SBIR-STTR Award

American Systems Technology, Incorporated (ASTI) proposes to first identify major existing and emerging opportunities to improve US Army ground vehicle performance through the introduction of dual voltage (14/42 Volt) and/or full 42 Volt electrical systems. ASTI will then search for commercially-available 42 Volt components, whether existing or in development, that may be applied to both military and commercial electrical systems. ASTI will also survey dual voltage power conversion and management devices. ASTI then proposes to devise, evaluate, and select for future development a reasonable number of these devices for either dual or single voltage applications. For the selected components, ASTI will propose a method of incorporating them in current or new electrical system architecture, with special consideration for migration from 14 volt to dual 14/42 Volt to a full 42 Volt systems. 1) Reduced vehicle weight (power-carrying wires up to 60% lighter, smaller motors, etc.) 2) Increased mechanical power for electrical actuators. 3) Reduced need for belt-driven peripheral equipment, reducing engine drag. 4) Overall, increased fuel economy and reduced exaust emmissions. 5) Reduced replacment part cost due to commercial availability of parts.

The Phase I effort began with a survey of 42-Volt research and development. All vehicle and top-tier component manufacturers recognize the numerous benefits of 42-Volt electrical systems for improved performance, fuel efficiency, packaging, and emissions. However, it was quickly determined that the commercial automotive industry has significantly reduced the pace of 42-Volt adaptation and therefore the near-term feasibility for military adoption of commercial 42-Volt technology is greatly reduced. However, the analysis completed during Phase I uncovered a number of significant challenges electrical system reliability, longevity, and safety. Therefore, ASTI has determined to develop a comprehensive Intelligent Multiple Battery Sustainment and Readiness System (IMBSRS) for ground vehicles which will monitor the needs of the battery system and employ multiple technologies to manage and protect critical components. The objectives of the IMBSRS are to prevent dead batteries, maximize the longevity of batteries, detect battery system problems and predict component failures, extend battery system performance, and demonstrate wide-scale applicability to legacy commercial and military vehicles and to the Army’s Future Combat Systems. The configurable system will include advanced wireless communications and embedded diagnostics and prognostics capabilities.

Benefits:
A 2% fleet readiness improvement implies a savings of $400 Million in vehicle acquisitions. Estimates of $600 per vehicle investment for 40% of the vehicle fleet will keep $160 million worth of vehicles in service, with a return on investment of over 250%. Estimation of the sustainment savings associated with increased battery life is $2,600,000 per year, for this 40% of the fleet. See Appendix B for assumptions. Additional savings are possible through reduced battery disposal/reprocessing fees.

Keywords:
42-Volt, Ground Vehicle, Battery, Readiness, Sustainment, Diagnostics, Prognostics