric or electric – internal combustion hybrid propulsion systems, and “drive by wire” auxiliary systems, each of which poses unique cooling problems. Replacing mechanical and electromechanical systems with electronically controlled devices eliminates many routes of thermal communication between heat generation and dissipative sites. This revolutionary change in vehicle propulsion and control requires a similar change in thermal management. Advanced, lightweight, passive thermal management systems must be developed to keep pace with automotive technology. The Army’s next generation of weapon systems (FCS) and tactical vehicles (21st Century Truck) will be designed with stringent requirements on survivability, efficiency, and performance. Electronics and electronic control is necessary to achieve these requirements. However, increased reliance on electronics complicates thermal management by distributing more energy throughout the vehicle structure. An innovative hardware solution is required to collect thermal energy from distributed sources. Many DoD initiatives propose autonomous robotics for weapon systems, logistical support, and RSTA sensor suites. Robotic vehicle platforms possess limited onboard battery life and power is at a premium. Therefore, the use of power to support ancillary cooling systems is unacceptable. A passive thermal management system is required for this application and is applicable to all related DoD programs. DESCRIPTION: An innovative hardware solution is required to produce a thermal management system capable of collecting thermal energy from distributed sources and dissipating it at a discrete location. This type of system is referred to as a ‘Thermal Bus’. The ideal thermal bus technology operates passively, and provides high power dissipation at a low temperature difference, low cost, and small weight/volume penalty. Passive operation eliminates the drain on limited system power resources. High power dissipation at a low temperature difference minimizes thermal signatures. It should also allow significant design and integration flexibility. Harsh operational environments upon deployment further complicate thermal management of next generation vehicles. The vehicle environment consists of ambient temperature extremes ranging from –54 to 85o C (1; 2). Maximum temperatures typical of an automobile electronic environment vary from 140o C on the engine or transmission to 70o C in the passenger compartment (4). Mechanical shock, vibration, electrical load duty cycles, dust, and steady or transient acceleration induced forces exist. All environmental parameters must be considered during concept development. PHASE I: Goals for Phase I should include a feasibility demonstration (e.g., concept analysis and subscale experiment) of the proposed thermal management hardware concept, address integration issues, and provide sufficient analysis to demonstrate system level payoffs. PHASE II: Goals for Phase II should include sufficient demonstration of the proposed thermal management concept to show integration viability into a vehicle platform. PHASE III DUAL USE APPLICATIONS: Next generation vehicles are a major research and development activity within the automotive industry. The development, demonstration, and integration of robust thermal management technologies into electric and hybrid-electric vehicles represents numerous technical challenges requiring innovative solutions which in turn can be directly applied in the military and private sectors. REFERENCES: 1) "Joint SAE/TMC Recommended Environmental Practices for Electronic Equipment Design (Heavy-Duty Trucks)," Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, PA 15096-0001, J1455, 1994. 2) "Recommended Environmental Practices for Electronic Equipment Design-SAE J1211," Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, PA 15096-0001, J1211, 1999. 3) Birur, Gajanana C., Johnson, Kenneth R., Novak, Keith S., and Sur, Tricia W., "Thermal Control of Mars Lander and Rover Batteries and Electronics Using Loop Heat Pipes and Phase Change Material Thermal Storage Technologies," SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001, 2000. 4) De Vos, Glen W. and Helton, David E., "Migration of Powertrain Electronics to On-Engine and On-Transmission," SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, 1999-01-0159, 1999. 5) Suitability of Loop Heat Pipes for Thermal Management of Ground Vehicles, P. Rogers, U.S. Army TARDEC, J. Ku, NASA-Goddard Space Flight Center, C. Hoff, Lawrence Technological University, SAE/ImechE Vehicle Thermal Management Conference, London, England, May 1999. KEYWORDS: Prototype Hardware,Thermal, Passive, Power dissipation, Electronics, FCS, Next generation vehicles, Robotics, signatures A03-229 TITLE: Virtual Prototyping Vehicle Electrical System Management Design Tool TECHNOLOGY AREAS: Ground/Sea Vehicles ACQUISITION PROGRAM: PM Brigade Combat Team OBJECTIVE: Investigate and study the issues related to the development of a management design tool for virtual prototyping of vehicle electrical propulsion systems for hybrid-electric vehicles. Determine the impact on the development process of these vehicle systems. Determine a reasonably-phased approach to implementation, and demonstrate the design tool modeling and simulating a vehicle's electrical system. DESCRIPTION: The Army’s next generation of weapon systems and tactical vehicles will be designed with stringent requirements on efficiency, performance, and survivability. To fulfill these requirements under constraints of development time and production cost, the operation of integrated systems must be optimized during the design process. Efficient electrical power utilization for vehicle systems and electric propulsion systems in hybrid-electric vehicles, versatile and efficient electrical power management, and cost-effective signature control and component integration with minimal power requirements must all be goals of the integrated design effort. This necessitates the development of a design tool that can efficiently optimize the design of these disciplines simultaneously. To meet these ambitious goals, the design tool must aim for integrated system-level design, yet be fully capable of accurately analyzing the details of the vehicle electrical system. No such tool exists yet. An innovative solution is required to produce a fast vehicle electrical system solver that has the capabilities to analyze current, proposed, and potential vehicle-electrical and propulsion-electrical systems (42/28/14V and higher - (300-600V)for electric propulsion) and to determine the most effective and efficient system design to result in minimal power consumption, per system component and for the system as a whole, and maximal performance capabilities. This solver must be tied to accurate models of electrical power generation, distribution, and conservation. All component models must predict the power consumption, power densities, and efficiencies, as well as the heat generation by the component. The CFD solver must be capable of analyzing complex electrical circuits and of modeling the electrical system for the vehicle under operating, idle, and stored conditions. The design tool must fully consider the effects of the environment, weather, and terrain on the system performance. PHASE I: Contractor shall study and research the issues related to virtual design and prototyping (Modeling & Simulation) of current and legacy vehicle electrical systems as they apply to the development of the propulsion system in electric and hybrid-electric vehicles. Determine impact on development process of these vehicle systems. Determine a reasonably-phased approach to implementation, and demonstrate the design tool modeling and simulating a vehicle's electrical system. PHASE II: Contractor shall implement approaches to designing the modeling-and-simulation tool discussed in Phase I on a candidate platform, clearly illustrating the dual-use nature of the design tool. Conduct a demonstration of this design tool, exemplifying its ease-of-use in the dynamic design process of vehicle electrical systems. Coordinate this effort with partners formed in Phase I. PHASE III DUAL USE APPLICATIONS: Industry clearly needs a design tool to accurately Model & Simulate vehicle electrical systems in their development process, and a demonstration of the dual-use applicability of this tool will position a company to commercialize the results with the commercial sector. The integration of rapid CFD with electrical/electronic design tools will be valuable to many vehicle design applications, both commercial and military. REFERENCES: Website: http://www.tacom.army.mil/tardec/vetronics/architecture.htm This website provides information regarding the subject matter's design tool. KEYWORDS: dual-use, power management, component integration, systems engineering, modeling and simulation. A03-230 TITLE: Transmission and Driveline Development and Their Components TECHNOLOGY AREAS: Ground/Sea Vehicles ACQUISITION PROGRAM: Family of Medium Tactical Vehicles, LMTV & MTV OBJECTIVE: The objective of this effort is to develop new technology transmission and driveline systems for military tactical wheeled and tracked vehicles. A second objective would be to develop new components within a transmission and driveline system which improve efficiency, reliability/durability and performance. A goal of these objectives will be savings through lower operation and service costs. In addition, development of new technology materials will be sought which can meet existing performance requirements while reducing weight by a minimum of 25%. Driveline systems include every component from the transmission to the vehicle tires or final drives. Components include, but are not limited to, the transfer case, propeller shafts, differentials, axles, geared hubs and final drives. Current development efforts are more focused on electric drive technology, however, future powertrain systems could include transmissions and conventional driveline systems. The conventional military driveline system is tailored to specific military vehicle requirements and continual advanced designs are needed to maintain the latest state-of-the-art technology. DESCRIPTION: New technology transmission and driveline systems and their components will be researched and evaluated to determine where substantial improvements in efficiency, performance and reliability/durability can be achieved. Efficiency improvements will be investigated in transmission/driveline new designs or new design transmission/driveline components. Examples for improving efficiency include: (1) draining of hydrokinetic transmission torque converter during gear engaged idle condition to reduce transmission input side spin losses and (2) transmission software design logic to match fluid fan horsepower requirements with transmission fluid safe temperature operating range. Efficiency improvements, for example, translate into smaller size fuel tanks for the same vehicle mileage range coverage. This could lead to increased space available for other vehicle needs such as additional ammunition or more cargo capacity. New materials will be investigated, such as polymers, which could substantially reduce component weight of transmission/driveline systems. Major component weight reduction improves vehicle performance and saves fuel. New materials will be required to meet current performance requirements of transmission and/or driveline systems. Development efforts for improving durability/reliability will also be investigated for new design transmission/driveline or existing transmission/driveline systems of major vehicles which exhibit short life. This would lead to reduced spare parts purchases and cost savings during a military vehicle’s usage. Some examples of transmission development efforts relating to durability/reliability include: (1) reducing transmission shift shock characteristics, (2) new transmission clutch materials, (3) new clutch pack activation devices (ex. cone, poly vee), and (4) new design approaches to improve cold oil flow requirements. Other transmission component development areas could include: (1) new gear set design (ex. coplaner), (2) new filtration design (ex. pressure line filter, partial flow type), (3) valve regulators, and (4) oil pump(s). Items (3) and (4) require increased life due to damage caused by contaminants which penetrate the transmission’s filter system. Note: a new design of an existing transmission filter is not applicable under this SBIR topic. The development of new transmission/driveline systems or new design transmission/driveline components will provide a leverage in maintaining existing or future conventional transmission/driveline systems in the event electric drive or hybrid electric drive technology requires substantially more development time. This enabling technology will provide a needed development goal to advance the state-of-the-art new design transmission/driveline systems and their components. PHASE I: In Phase I, the contractor will become knowledgeable of transmission and driveline systems and their components on military vehicles. Transmission and driveline systems and their components will be investigated which have reduced service life and where new design technology improvements can be implemented. A new design technology for a transmission and driveline system or a new developed transmission and/or driveline components must consider military environments, current maintenance manual recommendations and practices and performance specifications military vehicles operate under. A proposed new technology transmission or driveline system must be able to fit within tight volume constraints of current production transmission or driveline system. The contractor will establish preliminary design, performance and sizing of new transmission or driveline system or new components of transmission and driveline system to verify if the new design concept is doable. Preliminary performance analysis, theoretical calculations and computational fluid dynamics or equivalent will be conducted to verify if the new design concept will work. Design goals will be to determine if new concept transmission or driveline system or new system components provide commonality and could effectively replace an existing system or component. A preliminary economic analysis will be performed to substantiate potential cost savings. At the end of Phase I the proof-of-principle must be demonstrated and enough evidence presented to verify the new concept appears to accomplish the following goals: (1) efficiency and/or performance improvements and (2) improved reliability/durability resulting in operation and support cost (OSCR) savings. PHASE II: In Phase II the contractor’s new designed transmission or driveline system or new developed transmission and/or driveline component will be extensively evaluated, re-engineered and design up-dated to assure the design concept provides feasibility. For example, if there is more than one design approach an assessment will be made based on trade-off studies to provide the best design concept. Computational fluid dynamics or equivalent will be continued to assure the best design concept is selected. A prototype transmission or driveline system or a new design transmission or driveline component will be fabricated and preliminary lab evaluation tests conducted to verify the design. The evaluation tests will confirm the projected improvements in efficiency/performance and/or reliability/durability. The contractor will continue to harden the design by making design changes to provide improvements in at least one of following areas: efficiency, performance, reliability and durability. At this time, the economic analysis will be up-dated and a determination made to assure that the new design provides an operation and support cost reduction (OSCR) to the affected military vehicle(s). The new prototype design transmission and/or driveline system or new component design for a transmission or driveline system will undergo more rigorous lab simulation tests which depict future field test environments. Following these tests, a technical assessment will be made by the contractor to determine final prototype design configuration (if required). At the conclusion of Phase II the contractor will deliver at least one (1) prototype. PHASE III DUAL USE APPLICATION: Many military transmission and driveline system and their components are used in commercial applications. In addition, the Army buys many commercial construction, material handling and road building equipment which has dual use application. Cost savings are the bases for most new technological products. Success of the program described above will provide a direct link to a joint commercial and military endeavor. REFERENCES: 1) TARDEC Technical Report No. 13802, TITLED: Test and Evaluation of the LMTV Driveline, Dated June 1999, Contractor U. S. Army Tank Automotive Research, Development & Engineering Center (TARDEC). 2) 2002 SAE Handbook, Volume 2 Parts & Components and On-Highway Vehicles, Standards Development Program, Section 29 Transmissions, Pages 29.01 to 29.248 , Published by Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096-0001. 3) Eleftherakis, John G., TITLED: Optimizing Automatic Transmission Filtration, SAE Paper 99PC-418, Dated 1998, Society of Automotive Engineers Inc., Warrendale PA. KEYWORDS: Transmissions, Driveline, Transmission Components, Powertrain Components, Propulsion System Components, Improved Efficiency, Improved Perforance. A03-231 TITLE: Develop New Innovative Filtration Designs and Components for Improved Service Life, Performance and Durability TECHNOLOGY AREAS: Ground/Sea Vehicles ACQUISITION PROGRAM: PM Light Tactical Vehicles OBJECTIVE: The objective of this effort is to study, design, develop, improve and evaluate new filtration system components and components of existing filtration systems, which will lead to reduced maintenance and spare parts purchases, increased durability and improved readiness. This will provide an overall monetary cost savings during a military vehicle’s yearly operational cycle. Individual efforts will focus on improvements in the following areas: (1) air filtration system improvements will look at new innovative air cleaner design concepts and/or new filter media materials which provide either a higher number of air filter cleanings and/or increased air cleaner dust capacity/service life by a factor of 2, (2) develop new technology engine and transmission oil filters including on-board sensors to detect filter clogging and fluid contamination. A goal will be to develop new technology oil filters which approach the life of the engine/transmission while improving performance and environmental friendliness, and (3) develop new technology engine fuel filters and/or fuel system components which provide longer service life, increased performance, higher efficiency, less maintenance and environmental friendliness. DESCRIPTION: Engine induction air will look at new technique air filtration system improvements for high density vehicles such as the High Mobility Multi-Purpose Wheeled Vehicle (HMMWV) which currently uses cellulose base air filter media. With this media, the air filter is recommended to be cleaned only three (3) times before discard. In addition, the HMMWV air cleaner has a short service life of 16 hours based on lab testing requirements. This dictates that a new air cleaner design and/or new media material be developed to provide either a higher number of cleanings or much longer service life (2 times). New media material will consider the vibration effects an operating vehicle may transmit to the air cleaner housing to substantiate effects on air cleaner efficiency and longer service life/dust capacity. Engine/transmission oil filter technology will be developed to provide increased oil filter service life and efficiency while maintaining fluid quality. Military vehicles with a current recommended replacement interval for engine/transmission oil filters will be investigated to show where improvements are possible. A new design filter will be required to fit within space allocation of existing filter. Oil filters with on-board sensors will be developed to detect when an oil filter is in the bypass mode (filter clogging) and if fluid is becoming contaminated. Transmission oil filters will be developed to replace existing transmission oil filter and this SBIR topic will not consider development of combination pressure line filter (ex. partial flow type) in addition to main sump filter. Transmission oil filters will investigate new innovative designs, which provide higher efficiency which maintaining the cold oil flow requirements of transmissions. Fuel filter technology will be developed to demonstrate improved filter life and efficiency. Related fuel technology to be looked at includes: (1) temporary by-pass fuel system, (2) diagnostic sensors to detect percent of filter life left, and (3) improved water separator performance and service life. In addition, smart fuel pump(s) installed in fuel tank(s) which require considerable maintenance time for diagnosis will be developed to provide a quick check for satisfactory operation. The smart fuel pump with an on-board sensor would be a cost driver for minimizing maintenance costs. Fuel filters and fuel system components technology will also demonstrate cost savings forecast for any new design. PHASE I: In Phase I the Contractor will become knowledgeable of filtration systems on current military vehicle fleets and military vehicle operational annual mileage and usage conditions. The new proposed filtration system concept must consider military environments, current maintenance manual recommended interval cleaning or replacement and performance specifications military vehicles operate under. The proposed filtration or filtration component concept must consider engine manufacturer requirements for induction air, fuel and oil as applicable to a particular engine design and be able to interface and fit within tight volume constraints of existing filtration components. The contractor will establish preliminary design, performance and sizing of new filtration or filtration component concept to verify if the new design concept is feasible. Preliminary performance analysis, theoretical calculations, computational fluid dynamics (or equivalent) and initial lab evaluation will verify compatibility and commonality with current vehicle filtration systems. Design goals will be to provide a new filtration or filtration component concept that is adaptable, flexible and provides a direct replacement with current vehicle filtration system. As appropriate, a preliminary economic analysis will be performed to verify cost savings potential using the new filtration or filtration component concept. At the conclusion of Phase I the proof-of-principle must be demonstrated and enough evidence presented to verify the new filtration system design accomplishes its goals of: (1) improved service life/performance and (2) operation and support cost (OSCR) savings. 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