MAINSTREAM ENGINEERING CORP — Department of Defense SBIR Phase II: A18-100

Description

Mainstream Engineering has developed a 25 kW continuous, 35 kW peak-SiC based motor drive. The motor drive is cooled by the 105 °C engine coolant, includes an integrated EMI filter for compliance with Mil-Std-461, and includes reverse-polarity protection on both the 600 V power and 28 V control interfaces. The motor drive has a power density of 93 W/in3, weighs less than 12 lbs, and is 99% efficient. During Phase I, we built and tested the motor drive against applicable requirements in MIL-STD-461 and measured the efficiency to be 99% at full load and max coolant temperature. We also used the motor drive to rotate the selected Parker Hannifin motor at 500 RPM and full rated current. At the end of Phase I, the high temperature motor drive achieved a TRL of 4. During the Phase I Option, Mainstream will purchase hardware to load the Parker Hannifin motor, and complete closed-loop control testing of the motor drive. Phase II will focus on revising the printed circuit boards for deficiencies found during Phase I, as well as performing full military qualification testing on the second-generation hardware. At Phase II completion, Mainstream’s high temperature motor drive will achieve a TRL of 6.