SITIS Archives - Topic Details
Program:  SBIR
Topic Num:  N102-153 (Navy)
Title:  Innovative materials/manufacturing for a prototype 600-1000VDC DC/DC Converter for Shipboard Radar
Research & Technical Areas:  Materials/Processes, Sensors, Electronics

Acquisition Program:  NA, IWS 2.0 will transition technology into developing high power radars.
 RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is “ITAR Restricted”. The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the “Permanent Resident Card”, or are designated as “Protected Individuals” as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.
  Objective:  The objective of this topic is to develop a prototype 600-1000 VDC converter. This will require research and development of advanced materials, technologies, and manufacturing processes that will provide reliable and higher performance power conversion, that will minimize cost, weight, volume, and thermal management infrastructure required, and that will maximize efficiency, power density and electrical performance (regulation, ripple & noise).
  Description:  High power levels (peak and average) are required for future shipboard radar array systems. Shipboard power management demands are increasing. There is a need for a 600VDC input DC/DC converter for radar array applications. This topic seeks an advanced converter design incorporating improved component technologies, integration, thermal management, and speed to provide a 600 VDC DC/DC conversion capability. This design will be compatible with developing shipboard power systems and provide higher power density than current commercially available technologies. Converter performance improvements in size, weight, operating temperature, and cost while providing significantly higher power density and efficiencies are required. The technology development should focus on a specific Navy transition. High power radar and EW modules are required for Active Electronically Scanned Arrays (AESA) to provide significant system performance improvements. The power systems within these AESAs consume significant power, space and thermal management resources. The power converters selected will minimize cost, volume, thermal management infrastructure required and maximize efficiency, power density, and electrical performance (regulation, ripple & noise). The research and development of advanced magnetic and capacitive materials is sought to support novel converter design to significantly increase performance and decrease size, weight and cooling requirements. Power converter attributes sought include low cost manufacturing processes and materials, high Q - low profile inductor, high performance ferrite material and higher power capability.

  PHASE I: Identify, model, and develop an innovative converter design incorporating materials and manufacturing processes that significantly improve performance and reliability.
  PHASE II: Using the design in Phase I and the materials developed in Phase I and in this phase, build and test a prototype 600-1000 VDC DC/DC converter focusing on a Navy transition. The prototype design, materials, and processes developed will address the issues described in the description of this topic (e.g., performance, cost, size, weight, and so forth)

  PHASE III: The Small Business will team with the Navy to transition the phase II developed 600-1000 VDC DC/DC converter design into a Navy systems. PRIVATE SECTOR COMMERCIAL POTENTIAL/

  DUAL-USE APPLICATIONS: Improved and higher performance power converters are needed to support a number of emerging applications within the military and industry.

  References:   1. NAVMAT P-4855-1A Navy Power Supply Reliability, Design and Manufacturing Guidelines, 1989. 2. NAVSO P-3641A More Power For The Dollar, 1999. 3. Next Generation Integrated Power Systems (NGIPS) Roadmap: https://www.neco.navy.mil/synopsis_file/N00024NGIPS_Technology_Dev_Roadmap_final_Distro_A.pdf

Keywords:  Power,Converter,Radar,EW,AESA,DC

Questions and Answers:
Q: If this technology is ITAR regulated, is commercialization possible?
If so, what would the restrictions be to commercialization?
A: Any technologies that are ITAR restricted must be developed and inserted into applications following ITAR rules. The power converter developed may well develop or utilize ITAR technologies as well as other non ITAR regulated tecnologies,. Non ITAR technologies could be commerciallized but any ITAR controlled technologies must observe ITAR rules.
Q: The demanding performance can be met by innovative SiC devices. Is a proposal focusing only on fabricating the innovative SiC devices in Phase I suitable for the converter(with Phase II focusing onpackaging and the actual converter design and experimental implementation) considered responsive to this topic?
A: This topic seeks a power converter design, the phase I should address an overall converter design feasability so focusing only on the SiC device would not be acceptable for phase I . A converter design approach is required to demonstrate feasibility in order to successfully complete a phase I, and detailed analysis or studies demonstrating feasibility of key technologies for this specific design approach
should be conducted within the phase I.
Q: Is it a "must have", or "nice to have" feature that the DC/DC converter is isolated?
A: This is a must have requirement.
Q: For the pulsed loads --
1. what is the delta I,
2. what is the pulse duration, and
3. what is the time between pulses?
A: This DC/DC Converter is intended to provide power to T/R Modules within an advanced pulsed radar system however there is no specific system or prime contractor associated with this SBIR effort. Therefore there are no specifics for pulse widths, PRF, or pulse currents. The load will be typical of advanced T/R Modules such as might be used in the AMDR radar system currently under development.
Q: Just to clarify, the term "output stored energy less than 1 joule" refers to the stored energy at the output capacitor, correct? Or, is it stored energy in the inductor? Would you clarify it please?

A: The output energy limit should be thought of as a goal. The purpose is to push the DC/DC converter design to have a very fast response time such that the size of energy storage elements can be minimized. In this regard, the output energy storage refers to both capacitive and inductive energy.
Q: 1) Do you have specific metrics on the isolation requirement?
2) When you say "overshoot less than 4 percent" is that based solely on voltage or another parameter?
3) What do you mean by "baseplate temperature typically at 50C"? Does that mean you have a heat sink interface not to exceed...?
4) What kind of MTTF guidance can you give us in order to pick and choose among design approaches?
A: 1) Do you have specific metrics on the isolation requirement?
A - The isolation is to be provided by a transformer.

2) When you say "overshoot less than 4 percent" is that based solely on voltage or another parameter?
A - This requirement is based on voltage.

3) What do you mean by "baseplate temperature typically at 50C"? Does that mean you have a heat sink interface not to exceed...?
A - For design purposes, the baseplate temperature will not exceed 50C.

4) What kind of MTTF guidance can you give us in order to pick and choose among design approaches?
A - The MTTF requirements have not been defined however the power supply will be used in an application where long life, typical of military system logistical support, is desired.

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