SBIR-STTR Award

Currently 400 Hz power systems onboard US Naval ships use centralized and redundant frequency conversion, whereby 400 Hz power is generated in centralized locations and is then distributed to numerous loads located throughout the ship. This distribution system approach leads to the placement of large and expensive frequency converters onboard the ship and long cable runs. Additionally, the needed distribution equipment feeding all the 400 Hz loads is redundant to the 60 Hz distribution system. A more effective and survivable approach would utilize the existing 60 Hz distribution system to provide power to compact PUCs located directly at the load site. This would eliminate the need for separate 400 Hz distribution systems and eliminate the need for all the 400 Hz distribution equipment. In this Phase I SBIR, we propose to develop a 40 kW high power density, affordable PUC modules that have three times the power density and half the cost of the MFPMs used in the PNCC. We propose to develop these modules using SiC FETs and nano crystalline cores for the filter chokes. The successful development of this technology will improve the affordability and survivability of Naval ships.

Benefit:
The successful development of this technology will provide the required point of use conversion module to eliminate the 400 Hz power distribution system from ships and make the ships more survivable and affordable. The same technology can also be applied to other voltages such as 270 VDC. The proposed concept has a large potential for military and commercial applications. Commercial applications such as micro-grids would benefit from compact and affordable power conversion local to the end use application. This technology would also be applicable to commercial shipping, future electric cars and renewable energy markets.

Keywords:
power distribution, power distribution, power electronics, power frequency conversion, nano crystalline chokes, SiC power devices, point of use power conversion

The objective of this SBIR topic is to develop an affordable and compact Point of Use Conversion (PUC) module for 60 Hz to 400 Hz and 270 VDC power converters for shipboard applications. In phase I we demonstrated that our approach of using SiC solid state switches to increase the switching frequency in order to reduce the size, weight and cost is feasible. The feasibility was demonstrated via analysis and bench top testing. The concept design developed in Phase I showed that the size and weight of a PUC module is one third of the size and weight of current state of the art power processing modules. It also showed that the cost of a SiC based module is about one half the cost of Si Based module. The goal of the Phase II effort is to develop a prototype of a compact Point of Use Conversion (PUC) module for 60 Hz to 400 Hz power converters and a design of a compact PUC module for 60 Hz to 270 VDC power converters for naval shipboard applications with acceptable efficiency, power density and cost while eliminating the need for a separate 400 Hz distribution system.

Benefit:
The successful development of this technology will provide an improved capability for Naval ships. Utilization of PUC will eliminate the need for separate distribution systems and improved reliability and affordability. If successful, it will enhance future combatant ship survivability, and reduces the size and weight of the whole power distribution system. Potential commercial applications reside in applications where compact and affordable power conversion local to the end use application is beneficial such as micro grids, commercial shipping, future electric cars and renewable energy markets.

Keywords:
power electronics, point of use power conversion, power distribution, Silicon Carbide Devices, 400Hz power systems., power frequency conversion, simplified electrical distribution