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Contents
1. 2. 3. 4. 5.
5.1. 5.2. 5.3. 5.4. 5.5. 5.6.
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6 9 14 16 20
20 21 22 23 24 25
INTRODUCTION WHY HAVE THEM? MARINE MILITARY VEHICLES MILITARY AIRCRAFT KEY ENABLING TECHNOLOGIES
Introduction to the six key enabling technologies Traction batteries Traction motors Electronics/electrics Range extenders Fuel cells
6.
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Tables
Table 5.1 Table 6.1 First major use of new electric vehicle technologies IDTechEx Electric Vehicles Reports
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20 31
Figures
Fig. 1.1 Fig. 1.2 Fig. 1.3 Fig. 1.4 Fig. 2.1 Fig. 2.2 Fig. 2.3 Fig. 2.4 Fig. 2.5 Fig. 2.6 Fig. 2.7 Fig. 2.8 Fig. 2.9 Fig. 3.1 Fig. 3.2 Fig. 4.1 Pure electric truck for general use that is also used by the military Small pure electric vehicle used by the US military Polaris Industries Neighborhood Electric Vehicles (NEV)s used by the US Military Polaris Industries All Terrain Vehicle ATV specifically designed for military use Electric stealth vehicle General Dynamics Land Systems Shadow hybrid electric vehicle Millenworks light hybrid vehicle Hybrid Future Tactical Truck System (HFTTS) Oshkosh hybrid military Heavy Expanded Mobility Tactical Truck (HEMTT) 100mpg(US) Hybrid Hummer Bronco hybrid from Singapore Roboterwerk robot electric surveillance vehicle Green Wheel jeep style pure electric vehicle Swimmer type of AUV Hypersub submersible fast powerboat Boeing/ WheelTug electrified nosewheel uses Auxiliary Power Unit APU in large aircraft whereas the EADS version uses a fuel cell. Fig. 4.2 Fig. 4.3 Fig. 4.4 Fig. 5.1 AeroVironment Raven, the best-selling hand launched surveillance aircraft Aqua Puma Very small UAVs for surveillance etc
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6 7 7 8 9 9 10 11 11 12 12 13 13 14 15 16 17 18 19 21 23 23 25 26 27 28
Third generation lithium-ion battery, the lithium sulphur small UAV battery of Sion Power CERV TARDEC APD with in-wheel motors Evolution of range extenders Fuel cell AUV in Japan New and improved supercapacitors and their variants such as supercabatteries are becoming more and more useful in EVs The $517 million unmanned surveillance airship currently being made for the US Department of Defense by Northrop Grumman showing flexible photovoltaics. IDTechEx Ltd 2011 US Tel: +1 617 577 7890 UK Tel: + 44 (0)1223 813703 www.IDTechEx.com
Fig. 5.2 Fig. 5.3 Fig. 5.4 Fig. 5.5 Fig. 5.6
Fig. 5.7
Fig. 5.8
Glider type of AUV surfacing to recharge batteries using wave power (by hinging) and solar power (by photovoltaics) 29
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1.
Introduction
This white paper provides an introduction to military and allied electric vehicles and a pointer to the best sources of further information. It shares some of the information in the IDTechEx report, Electric Vehicles for Military, Police and Security 2011-2021. Military electric vehicles vary from those that are not designed primarily for such purposes - such as most Airport Ground Support Equipment GSE - and those that are. The general situation with electric vehicles of all types can be seen in the IDTechEx report, Electric Vehicles 2012-2022.
Fig. 1.1
Pure electric truck for general use that is also used by the military
Source Balqon
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Fig. 1.2
Fig. 1.3
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Fig. 1.4
Polaris Industries All Terrain Vehicle ATV specifically designed for military use
What is an EV? The term electric vehicle EV is limited to free running vehicles by land sea and air, so it does not include tethered Remotely Operated Vehicles (ROVs) under the sea that are often used by military forces. It does not include vehicles lacking a large traction battery or similar power source on board so we are not including large diesel electric and nuclear electric submarines and ships for example. Yet what remains is already a fast growing $53 billion business at ex-factory prices. Electric vehicles can be pure electric with only an electric power source a battery and or a supercapacitor bank - on board or hybrid meaning with another major power source on board as well that is not electric. That may drive the wheels when extra power is needed ie a parallel hybrid or simply charge the battery a series hybrid.
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2.
Fig. 2.1
Fig. 2.2
Some versions employ the long range, high power benefits of a hybrid drive train but revert to pure electric when stealth is needed. Indeed some electric vehicles can provide extra electricity for other equipment at destination, permitting silent operation of radar and so on. But there is
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more. A military force is usually limited in mission by its supply chains and a major part of that is always supply of fuel. The US Army sees hybrid-electric powered trucks and the hybrid-electric Future Combat Systems FCS as key in its objective of 75% lower fuel consumption by 2020. This is as much to do with operational flexibility - permitting previously impossible speed of deployments - as cost saving and reduction of pollution. Significant savings have already been demonstrated. Operating as a hybrid, with a 24-gallon tank, a truck travels 375 miles without refuelling compared to a conventionally powered vehicle, travelling less than 60% of that range. Primarily, savings do not relate from the cost of fuel itself, but to reduced army logistical transportation requirements - as fuel takes up about 70% of the logistical tonnage haul in a heavy armored division.
Fig. 2.3
Source Millenworks
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Fig. 2.4
Source DOD
Fig. 2.5
Source Oshkosh
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Fig. 2.6
Source Hummer
Fig. 2.7
Even hybrid battle tanks are being designed. Therefore, whereas less than 1% of military vehicles are electric today, something near to 40% is likely by the end of the decade on IDTechEx projections. As early as 2016, we forecast over 35,000 electric military land vehicles being sold at a total cost of over $3 billion. Often, the design requirements of military, security and police electric vehicles are similar. Add to that the many marine and airborne electric military, security and police vehicles both manned and unmanned. As the technology and its employment broadens, there are many other advantages coming to the fore. For example, it is easier to have a physically distributed and multiply redundant power train if it is electric. Electric power trains can be more reliable, easier to repair and last longer. We shall even discuss structural batteries and smart skin coming along where power electrics and electronics become part of the structure of
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the vehicle. In all cases, reduced maintenance is welcomed in military applications because that equates to greater security and operational flexibility not just cost control. The German Army, Deutsche Bundeswehr, recently demonstrated two of their military vehicles currently in use. There was an all- terrain unmanned surveillance electric vehicle a little larger than a quad bike and the unmanned smaller robot vehicle with surveillance camera shown below.
Fig. 2.8
Source IDTechEx
Green Wheel of China demonstrated the following all-electric jeep style vehicle at eCarTec in Germany in October 2011.
Fig. 2.9
Source IDTechEx
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3.
Fig. 3.1
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Fig. 3.2
Source MarionHSPD
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4.
Military aircraft
Military aircraft are mainly Unmanned Aerial Vehicles (UAVs) and that will continue to be the case for the next decade. There are civil manned aircraft but they are small single and two-seater propeller driven craft. When pure electric they have range of only 100 miles (160 km) or so and endurance of about one hour or two. This is of limited use to the military but progress is rapid. For example, a hybrid electric aircraft first flew in 2011 with potentially much longer range. Boeing and its largest competitor EADS in Europe are developing the ability for even the largest air transporters and airliners to be independent when on the ground by becoming electric vehicles thanks to an electric motor on the nose wheel. This is of enormous significance to military forces because it increases the range of aircraft by having the jet engines switched on only the instant before takeoff saving the megawatts of power wasted queuing for takeoff and it lets the pilot dock the aircraft silently after landing, without the vulnerability of waiting for ground support equipment.
Fig. 4.1
Boeing/ WheelTug electrified nosewheel uses Auxiliary Power Unit APU in large aircraft whereas the EADS version uses a fuel cell.
Source WheelTug
The AeroVironment Raven, the best-selling hand launched surveillance aircraft is pure electric and over 12,000 have been used by military and security forces from Australia to North America and Europe,.
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Fig. 4.2
Source AeroVironment
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Fig. 4.3
Aqua Puma
Very small surveillance aircraft are now being proved and some examples are shown below.
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Fig. 4.4
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5.
5.1.
Table 5.1
Source IDTechEx
For example, wireless transmission of energy has been largely developed for consumer electronics and non-military electric vehicles but it is leading to continuous power acquisition resulting in small or no traction battery being needed. Anyway, wireless charging of the vehicle traction battery when stationary is executed without the driver leaving the vehicle, so it is safer and cleaner. For more on this see the IDTechEx report, Wireless Power Transmission for Consumer Electronics and Electric vehicles 2012-2022.
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Traction batteries Traction motors Electronics/electrics such as battery management System BMS, on-board chargers, motor
controllers, and the Vehicle Management System that manages these with interfaces to controls and instruments, energy harvesting, supercapacitor banks etc. Range extenders Supercapacitors Energy harvesting such as regenerative braking by reverse motor, generator or flywheel, dampers that generate electricity and harvesting heat from the hybrids engine and exhaust.
However, although military vehicles pioneered almost all of the most advanced technologies some years ago, that is no longer the case today and benchmarking with all forms of non-military vehicle is now extremely important.
5.2.
Traction batteries
Military vehicles occasionally use single use batteries but the vast majority of configurations employ rechargeable batteries where lead acid and nickel metal hydride versions are on the way out because of performance inadequacies such as weight, space, poor handling of power surges, short life, memory effect, self-discharge etc.
Fig. 5.1
Third generation lithium-ion battery, the lithium sulphur small UAV battery of Sion Power
For the next decade, lithium-ion batteries will strongly dominate the traction battery scene for military electric vehicles but there are variants. During the next ten years, we shall see some progress from second generation lithium-ion batteries that have a better cost-performancesafety compromise, notably those with lithium ion phosphate or low cobalt cathodes, lithium
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polymer electrolyte construction (sold polymer with gel and no separator) and carbon or lithium titanate or other advanced anodes. Next come traction batteries with higher energy density, often of flat construction to improve performance. First of these to be used is lithium sulphur batteries already deployed in several unmanned aerial vehicles UAVs. Lithium air and lithium water batteries also have a place as their problems are overcome and truly solid state electrolytes, typically inorganic, will lead to a great saving in containment and safety system costs, including cooling. Indeed, third generation lithium-ion batteries often dispense with the organic electrolytes the part that can catch fire and employ solid state inorganic electrolytes in structures printed reel to reel to create a much more robust entity. For more see the IDTechEx report, Electric Vehicle Traction Batteries 2011-2021
5.3.
Traction motors
Here there is a battle between asynchronous and synchronous electric motors for electric vehicles with little difference between the needs of hybrid vs pure electric vehicles. Asynchronous motors never have permanent magnets because they are effectively rotating transformers. They therefore tend to be more temperature tolerant and independent of the cost of neodymium in magnets, an element that has sextupled in price and could go higher as long as China controls supply. For more see the IDTechEx report, Electric Motors for Electric Vehicles 2012-2022 In-wheel and near-wheel motors create redundancy and improve steering and traction and they are in use in military forces to a small extent while being largely unaffordable in other applications despite replacing transmission and differential. For instance, Quantum Fuel Systems Technologies Worldwide, Inc., has its Clandestine Electric Reconnaissance Vehicle (CERV), an allwheel-drive diesel hybrid electric vehicle designed by Quantum and TARDEC's National Automotive Center (NAC) with funding support from the US Special Operations Command (USSOCOM). The unit can maintain speeds of 80 miles per hour and climb 60 percent grades - all while reducing fuel consumption by up to 25 percent compared with conventional vehicles of comparable size. QT has developed a land-based V22 hybrid reconnaissance surveillance and targeting vehicle "RSTV", a hybrid FMTV truck and a hybrid line hauler. The development budget granted by the US military for the projects was $43 million.
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Fig. 5.2
CERV
Fig. 5.3
Source TARDEC
5.4.
Electronics/electrics
The electronics and electrics in electric vehicles are merging and changing from being wired discrete components and bus bars in the main. Rogers Corporation saves cost and improves performance with its copper high current conductors bonded to ceramic in place of copper bars. Many companies print electrics and electronics. Overall, the amount of electrics and electronics in a vehicle is growing rapidly, from about 30% of cost to up to 80%. For example, the asynchronous motors gaining market share substitute circuits for a mechanical commutator, addition of energy harvesting calls for new control and conversion circuitry. The call for improved safety in batteries and elsewhere leads to adoption of an increasing number of wired and
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wireless sensors. Without a Battery Management System and its cell sensors, one in 70,000 electric vehicle would explode if the same lithium-ion battery technology as used in laptops is used in EVs the point being that there are 10,000 or so more cells. Charging infrastructure appears both in and alongside electric vehicles these days and both are linked to energy harvesting circuits. For more read the IDTechEx reports, Introduction to Printed Electronics and Electric Vehicle Charging Infrastructure 2011-2021.
5.5.
Range extenders
Most hybrid vehicles today have a largely unmodified conventional engine. As hybrids trend towards being series hybrids where the engine never does more than charge the battery, the use of a conventional engine becomes increasingly ridiculous because the requirement is completely different and ultimately nothing much more than the equivalent of an emergency charger. In the meanwhile, we are talking of something as small. Low cost and lightweight as possible the only provides fairly constant power (and, if it rotates, torque). Necessary power from range extenders is being further reduced where there is ubiquitous fast charging and multiple energy harvesting on-board. The situation with range extenders is not as simple as that with batteries (mainly variants on the lithium-ion battery for the next decade) and motors (two basic choices). One way of looking at it is to say that there are many designed-to-purpose rotating machines that attach to a generator via a rotating shaft. Competing with these are the less proven but more elegant fuel generators that inherently generate electricity. Examples of range extenders being used or trialled, with fuel generator versions indicated with the red gen.
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Fig. 5.4
Source IDTechEx
Alternatively, one can make sense of the proliferation of options by saying the early ones are Second Generation range extenders nearly all designed to purpose internal combustion piston and rotary engines with various degrees of dependence on fossil fuels and their biofuel analogs just using less and Third Generation devices that are fully independent of fossil fuels but usually less ready for market. For more see the IDTechEx report, Range Extenders for Electric Vehicles 2011-2021
5.6.
Fuel cells
Fuel cells are in use as range extenders for electric vehicles but they are still unusual because they are fuel generators or third generation range extenders as characterised above, with issues of cost, refuelling infrastructure, reliability and life in most cases. This is despite being trialled for twenty years, initially as a complete alternative for the conventional internal combustion engine and latterly as simply a range extender at fairly constant load, a substantial battery coping with power surges, regenerative braking, hotel facilities when stationery and fuel cell start up time.
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Fig. 5.5
Source JAMSTEC
There are many variants deployed including high temperature solid oxide fuel cells SOFC and the favourite, the PEM being most commonly developed and used in transport. Proton Exchange Membrane PEM fuel cells, also known as polymer electrolyte membrane fuel cells PEMFC, convert atmospheric oxygen and hydrogen stored in the vehicle into water and electricity. The water is pure and it can be used in vehicle climate control. For all the jargon and explanation of many EV technologies see the IDTechEx Electric Vehicle Encyclopaedia that comes free with any IDTechEx EV report.
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Supercapacitors Look out for deployment of supercapacitors that take over much of the function of traction batteries beyond todays assistance with fast charge and discharge. This will be because supercapacitors and later supercabatteries (Asymmetric Electrochemical Double Layer capacitors) will offer longer life and greater reliability and possibly other benefits in military vehicle design. New and improved supercapacitors and their variants such as supercabatteries are becoming more and more useful in EVs. They started by being used across batteries to cope with fast charge and discharge but some now have useful amounts of power stored yet still the advantages over batteries such as life of over 20 years and very high reliability.
Fig. 5.6
New and improved supercapacitors and their variants such as supercabatteries are becoming more and more useful in EVs
Source Industry
Energy harvesting The main forms of energy harvesting being used or considered for military electric vehicles are harvesting of motion, heat and light. Primarily, capturing motion consists of the favoured brushless traction motors working in reverse to capture and electrically return up to 15% of braking energy and, soon to be introduced, dampers capturing vertical energy up to 1kW per damper on a large vehicle. However, complete energy harvesting active suspension is being researched and there are dreams of body flexing also generating energy. Wind turbines can be deployed when the vehicle is stationary. Air and marine vehicles achieve the equivalent of regenerative brakingby soaring, mooring in a tidestream or sailing with the propeller trailing.
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Next most popular is capturing light using photovoltaics (solar cells), here the progression is towards transparent or translucent film over the whole vehicle, even underneath as it is developed to capture infrared not just light,. Indeed, in the laboratory, some photovoltaics captures ultra violet as well. Meanwhile, structures that unfold or expand when parked gain more area and therefore electricity and some vehicle manufacturers are looking at self sufficient rear lights etc thanks to local photovoltaics, reducing the large cost and vulnerability of wiring. Examples include nantenna=diode photovoltaics promising flexibility with double the best efficiency achieved with PN junction and photoelectrochemical DSSC photovoltaics today. Meanwhile, we expect Copper Indium Gallium Diselenide CIGS photovoltaics to be a front runner for long life flexible, conformal photovoltaics. The much needed photovoltaics that harvests UV, visible and IR and/or that is transparent to be many years away.
Fig. 5.7
The $517 million unmanned surveillance airship currently being made for the US Department of Defense by Northrop Grumman showing flexible photovoltaics.
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Fig. 5.8
Glider type of AUV surfacing to recharge batteries using wave power (by hinging) and solar power (by photovoltaics)
Printed electronics and electrics Printed electronics and electrics will save up to 40% of weight, space and cost of control clusters and other human interfaces and wiring in electric vehicles, eventually encompassing much of the battery pack electrics and electronic circuitry and several forms of energy harvesting feeding the battery, multi-mode harvesting becoming commonplace, first in marine military vehicles the in air and land military vehicles. Structural components and smart skin Dumb vehicle bodies and chassis will progress to smart forms with advanced structural composites married to smart skin performing many functions including energy harvesting, storage and sensing condition in real time. Something of a halfway house is the incorporation of components into the body of the vehicle as with T-Ink printed tape replacing the much bulkier and heavier copper wire. Then there are the structural batteries in the Drayson racing cars being built in the UK in 2012 that have lessons for the military. Battery geometry is changing with this. Flat, wide batteries employed in aircraft wings, such as those of surveillance UAVs at over 10,000 meters up turn out to have faster charge-discharge and simpler cooling when well-made and this
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is now being applied to land vehicles. Add that to the conformal thin film photovoltaics now favoured, the capacitive skin that destroys incoming ordnance, printed logic and power circuits and so on and clearly various forms of smart vehicle skin are on their way for land, sea and air vehicles. That happens inside as well as outside, as with the printed and laminated T-Ink lighting and controls that release up to 40% of space, weight and cost of dashboard and overhead instrumentation. In-wheel motors are another devolution of function to the outer parts of the vehicle.
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6.
Table 6.1
MASTER REPORT
Electric Vehicles for Military, Police & Security 20112021 including land, sea and air
Light Electric Vehicles 2011-2021 including e-bikes and mobility vehicles for the disabled
Electric Aircraft 2011-2021 including manned and unmanned aircraft and airships
Marine Electric Vehicles 2011-2021 including surface craft, AUVs, private & commercial submarines, subaqua scooters
Wireless Power Transmission for Consumer Electronics and Electric Vehicles 20122022
Geographical
Electric Vehicles in East Asia 2011-2021 with forecasts for China, India, Japan, South Korea, Other East Asia
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