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Lightweight 2-kW Diesel-Powered Electric Generator

Lightweight 2-kW Diesel-Powered Electric Generator. 2005 Joint Service Power Expo May 3, 2005 Tampa, FL Presented by Greg Cole. Photo taken by Army CECOM. Mainstream Generator History. Engine Development (1991- ) Customer: U.S. Army RD&E Center (Natick)

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Lightweight 2-kW Diesel-Powered Electric Generator

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  1. Lightweight 2-kW Diesel-Powered Electric Generator 2005 Joint ServicePower ExpoMay 3, 2005Tampa, FLPresented by Greg Cole Photo taken by Army CECOM

  2. Mainstream Generator History • Engine Development (1991- ) • Customer: U.S. Army RD&E Center (Natick) • Application: Small, diesel-powered, personal cooling system • Alternator Development (1994 - ) • Customer: U.S. Army Aberdeen / OST • Application: Miniature, multi-fueled generator • Results • Diesel-cycle is better than Rankine, Stirling, Brayton, and converted spark ignition (gasoline) • Mainstream designs and produces integrated, custom machines

  3. 2-kW Generator Requirements • Customer: Marine Corps System Command (MCSC) • Application: Team Portable Collection System (TPCS) • Project Philosophy: Commercial hardware, not Mil-Spec hardware • Goals: • Power is expected to exceed 1 kW @ 28 VDC • Desired weight is less than 50 lbs • Desired fuel is diesel

  4. 2-kW, 28-VDC Generator Evolution • Phase I – MCSC • Initial demonstration • 1.6-kW Generator: 42-lbs unmounted (14” x 11” x 16”) • Phase II – MCSC • Revised prototypes • 2-kW Generator: 48-lbs unmounted • 2-kW Generator: 65-lbs backpack mounted (18” x 17” x 20”) • Phase III – ONR • Two test units delivered to Army CECOM • 2-kW Generator: 80-lbs roll cage mounted (18” x 18” x 20”) • Phase III – MCSC • Additional test units similar to ONR units • Addresses issues identified during Army CECOM tests

  5. Mainstream’s Generators • Integrated system designed for military applications • Alternator integrated into engine flywheel • resulting in a lighter system • no coupling – eliminates potential failure component • reduces component count and number of wear components • Air-cooling fan integrated into engine flywheel • cools power electronics, engine head, oil sump • runs cooler - increases life and reliability • Mainstream designed and fabricated engine and generator • Sized specifically for application • Not just packaging of commercial components

  6. 2003 Power Expo • Technology • Integrated machine • Light-alloy engine • Product • 2-kW, 28-VDC Unmounted Generator – 48 lbs (14”x11”x16”) • 2-kW, 28-VDC Backpack Generator – 65 lbs (18”x17”x20”) • Test Results • Performance tests at Mainstream (Voltage, Fuel, Noise, etc.) • Life tests at Mainstream (1000+ hrs) • Field tests at Ft. Drum (U.S. Army 10th Mountain Division & U.S. Air Force 20th Air Support Operations Squadron) • Future Work • Magnesium engine block requires further development

  7. MCSC Field Tests at Ft. Huachuca • Achievements • Generator #1 successfully tested from 12/8/03 through 12/12/03 • Issues • Vibration Mounts • Too much or too little stiffness • New mounts have been tested for 2000+ hours • Decompression Lever • Lever on Generator #2 was over extended, damaged, and repaired • New design includes a stop for lever • Cover Plate Gasket • RTV seal on prototypes broke off internally and clogged fuel pump • Production generators have metal gasket

  8. ONR Phase III Program • Mainstream delivered two 2-kW, 28-VDC generators • Program Goals: • Government tests to characterize equipment • Identify remaining issues that need to be addressed • Mainstream can provide a complete test report to government personnel upon request • Testing: • All tests performed by Army CECOM • All tests performed at Ft. Belvoir (Fall 2004) • All tests performed using JP-8 • Generators were tested as delivered, no voltage or speed adjustments were made

  9. Voltage and Speed Adjustments • Tested Throttle • Loosen knob and rotate • “Voltages are difficult to adjust on this unit, and not something that will likely be attempted in the field by the user” – Army CECOM • Revised Throttle • Friction-plate design • Slide lever left-right • Easier access to oil gauge and plug Both Designs • PM Generator: voltage proportional to speed • Set screw for maximum setting

  10. Army CECOM Laboratory Tests(per MIL-STD-705C) • Physical Characterization • Start and Stop Test (503.1) • Frequency and Voltage Regulation, Stability and, Transient Response (608.1) • Ripple Voltage (650.1) • Voltage Dip and Rise (619.2) • Fuel Consumption (670.1) • Sound Level (661.2) • Endurance (690.1) • Extreme Cold Start (701.1d) • High Temperature (710.1d)

  11. Physical Characterization Data provided by Army CECOM

  12. Frequency and Voltage Regulation, Stability, and Transient Response Test Data provided by Army CECOM • Mainstream generator was never designed to provide voltage regulation • MCSC Spec. (20-32 VDC) • CECOM Measured (31-37 VDC) • “Most DC-AC inverters require a voltage range from 24-32 VDC...” - Army CECOM • Mainstream redesigning alternator to produce same power, lower voltage (unregulated) • Voltage regulated machine with feedback can be designed

  13. Ripple Voltage Test Data provided by Army CECOM • Ripple is amplitude of the alternating component of the DC voltage • Lower ripple is better • “Ripple Voltage leads to EMI, the higher the ripple the worse the EMI” – Army CECOM • “Bad Ripple Voltage can “fatigue” some electronics components (capacitors, transistors)” – Army CECOM • “Some fast acting switches can be damaged by bad ripple voltage.” – Army CECOM

  14. Resolution of Ripple Voltage Issue • MCSC did not specify ripple voltage or EMI • MCSC goal was to minimize weight • Mainstream has added a commercial capacitor to reduce ripple voltage • 1.4” dia. x 2.8” long • 0.16 lbs • fits in existing enclosure • no cost impact • ripple valleys minimized resulting in mean voltage increase and power increase

  15. Voltage Dip and Rise Test Data provided by Army CECOM

  16. Fuel Consumption Test Data provided by Army CECOM * “The Power Generation Branch has numbers showing some MTGs to use only 0.26 gal/hr of JP8 at full load. The 0.33 is a fleet maximum.” – Army CECOM

  17. 7 6 8 5 9 4 10 3 11 13 2 12 1 Sound Level Test • Generator tested by Army CECOM had same muffler as that used on the 2-kW MTG • Mainstream has developed a new muffler. Tests indicate that noise can be reduced by 3 dB. Data provided by Army CECOM

  18. Endurance Test Data provided by Army CECOM • Due to limited time and budget, “conventional” 1000 hr test shortened to 150 hrs • Tested 8 hrs per day • “The unit did not have any critical failures throughout the test. The system was successfully started and operated throughout the entire 150 hours.” - Army CECOM • Passed

  19. Endurance Test – Human Factors Comments

  20. Extreme Cold Test • Every part of system (including fuel and oil) is cold soaked in an environmental chamber to a specified temperature for 24 hours. • The system is prepared for starting by adding lube oil to the engine head. • “Mainstream difficult to start below 37°F.” - Army CECOM • Mainstream generator was designed to start without any external power supply. • Electric starter is currently being developed.

  21. High Temperature Test • Tests consisted of starting and operating the system at a specified temperature and ensuring that the system could stabilize without overheating. • “The system was able to stabilize at rated load for over two hours at 125°F.” - Army CECOM • “The system was not able to provide 110%.” - Army CECOM • Maximum throttle setting was not changed. Mainstream’s generator can provide 110%.

  22. Mainstream’s Life Tests • Number of Generators Tested: 2 • Number of Hours Tested: 2000+ hours each • Approximate number of starts / stops: 60 each • Load: variable (0-2000 W) • Number of Critical Failures: 0 • Number of Hurricanes Survived: 1

  23. Additional Development • Electric Start • Integrated Alternator / Starter • In development with commercial electronics vendor • AC Power • Testing with commercial inverter • Cost Reduction • Scaling-up for production • Completing production fixtures and tooling

  24. Summary • 28-kW 28-VDC diesel-powered electric generator • 80-lbs fully instrumented • 18” x 18” x 20” • 0.22 gph at 2 kW • Improvements • Throttle • Muffler • Vibration Mounts • Voltage Range (24-32 VDC) • Voltage Ripple (3%) • Human Factors

  25. Contact Information • Company Address Mainstream Engineering Corp. 200 Yellow Place Rockledge, FL 32955 (321) 631-3550 http://www.mainstream-engr.com • Points of Contact • Technical: Greg Cole, gsc@mainstream-engr.com • Contracts: Michael Rizzo, mar@mainstream-engr.com

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