DC/DC Converter portfolio for Space Application Alcatel ETCA 1963 - 2005 More than 40 years of Experience in Space Alcatel ETCA - LPLC-PSU- 5012 Avril 2005 – Page 1 All rights reserved © 2003, Alcatel DC/DC converter portfolio for Space Application - Contain - 1. Heritage 2. Low Power Low Cost converter (LPLC) 3. µBuck 4. Standard Hybrid FB/FWD Controller 5. µconverter 6. Schedule LP-PSU-PPT-05012 1.0 12.04.05- Page 2 All rights reserved © 2003, Alcatel DC/DC converter portfolio for Space Application 1.1. HERITAGEHERITAGE LP-PSU-PPT-05012 1.0 12.04.05- Page 3 All rights reserved © 2003, Alcatel Application Heritage • SSPA Power Supply • Star Trackers • GyroLaser Drive • Gyro Control Telecommunication Gyroscope Mechanisms • Power Interface Unit TC/TM • On Board Data Handling • Camera Power Supply • Main Auxiliary Supply HousekeHousekeepingeping Earth Observation • Solar Panel Drive Supply • Plasma Thruster Auxiliary • Antenna Drive Supply supply Motor Drive DC/AC Application • Safety Control Equipment • Pyrotechnic Control HV • Laser Emitter Launchers High Voltage Operation • Magnetosphere Measurement Supply • Advanced SAR • Grid Spectrometer Synthetic Aperture Radar Scientific Experiments LP-PSU-PPT-05012 1.0 12.04.05- Page 4 All rights reserved © 2003, Alcatel Program Heritage VENUS EXPRESS GOCE AMAZONAS SYRACUSE 3 A SYRACUSE 3 B GE Americom APSTARS 6 ESSAIM ROSETTA CRYOSAT ATV PARASOL INMARSAT 4 PROBA 1 INTELSAT COROT PLANCK AFRISTAR INTEGRAL SILEX ASIASTAR HISPASAT HERSCHEL CALIPSO EMS SESAT SAR Lupe DEMETER PICARD STRV-1C AMERISTAR JASON 1 PROBA 2 JASON 2 EUROSTAR CLUSTER 2 METOP KOREASAT MICROSCOPE MEGATROPIQUE SMOS PLEIADES SINOSAT 2 GALILEO JWST LP-PSU-PPT-05012 1.0 12.04.05- Page 5 All rights reserved © 2003, Alcatel Program Heritage HELLAS ALPHABUS GALILEO IMMARSAT VENUS EXPRESS ISS ARIANE 5 AEOLUS PLEIADES ATV MILITARY All rights reserved © 2003, Alcatel LP-PSU-PPT-05012 1.0 12.04.05- Page 6 Main Customers LP-PSU-PPT-05012 1.0 12.04.05- Page 7 All rights reserved © 2003, Alcatel DC/DC converter portfolio for Space Application 2.2. LowLow PowerPower LowLow CostCost (LPLC)(LPLC) LP-PSU-PPT-05012 1.0 12.04.05- Page 8 All rights reserved © 2003, Alcatel Basic or Integrated Solutions ? Basic Solution Integrated Solution VIN V EMI IN Output Suppressor filters Vout's (DC only) External TC ON EMI Suppressor Vout's (DC or AC) TC Telecommand DC/DC Interface cell External Basic External Telecommand DC/DC Output TC Interface Filter The LPLC includes all the function requested in any space application. .... Not less, not more ...... LP-PSU-PPT-05012 1.0 12.04.05- Page 9 All rights reserved © 2003, Alcatel Targets Based on our heritage : ETCA has focused its development on the following technical targets : • flexibility related to input bus voltage, • flexibility related to output voltage number / values, • output voltage accuracy better than ± 5% in any case, • flexibility related to output power demand up to 30W. In addition : • limited NRE efforts • competitive recurring cost to potential external suppliers. LP-PSU-PPT-05012 1.0 12.04.05- Page 10 All rights reserved © 2003, Alcatel Technology SCPH technology : thick film hybrid packaged in hermetic aluminium structure • High mechanical, thermal and radiative tolerance • High power density • Low mass and volume • Full ESA qualification (ESA-PSS-01-608) LP-PSU-PPT-05012 1.0 12.04.05- Page 11 All rights reserved © 2003, Alcatel Product Range Type VIN range POUT Outputs Size Remark 20 to 50V ETC 2050-15 15 W DC and/or AC A Series ETC 2050-30 20 - 50 VDC 30 W DC and/or AC A ETC 2050-40 40 W Single DC output A Ext. settability ±5% 50 to 100V ETC 50100-15 15 W DC and/or AC A Series ETC 50100-30 50 - 100 VDC 30 W DC and/or AC A Other ETC 4050-40 40-50 VDC 40 W DC and/or AC A series ETC 25100-10 10 W DC and/or AC A 25-100VDC Outputs # Size A :≤ 4 Customisable, DC and/or AC Size A 85 x 77 x 20 mm³ 195 grs - More than 40 different variants exist today - LP-PSU-PPT-05012 1.0 12.04.05- Page 12 All rights reserved © 2003, Alcatel Functional Characteristics Performances • POUT up to 30 W • VIN up to 126 V CHASSIS VIN, + POWER CELL TRANSFORMER OUTPUT • 4 + 1 Outputs & DISTRIBUTION RECTIFYING V1 • Each output DC or AC square, V1, RTN -100 to +100 V I VIN, RTN V2 COMMON MODE DIFFERENTIAL • FILTER FILTER DRIVERS All EMI filters included V2/V3, RTN V3 AUXILIARY V V4 User Control Interface SUPPLY AUX • ON/OFF Telecommand V4, RTN • ON/OFF Status VIN DETECTION VAUX • Selectable Automatic Start + RUN • Inhibit Input VAUX STOP • Synchronisable AUTOSTART VAUX OVERVOLTAGE PROTECTION • Synchro OUT Signal TC INTERFACE + CLOCK PROT 56K (for Slave Equipment) ON TC ON VAUX STOP LATCH 10K TC OFF OFF 5K 1K 5K PROT 0K5 CS96/105 STATUS SYNCIN SYNCOUT INHIBIT Our products are fully qualified following ESA rules LP-PSU-PPT-05012 1.0 12.04.05- Page 13 All rights reserved © 2003, Alcatel LPLC Package LP-PSU-PPT-05012 1.0 12.04.05- Page 14 All rights reserved © 2003, Alcatel Distributed Voltage Application Typical Applications : • high output number / values required • need for multiple secondary grounds • generation of auxiliary buses The LPLC is the easy way to manage complex voltage distribution LP-PSU-PPT-05012 1.0 12.04.05- Page 15 All rights reserved © 2003, Alcatel High Voltage Application The LPLC is the easy way to mix low and high voltage applications LP-PSU-PPT-05012 1.0 12.04.05- Page 16 All rights reserved © 2003, Alcatel Program Organisation & lead times Customer specification Time (typical) 0 weeks Package NOK Components Feasability Layout 1 Implementation 5 BB available 10 EM manufacturing 17 NOK Electrical, T° Test Design correction 20 up to 26 FM 32 up to 40 LP-PSU-PPT-05012 1.0 12.04.05- Page 17 All rights reserved © 2003, Alcatel Orders LPLC ORDERS 300 (*) 250 200 y 150 Qt 100 50 0 001 002 003 004 005 996 997 998 999 000 2 2 2 2 2 1 1 1 1 2 (*) forecast LP-PSU-PPT-05012 1.0 12.04.05- Page 18 All rights reserved © 2003, Alcatel Key Figures (2004) LPLC ordered over the world MTBF Flight Heritage (without failure) Input bus voltage flexibility Volume/mass for integrated solution (4 outputs @ 30W) LP-PSU-PPT-05012 1.0 12.04.05- Page 19 All rights reserved © 2003, Alcatel LPLC Summary Hybrid Technology. Integrated solution (filters, I/F TC, …). Multi output (≅ 30W). Flexibility : Vin, Vout, protection. Improved design. High reliability. Well adapted to GEO mission. No RadHard component LP-PSU-PPT-05012 1.0 12.04.05- Page 20 All rights reserved © 2003, Alcatel DC/DC converter portfolio for Space Application 3.3. µBuckµBuck LP-PSU-PPT-05012 1.0 12.04.05- Page 21 All rights reserved © 2003, Alcatel Introduction The goal is to cover the low voltage need requested by the technological evolution of some components (ASIC, FPGA, µP). The products must be easily mountable on PCB very close to the user (dI/dt). Need of innovative Technology : → 3D+ LP-PSU-PPT-05012 1.0 12.04.05- Page 22 All rights reserved © 2003, Alcatel Preliminary Electrical Performances Input Voltage = 10V → 15V. Output voltage : - single output - selectable 1,8V or 2,5V or 3,3V - non isolated from input - accuracy better than ± 2% (EOL) Output current : 0A → 5A. Package : Mass < 20 grs. Dimensions : 30 X 30 X 11 mm³ Efficiency : > 90%. LP-PSU-PPT-05012 1.0 12.04.05- Page 23 All rights reserved © 2003, Alcatel Example of application + 5V Logic Electronic + 100V LPLC -100V Sensors 30W + 15V + 2,5V µBuck ASIC +3,3V µBuck FPGA LP-PSU-PPT-05012 1.0 12.04.05- Page 24 All rights reserved © 2003, Alcatel Preliminary Package 36mm 30mm 30mm LP-PSU-PPT-05012 1.0 12.04.05- Page 25 All rights reserved © 2003, Alcatel µBuck Summary 3D Technology. Selectability of output voltages (1,8V → 3,3V). Good voltage regulation (± 2%). Easy implementation on PCB. Low mass and size. High efficiency to facilitate the thermal management LP-PSU-PPT-05012 1.0 12.04.05- Page 26 All rights reserved © 2003, Alcatel DC/DC converter portfolio for Space Application 4.4. StandardStandard HybridHybrid FB/FWDFB/FWD ControllerController LP-PSU-PPT-05012 1.0 12.04.05- Page 27 All rights reserved © 2003, Alcatel Standard FB/FWD Controller Target Features : • Compatible with flyback and forward topologies •75kRad at component level • 20V to 110V input voltage range • Includes all major features : adjustable UVD inhibit & synchronisation input VEA and PCC loops * Target dimensions : 1’’ x 1’’ x 5mm complementary drivers VIN VDD1 • SMD mounting UVLO_SET OVP_SET INHIBIT DRIVER_Q1 • Minimum external components → limited SYNCHRO NC essentially to power elements CLOCK DRIVER_Q2 VEA_IN NC ISENSE_IN VSS1 Development status : VEA_P VDD2 • EM’s available end 2005 VEA_N VREF VEA_OUT VSS2 LP-PSU-PPT-05012 1.0 12.04.05- Page 28 All rights reserved © 2003, Alcatel DC/DC converter portfolio for Space Application 5.5. µµConverterµConverterConverter LP-PSU-PPT-05012 1.0 12.04.05- Page 29 All rights reserved © 2003, Alcatel µConverter existing version Main characteristics • Complete DC/DC including input and output, CM and DM filters • Full power operation from 20 V to 52 V or 40 V to 105 V • Primary or secondary to structure isolation (1 MOhm / 100 V) • INHIBIT interface • Bus under-voltage protection • Output over-voltage protection • Output over-load protection • Mass : 85 gr ± 5% • PCB dimensions : 100mm X 75mm. → Application Digital Sun Sensor TNO LP-PSU-PPT-05012 1.0 12.04.05- Page 30 All rights reserved © 2003, Alcatel Standard 5W µCVT proposed development Example Specification : Preliminary ICD : Min Typ Max Input Voltage Low Voltage 20 55 High Voltage 40 110 Outputs Pout 5.25W Out1 V +4.75V +5V +5.25V I 40mA 200mA Out2 * V -5.25V -5V -4.75V I 20mA 100mA Out3 V +14.25V +15V +15.75V I 30mA 150mA Out4 * V -15.75V -15V -14.25V Features : I 20mA 100mA Efficiency 75% • Rad-hard and rad-tolerant versions Mass 80g • PCB mounted / flexible product Dimensions 54 x 54 x 21 mm3 • Input CE : MIL-STD-461-C/E * Can be replaced by optional +1.8V / +2.5V / • Can be externally trimmed over range of 15% +3.3V / 250mA output LP-PSU-PPT-05012 1.0 12.04.05- Page 31 All rights reserved © 2003, Alcatel DC/DC converter portfolio for Space Application 6.6.