Power generation for weight and space limited USV systems Navy SBIR FY2004.3 Sol No.: Navy SBIR FY2004.3 Topic No.: N04-216 Topic Title: Power generation for weight and space limited USV systems Proposal No.: N043-216-0 Firm: SYNCHROTEK P.O. Box 4083 APPLETON, Wisconsin 54915 Contact: Shekar Rao Phone: (920) 989-8888 Web Site: www.synchrotek.net Abstract: Synchrotek Inc. proposes to design, during phase I, a 40 kW high frequency generator set for application in Unmanned Surface Vehicle (USV) platforms as a power source to support command and control equipment/modules. The design is based on Synchrotek's Variable Speed Constant Frequency (VSCF) technology. It uses a lightweight twin-cylinder rotary engine as prime mover. The generator is a lightweight permanent magnet generator, which produces variable voltage, variable frequency output when connected to the variable speed engine. An electronic power converter converts the generator output to precise power for AC load at constant voltage and constant frequency, or for DC load to precise DC voltage. The entire system is optimized for the lightest possible weight, expected to be less than 650 lbs. Additional benefits of the VSCF system are improved efficiency of the generator and the entire system over a range of load. This is achieved by controlling the speed of the engine for varying load conditions by an electronic speed controller that senses the load and adjusts the speed. Synchrotek has developed several gen-sets for the Army CECOM, as R & D Effort. Among them are the 3 kW and 5 kW generator/Inverter systems. Synchrotek has developed in-line generator for the Army for a constant speed application that produced 10 kW output at 120/208 V, 3ph, 60 Hz at engine speed of 1200 rpm. The generator is designed for speed range of 800 to 3400 rpm. Three prototype units have been incorporated into HMMWV system for field tests. The proposed high frequency generator will be designed with similar physical parameters, but for variable speed application. The phase I work effort will consist of a comprehensive assessment of mechanical, electrical and thermal trade off for an optimum configuration of a 40 kW generator coupled to a rotary engine The effort will address the electrical, mechanical and thermal considerations of the generator. The phase 1 effort will also evaluate its performance with the Power Electronics package to ensure 40 kW power at precise voltage and frequency and to generate drawings for fabrication of the generators during phaseII. Benefits: The anticipated benefits include readily available power within the vehicle to power command/modules requirement. The unit weighs less than 650 lbs. and thus allows spare additional payload capacity. Ease of maintenance and repair/replacability of modular units offer advantage over a generator that runs off the vehicle engine. For commercial applications this approach also reduces fuel consumption and pollution, when run under optimum variable speed conditions. Return