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Affordable Point of Use Conversion (PUC) Module for 400Hz Power System Applications
Navy SBIR 2013.1 - Topic N131-040 NAVSEA - Mr. Dean Putnam - [email protected] Opens: December 17, 2012 - Closes: January 16, 2013 N131-040 TITLE: Affordable Point of Use Conversion (PUC) Module for 400Hz Power System Applications TECHNOLOGY AREAS: Ground/Sea Vehicles ACQUISITION PROGRAM: PMS320, Electric Ships Office OBJECTIVE: Develop an affordable and compact Point of Use Conversion (PUC) module for 60 Hz to 400 Hz and 270 VDC power converters for shipboard applications. DESCRIPTION: Currently 400 Hz power systems onboard US Naval amphibious ships and destroyers use centralized and redundant frequency conversion, whereby 400 Hz power (defined by MIL-STD-1399) is generated in centralized locations and is then distributed to numerous loads located throughout the ship. This distribution system approach leads to the placement of large and expensive frequency converters at strategic locations onboard the ship and long cable runs. Additionally, the needed distribution equipment feeding all the 400 Hz loads is redundant to the 60 Hz distribution system. A more effective and survivable approach would utilize the existing 60 Hz distribution system to provide power to compact PUCs located directly at the load site. This would eliminate the need for separate 400 Hz distribution systems and eliminate the need for all the 400 Hz distribution equipment such as transformers, bus transfer switches, cableways, collars, and multiple cable transits penetrations. Since many 400 Hz vital loads are sensitive to power interruptions, most of these loads are fed via manual bus transfers, which require manual switching if the primary source of power is lost. The state of the art in power conversion equipment components has progressed suitably to allow for the development of compact PUCs that would fit in available spaces near to the loads and provide the power quality the loads require. However, the integration of those components in a small package while meeting tight electrical system tolerances that define Type II and Type III power will be a significant technical challenge to overcome. Type II power is 440 VAC or 115 VAC, 400 Hz ungrounded and Type III is similar, but with a tighter tolerance, as defined by MIL-STD-1399. The power density of commercial power electronics has increased due to the development of higher power ratings for the Silicon based components to fit within the tight ship constraints. But, the harsh nature of a naval environment will be a challenge due to limited cooling as well as high shock and vibration loads will require novel approaches to packaging the devices in a module. More advanced components based technology such as Silicon-Carbide may be necessitated to reduce the overall thermal load and advanced cooling techniques such as (but not limited to) direct spray cooling of the electronics to reduce the overall size. While the state of the art indicates this could be achievable, actual integration of the new or developmental components in to a working PUC module is a high risk. New power electronics technologies hold the potential to offer benefits which will result in simplified electrical distribution architecture and increase flexibility, survivability, reliability and efficiency for Navy systems (reference 3). The need is to develop a PUC whose size, weight, and cost would enable placement in proximity to the load site with minimal ship integration impact (able to pass through a 26"x66" oval opening and mountable on a ship�s bulkhead for arrangement flexibility). Proposed PUC module concepts should provide high quality output power (with the 440 VAC input) that exceeds the requirements of MIL-STD-1399-300 for 440 VAC and 115 VAC at 400 Hz and be able to provide 270 VDC and shall meet the definition of power conversion modules contained within reference 1. Power densities for the proposed solution shall have a threshold of 2 MW/m^2 with an objective of 3 MW/m^2. Proposed concepts will need to be address load survivability during system electrical faults and power interruptions by limiting current and being capable of seamless switching to alternate 60 Hz supply power sources. PUC modules should be able to isolate faults at the load site, without affecting adjacent loads or the rest of the electrical distribution system. Furthermore, these modules must protect the load from upstream anomalies such as high harmonics and input voltage swings exceeding �10%. The goal is to preserve power to the loads such that when the loads have two sources of power, the loss of one source will not cause a power interruption to the load. Proposed PUC module concepts should meet the applicable performance goals for 60 Hz to 400 Hz frequency converters in MIL-PRF-32272, Performance Specification, Integrated Power Node Center (IPNC) and shall conform to reference 2. PHASE I: The company will develop concepts to determine the feasibility of the development of a PUC module for use in shipboard power system applications with capabilities outlined in the description above. As applicable, the company will demonstrate the effectiveness of the solution with modeling and simulation. The company will develop an initial conceptual design and metrics to analyze the feasibility of the proposed solution. Develop a test and evaluation plan that contains discrete product development milestones for verifying performance and suitability for Navy needs. The small business will provide a Phase II development plan with performance goals and key technical milestones, and that will address technical risk reduction. PHASE II: Based on the results of the Phase I and Phase II plan, the company will develop and demonstrate the prototype(s) as identified in Phase I. Through system simulations, demonstrate and validate the performance goals as established in Phase I. The prototype must meet applicable performance goals of MIL-PRF-32272. The small business will further refine the prototype into a converter compatible with packaging requirements and military standards listed above and the company will refine the prototype into an initial design that will meet Navy requirements. The company will prepare a Phase III development plan to transition the technology to Navy use. PHASE III: If Phase II is successful, the company will be expected to support the Navy and applicable Industry partners in testing, validation and transitioning the technology for Navy use. The company will develop the converter systems for evaluation to determine its effectiveness in an operationally relevant environment. The final system is expected to be modular to accommodate various shipboard power distribution system architectures. The small business will participate in an integrated product team environment to develop the detailed interfaces required to integrate the converter with the power system and the combat systems loads. PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Advances in point of use conversion modules for naval applications will provide enhanced capability directly applicable to commercial applications, resulting in improved performance, higher reliability, increased durability, and graceful degradation. For example, terrestrial power systems such as micro-grids would benefit from compact and affordable power conversion local to the end use application. This technology would also be applicable to commercial shipping, future electric cars and renewable energy markets. REFERENCES: 2. "Naval Ships� Technical Manual Chapter 320 Electric Power Distribution Systems." S9086-KY-STM-010/CH-320R2 21 APR 1998. Date of access 18 March 2012 3. CAPT Petersen, Lynn, Hoffman, Donald, Borraccini, Joseph, & Swindler, Steven. "Next-Generation Power and Energy: Maybe Not So Next Generation." Paper from ASNE Engineering the Total Ship 2010 Conference, July 2010. Date of access 22 March 2012 KEYWORDS: point of use power conversion; power frequency conversion; power electronics; power distribution; simplified electrical distribution; 400Hz power systems
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