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Company
Portfolio Data
Back to Company SearchHEPBURN AND SONS LLC
UEI: TLLAP6FKHA99
Number of Employees: 60
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
SBIR/STTR Involvement
Year of first award: 2016
13
Phase I Awards
10
Phase II Awards
76.92%
Conversion Rate
$2,203,140
Phase I Dollars
$11,622,898
Phase II Dollars
$13,826,038
Total Awarded
Awards
Medium Voltage Direct Current Disconnect Switch Design
Amount: $641,989 Topic: N221-064
Hepburn and Sons LLC, teamed with Florida State University Center for Advanced Power Systems (FSU CAPS) and Georgia Tech Research Corporation (GTRC), proposes to prototype, validate, and optimize a family of medium voltage direct current (MVDC) disconnect switches and associated switchgear based on Thomson coil topology actuator design. Shipboard MVDC distribution does not exist in the U.S. Navy fleet, but there is significant advantage. The protection of such a system is of critical importance to the feasibility of the system design as well as to the safety of personnel. The team proposes an advanced modeling and simulation approach to further develop the appropriate DC disconnect switch design selected during Phase I to meet the U.S. NavyÆs needs. Existing Navy protection systems can detect and locate single line to ground faults on a given phase, but a second ground fault on a separate phase causes a line-to-line fault which trips breakers and removes power from downstream loads. Isolating an initial single ground fault can mitigate the risk of double faults and loss of power to mission critical equipment.
Tagged as:
SBIR
Phase II
2025
DOD
NAVY
Analysis of MELD Additive Friction Stir Deposition Applications to Improve the Production of Low-Cost Attritable UAVs
Amount: $749,752 Topic: AF212-CSO2
During Phase I, the Hepburn - MELD Manufacturing Corporation (MELD) team successfully down selected four components from different UAVs presented by AFRL as possible ideal options for applying their signature additive friction stir deposition (AFSD) proc
Tagged as:
SBIR
Phase II
2024
DOD
USAF
USV Modular Power Generator System: Design for Reliability using MBSE achieving Graceful Degradation through Supervisory Control
Amount: $139,993 Topic: N241-060
Hepburn and Sons LLC teamed with General Electric (GE) Vernova Advanced Research proposes to design a supervisory control methodology that enable graceful degradation of an Unmanned Surface Vessel (USV) modular generator system. The design will be optimized for system reliability, efficiency, and extended maintenance intervals. Key challenge facing USVs is the maintenance interval and autonomous fault management. Among other maintenance requirements, generator systems require oil changes every 700 hours. In order to reach a 2000-hour maintenance interval and 4000-hour mean time between failure (MTBF), USV power generation systems necessitates an innovative maintenance solution and graceful degradation from full mission capacity down to “limp home” mode. The design approach will include an extensive failure modes, effects, and criticality analysis (FMECA), incorporating the Hepburn team’s hull, mechanical, and electrical (HM&E) expertise into a model-based systems engineering (MBSE) approach to achieve an Authoritative Source of Truth (ASoT) model that follows the design lifecycle. The GE Research team brings supervisory control and energy conversion system expertise for an innovative and automatic maintenance solution for system graceful degradation. The team will assess the mission concept of operations (CONOPS) alongside the TPOC and extended Navy network in support of an effective MBSE design approach.
Tagged as:
SBIR
Phase I
2024
DOD
NAVY
In-situ Solid State Repair of Damaged Aircraft Structures Utilizing Impact Welding Technologies
Amount: $1,799,989 Topic: AF242-D020
Hepburn and Sons LLC teamed with Applied Impulse Inc. to incorporate novel manufacturing capabilities of impulse welding to provide crack repairs on damaged aircraft structural components. The solid-state joining process enables immediate restoration of component structural integrity through the bonding of wrought plate materials including alloys of aluminum, steel, and titanium. Utilizing wrought plate materials for joining in combination with impact welds preserves the initial microstructures and enables high strength repairs without post-processing or heat treating. In addition, the widely commercially available plate products improve supply chain capabilities, support cost reduction, and provide a more streamlined path to repair certification than experimental materials. The ability to apply the process in open environments and confined spaces makes the technology uniquely positioned to perform repairs in the ground support equipment environment. This research effort will demonstrate the effectiveness of impact weld crack repairs on a coupon level basis and provide evaluation articles of repaired aircraft structural elements. A final demonstration that provides evidence that the technology is deployable to the point of need will be held.
Tagged as:
SBIR
Phase II
2024
DOD
USAF
Digital Engineering Applied to the Boeing B-52H Stratofortress for Integration Risk Reduction
Amount: $179,957 Topic: AF242-0001
Hepburn and Sons LLC (Hepburn) proposes to leverage our teamÆs expertise in Model Based Systems Engineering (MBSE) and Digital Engineering (DE) to provide the Air Force with a digital ecosystem and framework for the B-52H legacy aircraft digital twin. HepburnÆs proposed approach is to use MBSE and DE principles to improve the Air Force Global Strike CommandÆs (AFGSC) cost-effectiveness in design and manufacturing of new systems and reduce risk for integration of equipment into the legacy B-52H legacy aircraft system through the 2050s. Rolls-Royce Corporation and its subsidiary Rolls-Royce North American Technologies, Inc. (LibertyWorks«) provided a letter of support, ōRolls Royce is very interested in Hepburn and SonsÆ proposed digital effort especially because of potential applicability to an Air Force digital pathfinder project such as the B-52 re-engine program.ö The purpose of this project in developing a B-52H digital twin is not simply to replicate the physical twin. Rather, the purpose of the proposed approach is to create a digital framework that enables AFGSC with the ability to increase mission assurance confidence while reducing risk (integration of new systems and equipment) over the life cycle of the aircraft to improve maintenance forecasting and training. Applying the latest policies and directives from DoD, Hepburn will model the legacy aircraft using Cameo Enterprise Architecture (Cameo) as the foundational model and as needed will use other software such as, but not limited to: OpenMBEE, AutoCAD, CATIA, SysML 1.6, and Python. The AFGSC will provide the style guide for this work and Hepburn will strictly align to that style guide. The final deliverable of Phase I will include the system concept, a completed feasibility study including a risk assessment, and HepburnÆs solution for creating a digital twin of the B-52H legacy system as part of the Phase II initial proposal. The system concept will be a digital framework that will be an evolving digital twin of the B-52H ready to accept and integrate virtual environments and other system models and simulations. The final deliverable(s) will be Cameo files that integrate the provided style guide. During Phase II, Hepburn will fully construct the approved concept into a prototype.ĀThe process involves a detailed review of the aircraft design, identification of mission critical systems (MCS), building a model that captures the aircraft features and systems as best as possible, updating the parameters through targeted testing, and iteratively simulating this model to better inform design decisions. The Hepburn process is referred to as a Model-Test-Model-Inform (MTMI) framework which is thoroughly reviewed.Ā
Tagged as:
SBIR
Phase I
2024
DOD
USAF
Binder Jet based Additive Manufacturing of Ni-Zn Ferrite Composites Enabling High Power Microwave (HPM) Directed Energy Weapons (DEW)
Amount: $139,997 Topic: N24A-T024
Hepburn and Sons LLC teamed with the University of Pittsburgh proposes a binder jet 3D printing (BJ3DP) additive manufacturing process with Ni-Zn Ferrite Composites and BaTiO3 batch infiltration to produce ferromagnetic and ferroelectric composite components that are power dense, cost-effective, high-resolution, and high-performance to enable High Power Microwave (HPM) Directed Energy Weapons (DEW) for Navy use. HPM generator technology has received increased attention corresponding with the emergence of non-lethal DEW as well as with improved wireless radar technologies. Priority is placed on minimizing size, weight, power, and cost (SWAP-C) for HPM sub-systems and optimizing its energy density at electronic targets of different sizes. HPM systems will benefit from BJ3DP capabilities as alternative to conventional, more costly fabrication and prototyping, sintering, and machining.
Tagged as:
STTR
Phase I
2024
DOD
NAVY
Ground Fault Detection System
Amount: $1,199,929 Topic: N21A-T005
Hepburn and Sons LLC proposes a ground fault detection system design for 440VAC three phase radial Navy shipboard power distribution, while teaming with their partner Florida State University, Center for Advanced Power Systems (FSU CAPS). Existing Navy ground fault detection systems can detect and locate single line to ground faults on a given phase, but a second ground fault on a separate phase causes a line-to-line fault which trips breakers and removes power from downstream loads. Quickly detecting, locating, and resolving an initial single ground fault can mitigate the risk of double faults and loss of power to mission critical equipment. The ground fault detection and localization system design will function for both permanent and non-permanent fault cases, particularly for USN Shipboard 440VAC three phase radial power distribution either grounded or ungrounded. The low voltage alternating current interface standard, MIL-STD-1399-300-1, provides further characteristics. For ungrounded and high resistance grounded power systems, a single line to ground fault is permissible on one of the three phases enabling continued operation. Without the benefit of simplified fault localization of a solidly grounded power system which trips upon a single ground fault, it is critical to quickly identify the faulted piece of Navy equipment or at least identify the shipboard compartment containing the fault. The Hepburn and CAPS team proposes a noise pattern analysis approach to ground fault protection which utilizes machine learning techniques and yields the benefit of passive localization. This approach mitigates an interference issue that comes with conventional protection strategies involving disruptive signal injection as well as manual disconnect hunting of fault localization by trial and error. The methodology is based upon a patent presenting an autonomous fault location approach differentiating fault location by signal oscillatory characteristics (US Patent 8067942 B2, ōMethod for locating phase to ground faults in DC distribution systemsö). In the presence of power electronic switching devices (converter, etc.), this noise pattern analysis-based fault localization does not necessarily require signal injection, but passively monitors a naturally occurring ringing circuit which is altered by a given fault case location. In the absence of such sources of continually occurring switching transients, separate injection of a small amount of signal noise may be required. The team is building upon extensive previous work and intellectual property. The Phase I design approach has been validated for the LVAC radial system of this topic. Phase II will involve prototyping, validating, and demonstrating the approach with plans for shipboard application.
Tagged as:
STTR
Phase II
2023
DOD
NAVY
Innovative Test Apparatus for Monitoring Insulation Health of Medium Voltage Direct Current Cables and Insulated Bus Pipe
Amount: $1,199,993 Topic: N211-069
Medium voltage alternating current (MVAC) systems have been used for over a century, and their insulation systems are well known and understood. The use of medium voltage direct current (MVDC) systems on Naval platforms is relatively new. While some MVAC system insulation integrity tests may be applied to MVDC insulation systems, others may not. Understanding MVDC insulation systems further will enable informed decisions regarding distribution cable lifetime and maintenance. The objective of this effort is to prototype two test apparatus, one for on-line monitoring of partial discharge and another test apparatus for off-line measurement of space charge on MVDC distribution insulation in harsh Navy shipboard environments. During Phase I, the team successfully analyzed the feasibility of the partial discharge and space charge testing capabilities. In Phase II, the team will design, prototype, and test the initial insulation health monitoring apparatus. After the completion and testing of the initial design, a ruggedized system design will be developed for testing in an operational environment aboard a Navy vessel or land-based facility.
Tagged as:
SBIR
Phase II
2023
DOD
NAVY
Analysis of MELD Additive Friction Stir Deposition Applications to Improve the Production of Low-Cost Attritable UAVs
Amount: $49,991 Topic: AF212-CSO2
Hepburn and Sons LLC, integrator and leader in technology transition, has teamed with MELD Manufacturing Inc., with support from the University of Dayton Research Institute (UDRI) and Kratos Defense & Security Solutions, Inc., to propose to conduct a thorough Analysis of Alternatives (AoA) for the application of MELD, a new and advanced method of additive friction stir deposition. Our team will compare MELD to the current state of Additive Manufacturing (AM) techniques that will improve and lower the construction costs of Low-Cost Attritable Aircraft Technology (LCAAT) and other unmanned aerial vehicles (UAVs). Having met with UDRI and Kratos to evaluating specific applications, we are considering a key component for analysis and demonstration of MELD in Phase I: the mid wing bulkhead of the Kratos XQ-58A Valkyrie. We will construct a prototype using MELD as part of Phase II, along with mechanical testing. The mid wing bulkhead is the highest loaded bulkhead in the Valkyrie vehicle. Our Phase I study will assess cost reduction, risk, TRL, MRL, and feasibility of applying the MELD technology for the mid wing bulkhead production to increase efficiency, strength margin, while reducing cost. This new capability will enable the U.S. Air Force to 3D print aerospace-grade airframe assemblies in a timely and cost-effective manner.
Tagged as:
SBIR
Phase I
2022
DOD
USAF
Medium Voltage Direct Current (MVDC) Disconnect Switch Design for Shipboard In-Line Distribution Protection
Amount: $239,957 Topic: N221-064
Hepburn and Sons LLC proposes to design a family of medium voltage direct current (MVDC) disconnect switches, while teaming with the University of Wisconsin Milwaukee (UWM). Shipboard MVDC distribution does not exist in the U.S. Navy fleet, but there is significant advantage. The protection of such a system is of critical importance to the feasibility of the system design as well as to the safety of personnel. The team proposes an innovative virtual prototyping process approach to developing the appropriate DC disconnect design to meet the U.S. Navy’s needs. Virtual prototyping is a modeling and simulation approach while incorporating multi-objective design optimization. Existing Navy protection systems can detect and locate single line to ground faults on a given phase, but a second ground fault on a separate phase causes a line-to-line fault which trips breakers and removes power from downstream loads. Isolating an initial single ground fault can mitigate the risk of double faults and loss of power to mission critical equipment.
Tagged as:
SBIR
Phase I
2022
DOD
NAVY