SBIR-STTR Award

The goal of this SBIR Phase I project is to establish the feasibility and performance merits of an innovative high current solid-state power controller for power management and fault protection for applications in both commercial and military aerospace electrical power systems. An innovative high current solid state power controller can be achieved with emerging new technologies in high temperature power electronics, high temperature electronics, and advanced composite materials.

Benefits:
Silicon carbide based solid state power controllers have strong commercial application potential for both military and commercial sectors. The ability to operate at higher temperatures make silicon carbide based solid state power controllers ideal for harsh environments and potentially eliminates the need for special cooling schemes and apparatus in an aircrafts and spacecrafts. Conventional silicon based solid state power controllers generally rely on elaborated refrigerated air cooling systems due to its limited maximum operating temperature. The elimination of special cooling schemes and apparatus offers significant positive benefits for the weapon systems (aircraft). This technology will be marketed to a number of potential customers such as the U.S. Air Force Air Combat Command, Material Command and Space Command; U.S. Navy Air Systems Command and Space & Naval Warfare Systems Command; U.S. Army Aviation & Missile Command, Material Command, and Space & Missile Command.. Phase I results will be presented to potential customers, including commercial aircraft and spacecraft manufacturers, to make them aware of the benefits and potential participation by them in Phase II for a specific application. Manufacturing and production will follow Phase II.

Keywords:
Electrical Power Management, High Temperature Electronics, High Temperature Power Electronics, Electrical Fault Protection, Silicon Carbide Semiconductor (SiC), Silicon on Insulator (SOI), Solid State Power Controller (SSPC), More Electric Aircraft (MEA)

The overall objective of the proposed project is to develop high current (40 to 100 Amperes), 270 Volts direct current, solid-state power controllers (SSPC) for power management and fault protection for applications in both commercial and military electrical power systems. Mechatronic Systems' (MSL) SBIR Phase I conceptual designs, analysis, modeling and simulation results have shown the feasibility and advantages of a Silicon Carbide (SiC) based SSPC. Phase II effort will focus on detailed engineering design, development and hardware demonstration of a high current, high temperature silicon carbide (SiC) semiconductors and silicon-on-insulator (SOI) electronics based, 40 to 100 Amperes, 270 Volts dc, SSPC for use in both commercial and military electrical power systems. Phase II effort will include detailed engineering analysis, design, modeling and simulations, hardware fabrication and testing of a high current and high temperature SSPC. Phase II efforts are also focused on achieving risk reductions; demonstrate performance and commercialization potential. Phase III is envisioned to focus on the manufacturing development of qualified hardware units for demonstration and testing in the actual operational environment aboard an Air Force aircraft. Mechatronic Systems recommended approach for the Phase II effort not only encompasses the high temperature SiC die and power modules, but it also includes high temperature digital and analog silicon-on-insulator (SOI) based electronics, and advanced composite materials for thermal management that make up a high current and high temperature SSPC. Taking this approach will result in a high current and high temperature SSPC that totally eliminates the need for active cooling and is capable of operating at high environmental temperatures. Phase II efforts will yield detailed engineering designs, models, analysis and simulation results including performance estimates, such as weights, volumes, power dissipations, and efficiencies, hardware development and fabrication, and hardware demonstration in an engineering laboratory. Our proposed Phase II effort includes the participation on a consultant basis of a world leader in manufacturing of high precision servo systems for military and commercial markets, and a premier manufacturer of Air Force systems (aircrafts). Mechatronic Systems has achieved significant progress on the development of high temperature and high power density SiC based electric motor drives for servo applications under SBIR contracts from the U.S. Air Force [11-14]. Mechatronic Systems qualified suppliers have demonstrated the capability to manufacture and deliver high temperature SiC bare die and SiC power modules per our engineering designs and performance specifications [11-14]