Case Study: M3PHV Military Power Supply Shelf Using Mercury Flex Modules

Military Naval Sonar SystemsAchieving  Power Precision and Accuracy to Optimize Military Naval Sonar Systems

A world-class organization approached Astrodyne TDI partners to collaborate on the development of state-of-the-art naval sonar systems. These systems play a pivotal role in maritime defense and surveillance operations, requiring a dependable and efficient power source to function optimally in diverse marine environments. Leveraging advanced technology, the naval sonar systems are designed to detect underwater objects, track potential threats, and uphold the safety and security of naval fleets with precision and accuracy.


Power Certification Challenges

Considering the specific requirements of the application, it was essential to find a solution that not only met stringent environmental certifications like VITA62 but also provided high power levels. Despite searching for an off-the-shelf solution to align with cost constraints and quick turnaround times, the organization faced challenges in finding the perfect fit. However, everything changed once they discovered Astrodyne TDI's revolutionary MercuryFlex 3-Phase High Voltage solution, also known as M3PHV. 

Unique Power Requirements:

  • Efficient and space-saving design with advanced thermal management
  • Designed for three-phase, 4-wire operation to prevent damage from low input voltages.
  • With an efficiency of over 89%, the system delivers 200V DC at 60A DC for optimal performance
  • 200V DC, allowing for a versatile output voltage range from 15V DC to 450V DC
  • Programmable to 0V DC, adjustment is not possible within the range of 0 to 14.9V DC
  • Designed to meet stringent MIL-STDs

Astrodyne TDI's Innovative Power Solution

Astrodyne TDI sets itself apart by offering a power block that not only meets military standards for EMI, shock, and vibration performance but also delivers unparalleled power efficiency. The groundbreaking M3PHV solution seamlessly combines the benefits of a COTS power supply with a cost-effective approach that surpasses the competition's custom systems. This 12 kW AC-DC Rectifier Power Supply, housed in a 6U chassis, acts as an isolated converter, transforming 3-Phase 480VAC to 0-200VDC. By connecting pairs of power supplies in series across each phase-to-phase voltage, voltage balance is maintained through an autotransformer that distributes the differential power between each unit. Through electronic means, the unit output current is shared to ensure that the input power differential between units remains minimal, typically around 100-200W at peak output power.

With an unwavering commitment to precision, the system is meticulously crafted to meet stringent quality and performance standards, eliminating the need for additional certifications. Compliant with MIL-STD-810G with Change 2, Method 514.7, Procedure I, the system excels under the duress of a random vibration spectrum for 2 hours per axis, guaranteeing steadfast reliability and stability in even the most challenging environments (0.711Grms). Additionally, following MIL-STD-810G Method 516.7, Procedure I, the system undergoes thorough testing for Functional Shock, navigating the Shock Response Spectrum with a peak of 20g at 15Hz crossover. This ensures that the system remains resilient and operational when faced with intense shocks and vibrations.

Additional Benefits of Astrodyne TDI's Solution

  • 12kW AC-DC Rectifier Power Supply in a 6U chassis converts 3-Phase 480VAC to 0-200VDC
  • Meets MIL-STD-810G for vibration and shock, ensuring operational reliability in challenging conditions
  • Combines COTS power supply benefits with cost-effective superiority over custom systems