Hybrid-Cable-System with an Advanced Data and Power Architecture Product Brief

Hybrid-Cable-System with an Advanced Data and Power Architecture Product Brief Brugg Cables and PowiDian 11-11-2015

What is PowiDian? PowiDian is a Smart-Energy-Systems-Integrator and is covering: Production Storage Distribution Management PowiDian is offering turn key solutions based on commercial products (COTS or MOTS), integrated in suitable containments and designed, supervised and controlled by advanced SNMP management software. Spin-off from Airbus

What is Brugg Cables? Brugg Cables is a cable manufacturer and is covering following: Manufacturing of power- and fiber-optic data cables Deployment accessories Measurement- and maintenance-kits Devices providing connectivity, media- and power conversion Brugg Cables is offering tactical fiber optical cables developed in Brugg (CH) together with a big variety of accessories and devices engineered in Brugg and developed and manufactured with partner companies worldwide.

Objectives This presentations aims at proposing advanced hybrid network solutions for both data and power. It covers the following topics: Current possible situation New hybrid system Comparison and advantages Components needed o o o o o Hybrid-cables, -connectors, reels and deployment accessories Hybrid nodes (Hybrid Network Distributors, Hybrid Media Converters) Step up and step down converters Power generation Storage o Power Management What is next step?

Current situation To support modern warfare in the field there is an increasing need for: Power Data communication Radio communication. Field constraints like rapid deployment, security, reliability, survivability, detectability, interference, jamming and TEMPEST are challenging todays solutions as well as the constant logistic for fuel supply.

Current situation HQ-B HQ-C 3 separate networks Need for specialists for each network Static network not easy reconfigurable Reduced redundancy High consumption of fossil fuel High risk for fuel transportation CP HQ-A CP CP CP

Current situation 3 separate networks Need for specialists for each network Static network not easy reconfigurable Reduced redundancy High consumption of fossil fuel High risk for fuel transportation CP HQ-B Fuel transportation Fuel transportation HQ-A CP HQ-C CP CP

Objectives The objectives that are targeted with the hybrid solution: Rapid deployment Modular reusable solution Deliver high bandwidth data connections Keep noise and pollution away from sleeping or administration quarters Reduce the IR-signature of sensitive parts of the camp Use the best power available be it hydropower, solar or wind power Create safe power storage Increase the efficiency in power production Increase redundancy in all networks Save power and money

Hybrid solution Fully combined data & electricity networks Redundancy towards remote sites and in camp Distributed power stations Limited consumption of fossil fuel due to renewable Power Keep all RF emitting devices on distance outside the camp Wind-power HQ-B Diesel-genset CP Tent or shelter with Solar-power HQ-A HQ-C Solar-power Shelter with Solar-power Fuel-cell Hydropower

Hybrid-Cable-System BRUpowermil Ø5.8mm / 69kg/km 4F SM, 2x 1.6mm 2 Cu 1000VAC / 1500VDC / 16 A Max power 24 kw Hybrid-connector Transformer (source + consumer) The design of the ruggedized cable is optimized for low volume and low weight. > A thin cable (5.8mm) distributes data (Gb/s) and Energy (kw). The solution is cost effective and the cabling is simplified a lot. > One cable and interface for data and current. The topology of the network may be point to point, point to multi point, ring ore mesh. > Flexibility and redundancy. The electrical sources may be distributed over the whole network. > Best place and redundancy Centralized power source may be used to feed remote stations. > Long distance (e.g. 5km) and high power (e.g. 2kW) The data-power-devices are scalable easily and the number of interfaces, the LAN and the amount of power can grow according the needs. Hybrid-network-distributor

Hybrid Solution Deployable solar panel Deployable hydropower device > Hybrid-network-distributors and transformers The hybrid-cable-system supports renewable energy sources. Therefore the local energy resources can be used, which are e.g. solar energy, wind force and hydropower. > Reduction of expensive fossil energy resources All the energy inputs and outlets are intelligent nodes and are connected to the LAN. This enables efficient surveillance and control of all the devices. > Optimized energy sources, energy storage and consumption. The management system supports ad hoc configuration and supports the user by proposal and generates warnings to prevent errors. > Supports planning, installation and extension of the network Transportable energy management Comprehensive management system

Characteristics of the hybrid solution This architecture is based on: An innovative tactical cable for distribution that uses copper wires for power transmission and optical fibre for data transmission both in base camp and towards remote sites. A Hybrid-Network-Distributor combining both data and power onto the same cable A hybrid power production system ready for using renewable power An innovative completely passive outdoor cabinet to protect equipment against extreme environmental conditions without air-conditioning and reduce system self-consumption Re-use of existing gensets and in-camp data and power distribution in first example Distribution of Radio Base Station via IP Central management SNMP system Redundancy via tactical cable for data and power distribution Redundancy via radio links for data distribution

Components in hybrid solution The new architecture consists of a number of components: Power generation o Fossil Fuel, Sun, Wind, Water or any combination can be used to generate power Storage o Lead-Acid batteries, Li-Ion Batteries, Vanadiun/Redflow, Hydrogen storage, Super Capacitor Power Management o Intelligent, operation and control, universal, redundant, modular, flexible Distribution of data and power o AC/DC, IP, Fibre for data, cupper for power, redundancy (ring, mesh)

Components in hybrid solution

Comparison between existing and the hybrid solution architecture Subject Existing architecture New hybrid architecture Number of systems to maintain 3 1 Design 3 different 1 complete Operational costs (OPEX) Relatively high Low depending on renewable Power available Capital Expenditure (CAPEX) Pollution Low CO2: High Noise: High Moderate CO2: Almost zero Noise: None Life time +5 years +15 years Logistics fuel High recurrent Limited Skilled personnel 3 different technologies 1 integrated system Moveable Limited Highly Modular Limited Yes Easy to redesign Moderate Yes Autonomy Limited depending on fuel Up to 100% Redundancy Complex x3 Intuitive

Advantages with hybrid solution Reduced space for storage and transport du to low volume Reduced fossil fuel due to local power sources and optimized operation Reduced man power for only having one network to design and operate Reduced training of man power simple installation, SW-tools Reduced installation costs as the hybrid system is lighter, lower in volume and more flexible Reduced logistic costs as the hybrid system is lighter and lower in volume Reduced planning and installation costs as the tools support proper design in advance Reduced back-up costs as the network redundancy serves as a power back-up Reduced maintenance costs as there are less moving parts when you use solar power Reduced stress/illness from soldiers as the solution is more quiet and makes less pollution Reduced operating costs as the management system can help predict future problems in time

Components in a hybrid solution Tactical hybrid cables: BRUpowermil 5.8mm 69kg/km 4F SM, 2x1.6mm 2 1000VAC / 1500VDC / 16A Max power 24kW BRUpowerfield 4.5mm 36kg/km 4F SM, 2x1.0mm 2 1000VAC / 1500VDC / 10A Max power 15kW

Extended Power and Distance

Components in a hybrid solution Harsh environment hybrid connectors: hermaphroditical, expanded beam receptacles plugs

Components in a hybrid solution Deployment accessories: hybrid assemblies on hand reels and reels for vehicle and backpack deployment

Components in a hybrid solution Hybrid Remote Power Supply: point to point

Components in a hybrid solution Hybrid nodes: hybrid network distributor, hybrid media converter

Components in a hybrid solution Step up and step down converters: Step up converter e.g. 2500 W Step down converter e.g. 2000 W

Components in a hybrid solution Step up and step down converters: point to point 5 km Step up converter e.g. 2500 W Step down converter e.g. 2000 W

Components in a hybrid solution Step up and step down converters: point to point Twice the power 2.5 km

Example: Hybrid-Network Network Topology with Hybrid Network Distributors

Example: Hybrid Network Network Topology G G

Example: Hybrid Network Network Topology Power Output G G

Example: Hybrid Network Scalability Power Output G G

Example: Hybrid Network Scalability: user interfaces Power Output G G

Example: Hybrid Network Scalability: power input G Power Output G G

Example: Hybrid Network Scalability: power output G Power Output G Power Output Power Output G

Example: Hybrid Network Scalability: remote locations G Power Output Power Output G Power Output Power Output G

Components in a hybrid solution Fixed installed SAGES systems Container Solar Solution

Components in a hybrid solution Methanol Fuel Cell Gas Fuel Cell Hydro electrical water turbine Wind Turbine

Components in a hybrid solution Portable Fuel Cell SAGES Power Solution Trailer Gas Fuel Cell SAGES Power Solution SAGES Energy Box including 4 kwh storage

Components in a hybrid solution SAGES Solar Box semi flexible lightweight solar panels 700 Wc Energy Management System in Outdoor Cabinet SAGES SNMP Management

Components in a hybrid solution Electrolyser and hydrogen storage Li-Ion batteries Lead Acid batteries Vanadium Container Solution

Example of Energy Station

What is next step? When you look at your needs for a hybrid future data / power network you must consider the following criteria: The existing power sources The geographical location (which renewable power available) The existing data interfaces The existing power and data consumers (main and auxiliaries) The logistical constraints The number of power and data interfaces at different places The environmental conditions and MIL-standards (water, dust, vibration, shock, EMI, EMC, temperature, solar irradiation, wind speed, communication needs available ) Based on the answers a bespoke solution can be designed using standard available components

Back-up slides

Example of a Hybrid-Network BRUpowermil 300m BRUpowermil 300m Network Distributor 8 x power-outs 8x data interface Network Distributor 8 x power-outs 8x data interface BRUpowermil 300m 24VDC 1500VDC 24VDC 1500VDC BRUpowermil 300m Network Distributor 1500VDC DC or AC Power INPUT 6000W Network Distributor 8 x power-outs 8x data interface 8 x power-outs 8x data interface Step-up-converter 3000W Step-up-converter 3000W Network Distributor 1500VDC 24VDC Power OUTPUT 2000W 8 x power-outs 8x data interface Power INPUT 3000W Power OUTPUT 2000W Network Distributor 8 x power-outs 8x data interface Step-up-converter 3000W Step-up-converter 3000W BRUpowermil 300m BRUpowermil 1000m DC or AC 1500VDC Network Distributor 8 x power-outs 8x data interface 24VDC 1500VDC 24VDC 1500VDC Network Distributor 8 x power-outs 8x data interface Network Distributor 8 x power-outs 8x data interface BRUpowermil 300m Power INPUT 6000W BRUpowermil 300m