MILSPRAY Pushes Engineering Boundaries with Alternative Energy Military Tech
MILSPRAY's eXV-1™ in action
Ahead of the International Armoured Vehicles conference in London next January, Defence IQ recently sat down with confirmed speaker Joseph Gerschutz, Director of Engineering at MILSPRAY Military Technologies, to understand more about his work in alternative energy systems for military and commercial applications.
Gerschutz has been with the company since 2011, working on projects including product development and programme management of hybrid renewable energy systems, energy storage systems, and electric vehicle development. With over 10 years professional experience, his previous work includes developing fuel cell vehicles in a partnership between General Motors and the U.S. Army, as well as work on other major automotive OEM research and development teams. Joseph received his bachelor's degree in mechanical engineering from the University of Dayton, and holds a master's degree in electrical engineering from Rutgers. His interest lies in energy generation and management, microgrids, vehicle platforms, and new technology integration.
Defence IQ: Thanks for joining us today, Joseph. We recently spoke with your CEO and President Brian Feser and he mentioned the company's Scorpion Energy Hunter™ – could you tell us more about the system? What benefits does it offer to end users and how does it differ from other solutions on the market?
Joseph Gerschutz: Absolutely. The system is a patented, turnkey hybrid energy system that reduces fuel demand in off-grid situations and unfamiliar environments. What we've done is paired the energy generation, storage, management and distribution pieces all together in a rugged, deployable package. The system can be set-up and powering critical loads in about an hour and the renewable generation equipment can be tailored to the local available sources, be it wind, solar, or we can even do micro-hydro.
When designing this system we understood that portability and quick set-up were critical to meeting the military needs here, along with reliability, ease-of-use and the fuel savings aspect. Speaking of fuel savings, when compared to the status quo of running diesel generators, with the Scorpion Energy Hunter™ we're achieving fuel savings of up to 80% or more. But aside from the obvious cost savings, the real benefit of it is the strategic advantages it gives you in that you're not so heavily dependent on petroleum, which is an easily disrupted commodity.
Energy security is vital to performing core missions; we learned that certainly in Iraq and Afghanistan by how easy it is for insurgents to disrupt fuel convoys. So we're really addressing that here, to the point where the Scorpion system can even be run completely fuel-free, strictly using renewable energy sources and the on-board energy storage. Scorpion has very little acoustic signature, it doesn't make any noise, and it doesn't generate a lot of heat. It's also unique in its ability to offer a flexible platform for renewable integration and also has a power point where it can actually make a meaningful difference. We kept the military customer in mind throughout the design and development process so that we can actually pair the Scorpion system to the existing military generators – TQG's (Tactical Quiet Generators) in the case of the US military. We can install auto-start kits and this allows them to only run when needed, which results in lower fuel costs, less maintenance and less service costs.
Who is your target audience for this? Is it just military or are there commercial applications too?
We've identified the commercial market as a growth area for us, certainly. On the commercial side they're more concerned with the cost aspect of it and with the system we've been able to build at a price-point so that it makes more financial sense, not just for use in extreme conditions like you'd see in the military but in more common everyday applications too.
How intent do you think the US government is about using renewable energy in the military? Are they investing heavily in this space? What programmes is the US funding?
The US military are certainly investing heavily in the renewable energy sector and we expect that to continue in the near and long-term. There are many initiatives and mandates in the Department of Defense (DoD) –the National Defense Authorization Act of 2007 stipulates that 25% of the DoD's energy needs should come from renewable energy sources by 2025. Along those same lines, president Obama's Climate Action Plan calls for 20% renewable energy usage by 2020 for the entire U.S. federal government so certainly at the highest levels there are a lot of initiatives. The U.S. Army is also looking reduce its net energy usage at its installations to zero under a programme called Net Zero.
These are large projects that typically do not target operational energy use, but that's really what we're looking at. We see this as a much more dynamic market over the next decade with huge potential for growth. As the projects move to the operational level we believe a close working relationship with the military is critical. But it's not just the US, many international governments and commercial entities are seeing the benefits of renewable energy sources and they all have their own initiatives too.
Is the US a leader in this space? Or are there other countries invested in renewables to the same extent?
I think the US is certainly at the forefront as they're in the position to be able to fund many of the new technologies we're talking about. Smaller governments can't fund this type of research. The funding of the US's core research is made possible thanks in part to federal agencies like the Department of Defense and Defense Advanced Research Projects Agency (DARPA) and our national labs.
Are there any specific projects or programmes you are working on with customers that you can discuss to highlight your work in this sector?
Sure – in October 2014, we participated in the Army's Base Camp Integration Laboratory (BCIL) at Fort Devens, MA, where we demonstrated the ‘art of the possible' with our Scorpion Energy Hunter™. We provided power to the kitchen facility of a 150-man base camp. Another focus area for us is to work on large scale systems that are more appropriate for forward operating bases or disaster response. We're also looking at smaller, more mobile solutions for a platoon or company to give them the operational edge. We're looking at microsystems that can be integrated into OEM vehicle platforms, which is more of an auxiliary power role.
On the energy management side we've developed an energy storage system that basically boosts the efficiency of generator-driven micro grids. We have also formed various partnerships – one with the US Military Academy looking to increase energy consciousness within the military. With our systems, we're able to highlight the benefits of using energy more efficiently. So we're helping bring about a culture change about energy usage in the armed forces with these future leaders.
I understand MILSPRAY will be showcasing its electric utility vehicle at the International Armoured Vehicle (IAV) conference and exhibition in London next January – the eXV-1™ – could you tell us a little more about the vehicle and what it consists of?
Of course – we've developed the eXV-1™, which is a light tactical vehicle that not only reduces fuel consumption but it also offers certain strategic benefits with it being electric drive. For example, there's silent watch [which is an increasingly important combat vehicle application where acoustic signature is required to be kept to a minimum, there's off-boarding power where the system can take the role of a vehicle but it can also be used as generator in its own right.
The vehicle is allowing us to offer a complete solution to a specific military need. With the Scorpion Energy Hunter™ systems we are looking at the supply side but this new electric utility vehicle now means we can fill the demand side too.
The vehicle also gives the user more electrical power in the vehicle, which fits with the military's ever increasing C4ISR demands that require more and more electricity. The vehicle's electric drive train is augmented by an on-board range-extending generator, which allows us the benefits of electric drive but without having the restriction of low range. The vehicle uses JP-8 [military grade diesel fuel so it can easily fit into the supply chain.
When working on the vehicle our RD team, in conjunction with the Army Research Lab, has developed new lightweight ballistic and blast armour technologies that will also be featured on the vehicle. The lightweight materials allow us to increase the efficiency and performance of the vehicle and we're really excited about demonstrating them at the IAVs show in London next year.
You're speaking at the IAV event too – what will you be concentrating on during your presentation?
Our engineering department is working with the RD team here to explore alternative energy applications for the military, which will be the main focus for my presentation. That will specifically include the use of electric drive for armoured vehicles, future trends in the armoured vehicle market, and the use of lightweight composite materials. We've identified the international market as a significant growth area for MILSPRAY so the IAV conference is a great opportunity for us to demonstrate our capabilities to the international community.
About MILSPRAY
MILSPRAY is a certified small business that specializes in (1) Mobile Corrosion Prevention and Control Services for Vehicles and Equipment, (2) Deployable Renewable Energy Systems, (3) Vehicle Wash Systems, (4) Weapons Repair (5) Touch-up Paints and Specialty Coatings and 6) Applied Research and Development.
We provide our products, systems and services to the Department of Defense (DOD), government agencies, law enforcement and commercial customers, domestically and internationally. These services and technologies are designed to extend the useful life of military vehicles, aircraft, ships, weapons and equipment. In addition, MILSPRAY is a developer and manufacturer of renewable energy systems for the military, disaster relief and commercial use.
MILSPRAY embraces the diversity of talent and perspective of our employees. We have created an atmosphere of inclusion where everyone has a voice and is empowered to perform at their greatest level regardless of our differences. Our total workforce is comprised of 35% minorities, 15% women and 33% veterans.  Our executive management team is comprised of 50% women with 50% of our management team being service disabled veterans. By leveraging our unique talents, experiences and points of view, we can successfully deliver innovative solutions and value to our customers.
