SBIR-STTR Award

Diversified Technologies, Inc., (DTI) proposes to develop a compact, lightweight 112.5 kVA militarized isolation transformer for suitable Navy shipboard vital loads. In Phase I, DTI and our subcontractor Neeltran, Inc. will design a complete 60 Hz, 440 VAC, 112.5 kVA isolation transformer as specified, including the protective cabinetry weight, and work with the Navy on a new 150 kVA transformer specification and design. The design will be ruggedized for military usage and optimized for increased power density on weight and volume bases and reduced losses. In addition, the transformer will have improved fault-current performance with reduced stray magnetic fields. In the Phase I Option, DTI and Neeltran will fabricate, demonstrate, and test two full-scale 112.5 kVA transformers of the optimized design. The main Phase I technical objective is to reduce the size and weight of single-core three-phase transformers for use within shipboard power distribution systems. DTI has a long history of developing advanced power electronics systems for the Navy and has extensive capabilities in electromagnetics design, which forms a key element of our power electronics capabilities. Transformer technology is relatively stable and yet new and challenging applications of transformers occur every day. These challenges are met and exceeded with improvements in materials technology along with sophisticated computational analyses and plain, old American ingenuity and practicality. Diversified Technologies, Inc. (DTI) has had four relevant MIL-SPEC programs (including two products as critical components now deployed on submarines and aircraft carriers, each with unit volume of approximately 100-units), three relevant Phase III success programs, three relevant high-power density and low SWaP (Size, Weight and Power) programs, three relevant pulse transformer programs, and one relevant 25-year high-reliability undersea program. Each of the eleven separate referenced programs (some qualify as duplicates) demonstrate that excellence in magnetics is a core capability at DTI.

Benefit:
The proposed transformer the benefits listed below: Compact, power-dense design (41 x 22.5 x 30 ) Rugged and high impact shock resistant. Significant weight reduction (1038 lbs estimated, including cabinetry) Provides voltage and power flexibility with scaling to deliver a range of voltage and power levels at the point of load. Greater efficiency (98.5%/1690 W estimated). Provides galvanic isolation between loads and source which helps protect the rest of the power system from a single electrical fault or battle damage. Better fault handling. Reduced stray magnetic field. Two examples of potential commercial applications which could benefit by the design of smaller, rugged, high efficiency three-phase distribution transformers are power distribution systems of civilian marine vessels, and the power collector networks of wind and solar farms.

Keywords:
Shock and vibration, Shock and vibration, low SWAP, transformer, Galvanic Isolation, Lightweight, Distribution, point-of-load, Compact

In Phase II, Diversified Technologies Inc. (DTI) and subcontractor Neeltran, Inc. propose to develop a compact, 60 Hz, 440 Vrms, 150 kVA, militarized, 1:1 galvanic isolation transformer, meeting and exceeding the original Phase I required power level of 112.5 kVA. The main objective is to reduce the size and weight of militarized single-core three-phase transformers for use within Navy shipboard power distribution systems, while meeting the Navy-specific requirements for shipboard use. DTI and Neeltran will update the specification, design, and power level as desired by the Navy. DTI will fabricate and electrically demonstrate four transformers, and prepare the units for qualification testing, achieving TRL 6. In Phase II Option 1, DTI will complete Environmental Qualification Testing on three units. The transformers will be validated through testing to MIL-STDs by an independent test facility. In Phase II Option 2, DTI will deliver, install, and fully test a qualified final isolation transformer shipboard or at a U.S. Navy test facility, thereby achieving TRL 7. Together, DTI and Neeltran have the electromagnetics expertise, design capabilities, experience with the Navy procurement process, and domestic transformer manufacturing facilities required to develop and produce compact and lightweight isolation transformers. DTI has extensive experience delivering advanced power electronics systems, especially transformer-based systems, to the Navy. DTI has directly transitioned products from three Navy SBIRs into production and deployment. Our Phase III revenues from sales to the Navy, Air Force, and commercial customers based on SBIR technology have allowed us to double our revenues over the last five years. As a result, DTI is one of the highest-rated firms in the country with respect to SBIR commercialization success.

Benefit:
Power transformers are key components in shipboard AC electrical power distribution systems. Their function is to provide galvanic isolation and efficiently transform electrical energy to more convenient voltages at the point-of-load. Transformers for Naval ships have a number of unique requirements including reliability, high impact shock (MIL-STD-901), reduced magnetic and acoustic signature, and specific space / size requirements. Reducing Size, Weight, and Power losses (SWaP) are important for shipboard applications. Commercially available distribution transformers are generally not able to meet all these requirements. The planned transformer is single-core, power dense, meets specified shipboard Military Standards, easily fits through hatches with a front face of less than 57.5 , has reduced footprint, and satisfies the touch-temperature requirement of less than an 80 C rise.

Keywords:
single-core, reduced footprint, Galvanic Isolation, 3-Phase, power transformer, TRL 7