TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: PEO Aircraft Carriers, PMS 378 ACAT IV

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), which controls the export and import of defense-related material and services. Offerors must disclose any proposed use of foreign nationals, their country of origin, and what tasks each would accomplish in the statement of work in accordance with section 3.5.b.(7) of the solicitation.

OBJECTIVE: The proposed topic intends to focus innovation to the controlled generation of linear motion/ force in an affordable, lightweight, universally applicable and easily integrated package. Linear electric motors have demonstrated great capability to enable improved shipboard machines including the ElectroMagnetic Aircraft Launch System (EMALS) and Advanced Weapons Elevator (AWE) programmed for CVN 78. Concepts also exist for the internal movement of aircraft, weapons and stores with advanced linear motion, and for improving the cost, weight and maintenance of existing hull and deck machinery systems such as hatch covers and hangar doors. Weight and cost reduction targets of 20% or more each as compared to commercially available and legacy linear motion equipment, including linear electric motors, of equivalent power are desired. A lightweight, low profile, affordable, possibly modular, possibly portable device, or system that can be integrated with minimum impact to the ship for a wide range of applications requiring linear motion is the objective of this topic.

DESCRIPTION: A common motor, device, system or subsystem to generate linear motion/force for a variety of high capacity shipboard applications, that is shown to be lower cost and mass than equivalent commercially available equipment, is desired. The cost and weight of associated cooling systems, if required, must be included in the total for the system shown to result in a net savings. The system may be a modular, building block type design wherein one or more common units could be easily connected or otherwise combined to service a variety of applications, each of which requires a different force/stroke. Other concepts that enable the use of common, affordable, lightweight components for a variety of shipboard functions requiring linear motion are solicited. Simplicity and cost effectiveness of design, materials, manufacturing, set-up, installation, integration, operation and maintenance are key attributes, as is compliance with shock and EMI requirements. Also critical is integrated control or a design that is shown to be easily controllable from common, commercially available drives. Electric powered is encouraged, and hydraulic, steam and air powered is discouraged.

For the purposes of this research:
- Nominal peak motor thrust range: 5,000 LB (22kN) to 15,000 LB (67kN)
- Nominal continuous motor thrust range: 3,000 LB (11kN) to 12,000 LB (53kN)
- Variable velocity from 20 ft/min to 100 ft/min

PHASE I: Develop concept proposal for an affordable, lightweight, low volume, power dense, linear motion system that can be universally applied to service a variety of shipboard operations that require a broad range of force and stroke. Illustrate the ability of common components to meet widely disparate linear motion/force requirements while minimizing weight and volume. Conduct a study to illustrate conventional linear induction and linear synchronous motor design and associated cost and weight drivers compared with those of the proposed system. Also show comparison of the proposed system with more conventional linear motion equipment such as hydraulic, pneumatic and electro-mechanical machinery. Clearly articulate how cost, volume and weight savings are realized. Present findings with data, illustrations, related work, etc. to demonstrate feasibility of an affordable, lightweight, high capacity, universal linear motion system.

PHASE II: Design and develop two or more working prototype(s) that will be used to demonstrate feasibility of use with a variety of applications. Prototypes shall be full scale and power. Associated drives and control or other supporting equipment necessary for the prototype must be provided by the proposing small business. Demonstrate prototype in actual hardware tests with one or more machinery systems to be agreed upon and arranged with the TPOC. Additionally, conduct modeling and simulation of the prototype driving one or more alternate machinery systems. Further illustrate the universal applicability of the prototype using 3D modeling, drawings or actual demonstrations with photographs/video of the prototype integrated with a selection of disparate military and commercial machines and equipment with a broad range of force and stroke requiremts.

PHASE III: Partner with prime contractor/manufacturer. Conduct manufacturing engineering study to determine most cost effective production methods. Develop business plan to bring production units to military and commercial market. Produce necessary prototypes to drive a full scale machinery system such as the Navy Standard Elevator Land Based Engineering Site or other identified existing or developmental Naval machinery system(s). Integrate prototypes with test system and perform full spectrum of load cycle testing and endurance testing. Conduct environmental testing of prototype test articles including ship motion, shock and EMI. Develop integration plan for selected systems and ships. Seek other opportunities such as JCTD for joint application and resources.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Linear motion systems are in ever-increasing demand in many industries including shipbuilding, manufacturing, automation, material handling, transportation, aerospace and amusement industries. Accurate positioning of large, heavy parts in production lines or machines and equipment in the manufacturing process; large machine tool applications; as prime mover in warehouse material handling systems, airport baggage handling and aircraft cargo loading systems, vertically or horizontally sliding doors; propulsion of plant equipment, commercial passenger vehicles such as trains and city shuttle systems, amusement rides; and launching of aerial vehicles are all ideal applications for high capacity linear motion systems.

REFERENCES:
1. NAVSEA OP 3565/NAVAIR 16-1-529 Electromagnetic Radiation Hazards Vol. 2.

2. MIL-S-901D Shock Tests, high impact, Shipboard Machinery, Equipment and Systems, Requirements for.

3. www.dt.navy.mil/mac-res-eng/index.html

KEYWORDS: Linear; motion; affordable; universal; lightweight; machinery.

** TOPIC AUTHOR (TPOC) **

DoD Notice:   Between April 21 and May 18, 2008, you may talk directly with the Topic Author(s) to ask technical questions about the topics. Their contact information is listed above. For reasons of competitive fairness, direct communication between proposers and topic authors is not allowed starting May 19, 2008, when DoD begins accepting proposals for this solicitation.

However, proposers may still submit written questions about solicitation topics through the DoD's SBIR/STTR Interactive Topic Information System (SITIS), in which the questioner and respondent remain anonymous and all questions and answers are posted electronically for general viewing until the solicitation closes. All proposers are advised to monitor SITIS (08.2 Q&A) during the solicitation period for questions and answers, and other significant information, relevant to the SBIR 08.1 topic under which they are proposing.

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