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NASA NTRS2000

Wide-Temperature Electronics for Thermal Control of Nanosats

This document represents a presentation which examines the wide and low-temperature electronics required for NanoSatellites. In the past, larger spacecraft used Radioisotope Heating Units (RHU's). The advantage of the use of these electronics is that they could eliminate or reduce the requirement for RHU's, reduce system weight and simplify spacecraft design by eliminating containment/support structures for RHU's. The Glenn Research Center's Wide/Low Temperature Power Electronics Program supports the development of power systems capable of reliable, efficient operation over wide and low temperature ranges. Included charts review the successes and failures of various electronic devices, the IRF541 HEXFET, The NE76118n-Channel GaAS MESFET, the Lithium Carbon Monofluoride Primary Battery, and a COTS DC-DC converter. The preliminary result of wide/low temperature testing of CTS and custom parts and power circuit indicate that through careful selection of components and technologies it is possible to design and build power circuits which operate from room temperature to near 100K.

Dickman, John Ellis↗

NASA NTRS2000

Radiation Damage and Single Event Effect Results for Candidate Spacecraft Electronics

We present data on the vulnerability of a variety of candidate spacecraft electronics to proton and heavy-ion induced single-event effects and proton-induced damage. We also present data on the susceptibility of parts to functional degradation resulting from total ionizing dose at low dose rates (0.003-0.33 Rads(Si)/s). Devices tested include optoelectronics, digital, analog, linear bipolar, hybrid devices, Analog to Digital Converters (ADCs), Digital to Analog Converters (DACs), and DC-DC converters, among others.

OBryan, Martha V.↗

NASA NTRS2000

Radiation effects on DC-DC Converters

DC-DC switching converters are circuits that can be used to convert a DC voltage of one value to another by switching action. They are increasing being used in space systems. Most of the popular DC-DC switching converters utilize power MOSFETs. However power MOSFETs, when subjected to radiation, are susceptible to degradation of device characteristics or catastrophic failure. This work focuses on the effects of total ionizing dose on converter performance. Four fundamental switching converters (buck converter, buck-boost converter, cuk converter, and flyback converter) were built using Harris IRF250 power MOSFETs. These converters were designed for converting an input of 60 volts to an output of about 12 volts with a switching frequency of 100 kHz. The four converters were irradiated with a Co-60 gamma source at dose rate of 217 rad/min. The performances of the four converters were examined during the exposure to the radiation. The experimental results show that the output voltage of the converters increases as total dose increases. However, the increases of the output voltage were different for the four different converters, with the buck converter and cuk converter the highest and the flyback converter the lowest. We observed significant increases in output voltage for cuk converter at a total dose of 24 krad (si).

Zhang, Dexin↗

NASA NTRS2001

ISS EPS Orbital Replacement Unit Block Diagrams

The attached documents are being provided to Switching Power Magazine for information purposes. This magazine is writing a feature article on the International Space Station Electrical Power System, focusing on the switching power processors. These units include the DC-DC Converter Unit (DDCU), the Bi-directional Charge/Discharge Unit (BCDU), and the Sequential Shunt Unit (SSU). These diagrams are high-level schematics/block diagrams depicting the overall functionality of each unit.

Schmitz, Gregory V.↗

NASA NTRS2001

Recent Radiation Damage and Single Event Effect Results for Candidate Spacecraft Electronics

We present data on the vulnerability of a variety of candidate spacecraft electronics to proton and heavy-ion induced single-event effects and proton-induced damage. Devices tested include optoelectronics, digital, analog, linear bipolar, hybrid devices, Analog-to-Digital Converters (ADCs), Digital-to-Analog Converters (DACs), and DC-DC converters, among others.

Martha V. OBryan↗

NASA NTRS2001

Radiation Effects on DC-DC Converters

In this work, several DC-DC converters were designed and built. The converters are Buck Buck-Boost, Cuk, Flyback, and full-bridge zero-voltage switched. The total ionizing dose radiation and single event effects on the converters were investigated. The experimental results for the TID effects tests show that the voltages of the Buck Buck-Boost, Cuk, and Flyback converters increase as total dose increased when using power MOSFET IRF250 as a switching transistor. The change in output voltage with total dose is highest for the Buck converter and the lowest for Flyback converter. The trend of increase in output voltages with total dose in the present work agrees with those of the literature. The trends of the experimental results also agree with those obtained from PSPICE simulation. For the full-bridge zero-voltage switch converter, it was observed that the dc-dc converter with IRF250 power MOSFET did not show a significant change of output voltage with total dose. In addition, for the dc-dc converter with FSF254R4 radiation-hardened power MOSFET, the output voltage did not change significantly with total dose. The experimental results were confirmed by PSPICE simulation that showed that FB-ZVS converter with IRF250 power MOSFET's was not affected with the increase in total ionizing dose. Single Event Effects (SEE) radiation tests were performed on FB-ZVS converters. It was observed that the FB-ZVS converter with the IRF250 power MOSFET, when the device was irradiated with Krypton ion with ion-energy of 150 MeV and LET of 41.3 MeV-square cm/mg, the output voltage increased with the increase in fluence. However, for Krypton with ion-energy of 600 MeV and LET of 33.65 MeV-square cm/mg, and two out of four transistors of the converter were permanently damaged. The dc-dc converter with FSF254R4 radiation hardened power MOSFET's did not show significant change at the output voltage with fluence while being irradiated by Krypton with ion energy of 1.20 GeV and LET of 25.97 MeV-square cm/mg. This might be due to fact that the device is radiation hardened.

Zhang, De-Xin↗

NASA NTRS2002

Intelligent Systems for Power Management and Distribution

The motivation behind an advanced technology program to develop intelligent power management and distribution (PMAD) systems is described. The program concentrates on developing digital control and distributed processing algorithms for PMAD components and systems to improve their size, weight, efficiency, and reliability. Specific areas of research in developing intelligent DC-DC converters and distributed switchgear are described. Results from recent development efforts are presented along with expected future benefits to the overall PMAD system performance.

Button, Robert M.↗

NASA NTRS2002

Digital Control Technologies for Modular DC-DC Converters

Recent trends in aerospace Power Management and Distribution (PMAD) systems focus on using commercial off-the-shelf (COTS) components as standard building blocks. This move to more modular designs has been driven by a desire to reduce costs and development times, but is also due to the impressive power density and efficiency numbers achieved by today's commercial DC-DC converters. However, the PMAD designer quickly learns of the hidden "costs" of using COTS converters. The most significant cost is the required addition of external input filters to meet strict electromagnetic interference (MIAMI) requirements for space systems. In fact, the high power density numbers achieved by the commercial manufacturers are greatly due to the lack of necessary input filters included in the COTS module. The NASA Glenn Research Center is currently pursuing a digital control technology that addresses this problem with modular DC-DC converters. This paper presents the digital control technologies that have been developed to greatly reduce the input filter requirements for paralleled, modular DC-DC converters. Initial test result show that the input filter's inductor size was reduced by 75 percent, and the capacitor size was reduced by 94 percent while maintaining the same power quality specifications.

Button, Robert M.↗

NASA NTRS2002

Intelligent Systems for Power Management and Distribution

Button, Robert M.↗

NASA NTRS2002

SSP Technology Investigation of a High-Voltage DC-DC Converter

The goal of this project was to establish the feasibility of a high-voltage DC-DC converter based on a rod-array triggered vacuum switch (RATVS) for the Space Solar Power system. The RATVS has many advantages over silicon and silicon-carbide devices. The RATVS is attractive for this application because it is a high-voltage device that has already been demonstrated at currents in excess of the requirement for an SSP device and at much higher per-device voltages than existing or near-term solid state switching devices. The RATVS packs a much higher specific power rating than any solid-state device and it is likely to be more tolerant of its surroundings in space. In addition, pursuit of an RATVS-based system would provide NASA with a nearer-term and less expensive power converter option for the SSP.

Pappas, J. A.↗

NASA NTRS2002

Efficient Design in a DC to DC Converter Unit

Space Flight hardware requires high power conversion efficiencies due to limited power availability and weight penalties of cooling systems. The International Space Station (ISS) Electric Power System (EPS) DC-DC Converter Unit (DDCU) power converter is no exception. This paper explores the design methods and tradeoffs that were utilized to accomplish high efficiency in the DDCU. An isolating DC to DC converter was selected for the ISS power system because of requirements for separate primary and secondary grounds and for a well-regulated secondary output voltage derived from a widely varying input voltage. A flyback-current-fed push-pull topology or improved Weinberg circuit was chosen for this converter because of its potential for high efficiency and reliability. To enhance efficiency, a non-dissipative snubber circuit for the very-low-Rds-on Field Effect Transistors (FETs) was utilized, redistributing the energy that could be wasted during the switching cycle of the power FETs. A unique, low-impedance connection system was utilized to improve contact resistance over a bolted connection. For improved consistency in performance and to lower internal wiring inductance and losses a planar bus system is employed. All of these choices contributed to the design of a 6.25 KW regulated dc to dc converter that is 95 percent efficient. The methodology used in the design of this DC to DC Converter Unit may be directly applicable to other systems that require a conservative approach to efficient power conversion and distribution.

Bruemmer, Joel E.↗

NASA NTRS2002

A Nonlinear Digital Control Solution for a DC/DC Power Converter

A digital Nonlinear Proportional-Integral-Derivative (NPID) control algorithm was proposed to control a 1-kW, PWM, DC/DC, switching power converter. The NPID methodology is introduced and a practical hardware control solution is obtained. The design of the controller was completed using Matlab (trademark) Simulink, while the hardware-in-the-loop testing was performed using both the dSPACE (trademark) rapid prototyping system, and a stand-alone Texas Instruments (trademark) Digital Signal Processor (DSP)-based system. The final Nonlinear digital control algorithm was implemented and tested using the ED408043-1 Westinghouse DC-DC switching power converter. The NPID test results are discussed and compared to the results of a standard Proportional-Integral (PI) controller.

Zhu, Minshao↗

NASA NTRS2002

Current Single Event Effects and Radiation Damage Results for Candidate Spacecraft Electronics

We present data on the vulnerability of a variety of candidate spacecraft electronics to proton and heavy ion induced single event effects, total ionizing dose and proton-induced damage. Devices tested include optoelectronics, digital, analog, linear bipolar, hybrid devices, Analog-to-Digital Converters (ADCs), Digital-to-Analog Converters (DACs), and DC-DC converters, among others.

OBryan, Martha V.↗

NASA NTRS2003

The Series Connected Buck Boost Regulator Concept for High Efficiency Light Weight DC Voltage Regulation

Improvements in the efficiency and size of DC-DC converters have resulted from advances in components, primarily semiconductors, and improved topologies. One topology, which has shown very high potential in limited applications, is the Series Connected Boost Unit (SCBU), wherein a small DC-DC converter output is connected in series with the input bus to provide an output voltage equal to or greater than the input voltage. Since the DC-DC converter switches only a fraction of the power throughput, the overall system efficiency is very high. But this technique is limited to applications where the output is always greater than the input. The Series Connected Buck Boost Regulator (SCBBR) concept extends partial power processing technique used in the SCBU to operation when the desired output voltage is higher or lower than the input voltage, and the implementation described can even operate as a conventional buck converter to operate at very low output to input voltage ratios. This paper describes the operation and performance of an SCBBR configured as a bus voltage regulator providing 50 percent voltage regulation range, bus switching, and overload limiting, operating above 98 percent efficiency. The technique does not provide input-output isolation.

Birchenough, Arthur G.↗

NASA NTRS2003

A Compact, Soft-Switching DC-DC Converter for Electric Propulsion

A hybrid, soft-switching, DC-DC converter has been developed with superior soft switching characteristics, high efficiency, and low electro-magnetic interference. This hybrid topology is comprised of an uncontrolled bridge operating at full pulse-width, and a controlled section operating as a conventional phase modulated converter. The unique topology is able to maintain zero voltage switching down to no load operating conditions. A breadboard prototype was developed and tested to demonstrate the benefits of the topology. Improvements were then made to reduce the size of passive components and increase efficiency in preparation for packaging. A packaged prototype was then designed and built, and several innovative packaging techniques are presented. Performance test data is presented that reveals deficiencies in the design of the power transformer. A simple redesign of the transformer windings eliminated the deficiency. Future plans to improve the converter and packaging design are presented along with several conclusions.

Button, Robert↗

NASA NTRS2003

A High Efficiency DC Bus Regulator/RPC for Spacecraft Applications

DC bus voltage regulation may be required in future high powered spacecraft due to the length of the busses or because they are not generated at precise voltage levels. In these cases the regulation range is often only a few percent increase or decrease, but conventional DC voltage regulators switch all the power passing through them, and this level of power switched determines the size and losses in the regulator. A recently developed concept used a low power DC-DC converter in series with the bs to raise or lower the bus voltage over a small range. This partial power processing technique combines the small size and power losses of the low power converter with the ability to regulate, (over a small range) a high power bus. The Series Connected Buck Boost Regulator (SCBBR) described herein provides bus regulation with an efficiency of 98%. The circuit also provides bus switching and overcurrent limiting functions of a Remote Power Controller (RPC). This paper described the circuit design and performance of a breadboard SCBBR configured as a bus voltage regulator providing plus of minus 40% voltage regulation range, bus switching, and overload limiting.

Birchenough, Arthur G.↗

NASA NTRS2005

Power Processing for a Conceptual Project Prometheus Electric Propulsion System

NASA has proposed a bold mission to orbit and explore the moons of Jupiter. This mission, known as the Jupiter Icy Moons Orbiter (JIMO), would significantly increase NASA s capability to explore deep space by making use of high power electric propulsion. One electric propulsion option under study for JIMO is an ion propulsion system. An early version of an ion propulsion system was successfully used on NASA's Deep Space 1 mission. One concept for an ion thruster system capable of meeting the current JIMO mission requirement would have individual thrusters that are 16 to 25 kW each and require voltages as high as 8.0 kV. The purpose of this work is to develop power processing schemes for delivering the high voltage power to the spacecraft ion thrusters based upon a three-phase AC distribution system. In addition, a proposed DC-DC converter topology is presented for an ion thruster ancillary supply based upon a DC distribution system. All specifications discussed in this paper are for design convenience and are speculative in nature.

Scina, Joseph E., Jr.↗

NASA NTRS2005

Advanced Power Regulator Developed for Spacecraft

The majority of new satellites generate electrical power using photovoltaic solar arrays and store energy in batteries for use during eclipse periods. Careful regulation of battery charging during insolation can greatly increase the expected lifetime of the satellite. The battery charge regulator is usually custom designed for each satellite and its specific mission. Economic competition in the small satellite market requires battery charge regulators that are lightweight, efficient, inexpensive, and modular enough to be used in a wide variety of satellites. A new battery charge regulator topology has been developed at the NASA Lewis Research Center to address these needs. The new regulator topology uses industry-standard dc-dc converters and a unique interconnection to provide size, weight, efficiency, fault tolerance, and modularity benefits over existing systems. A transformer-isolated buck converter is connected such that the high input line is connected in series with the output. This "bypass connection" biases the converter's output onto the solar array voltage. Because of this biasing, the converter only processes the fraction of power necessary to charge the battery above the solar array voltage. Likewise, the same converter hookup can be used to regulate the battery output to the spacecraft power bus with similar fractional power processing. The advantages of this scheme are: 1) Because only a fraction of the power is processed through the dc-dc converter, the single- stage conversion efficiency is 94 to 98 percent; 2) Costly, high-efficiency dc-dc converters are not necessary for high end-to-end system efficiency; 3) The system is highly fault tolerant because the bypass connection will still deliver power if the dc-dc converter fails; and 4) The converters can easily be connected in parallel, allowing higher power systems to be built from a common building block. This new technology will be spaceflight tested in the Photovoltaic Regulator Kit Experiment (PRKE) on TRW's Small Spacecraft Technology Initiative (SSTI) satellite scheduled for launch in 1996. This experiment uses commercial dc-dc converters (28 to 15 Vdc) and additional control circuitry to regulate current to a battery load. The 60-W, 87- percent efficiency converters can control 180 W of power at an efficiency of 94 percent in the new configuration. The power density of the Photovoltaic Regulator Kit Experiment is about 200 W/kg.

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