N091-001 TITLE: DC Power Supply Technology for Air Cooled Systems

TECHNOLOGY AREAS: Ground/Sea Vehicles, Materials/Processes, Battlespace

ACQUISITION PROGRAM: USMC G/ATOR Program, PM John Mcgough: [email protected]

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: Design and develop high efficiency, high power density, fast transient response, DC-to-DC (DC/DC) converters and technology that support both high peak power pulsed loads and high average power loads for air cooled radar applications. Advanced, high density packaging, interconnect, magnetic, switching components and control technologies are needed.

DESCRIPTION: High peak and average power levels of future USMC active array radar systems require significant advancement in component technologies, integration and speed, to achieve reductions in antenna weight, thermal loading, size, and cost while providing significantly higher power per unit volume than present available commercial technologies. Fast transient response, isolated DC/DC converters are needed for both high pulsed and average current loads, that minimize output energy storage capacitor requirements. Advancements are required in the development of power conversion technologies, assemblies, and increased switching speeds for isolated DC/DC converters with significantly lower noise, cost, and weight. Desired characteristics: fast transient response, low overshoot and output voltage droop, higher efficiency, and higher power density. Goals for this fast transient response 300V input, 12-48V output isolated DC/DC converter include output power greater than 1kW, efficiency greater than 90 percent, power density greater than 500W per cubic inch, response time less than 10 microsecond, settling time less than 10 microseconds, overshoot less than 4 percent, base plate temperature 70C. 10mm. Isolated DC/DC converters with innovative, high speed, low loss switching topologies, advanced control loop design, low internal and output inductance, high slew rate output, and advanced component technologies are of interest. DC/DC converters incorporating advanced low loss switches, low inductance high common-mode isolation transformer, low loss inductors, advanced thermally enhanced board, and advanced control loop design are of interest.

PHASE I: Identify potential new and innovative research and development approaches to meet the power conversion needs discussed in this topic. Develop and design a conceptual fast responding isolated DC/DC converter, or a technology that supports the development of an advancement in the design of DC/DC converters, and perform supporting analysis and critical technology demonstrations.

PHASE II: Develop a prototype DC/DC converter, or supporting technology, based upon the Phase I design effort. Demonstrate the capability of the converter, or technology under both pulsed and high average load conditions and also demonstrate commercial viability of the proposed converter.

PHASE III: Develop pre-production and production components and sub-systems for integration into radar systems.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Servers, advanced computer systems, and the cell phone industry could leverage these advancements. require

REFERENCES:
1. Mohan, Undeland, and Robbins, Power Electronics: Converters, Applications, and Design, New York, John Wiley & Sons, 1995.

2. R. W. Erickson, Fundamentals of Power Electronics, New York, Chapman and Hall, 1997.

3. D. M. Mitchell, DC-DC Switching Regulator Analysis, New York, McGraw-Hill, 1988.

KEYWORDS: DC-to-DC Converters; High Speed Switching Technology; Advanced Magnetics; Control Loop Technology; Advanced Thermal Circuit Board Technology; Air Cooled

** TOPIC AUTHOR (TPOC) **

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