Emerging Technology & Products for Mission-Critical Space Power Distribution

Transcription

1 Emerging Technology & Proucts for Mission-Critical Space Power Distribution - An Invite Talk April 2, 2015 Don Tan Fellow / Power Proucts Development Manager NGAS, One Space Park Reono Beach, CA 90278

2 Trens in Space Power Trens: Space power emans are ever increasing Payloa voltage levels are ever ecreasing Relentless pressure on cost an scheule We have been working together with our customers to stay at the forefront of these trens with multiple technology an prouct evelopment programs Aiabatic Point-of-Loa Converter (APOL) Avance Electrical Power Systems (AEPS) Toay, we will report some of the progress that we have mae on power istribution technology an proucts 2 * - Don Tan, A review of intermeiate bus architecture: a system perspective, IEEE Journal of Emerging an Selecte Topics in Power Electronics, Vol. 2, No. 3, Sep., 2014, pp (Invite)

3 APOL: The Nee Power Supply Slice (R) Power Supply Slice (P) Digital Slice 1 Reunant 100 V Prime 100 V Centralize bus with one-step conversion Back-Harness Distribution at: A A Problem: With the increase of prime bus an the ecrease of loa voltage levels, the centralize architecture can no longer eliver the efficiency require Excessive cable IR rops & weight Significantly egrae power efficiency Solution: An intermeiate power bus an ultra-efficient power converters Reuction of 67% issipation Increase of 68% through power Reuction of power generation, storage an thermal removal Bus Converter Moule (R) Bus Converter Moule (P) Digital Slice V 1.0 V 2.5 V 1.0 V POL 2.5 V 1.0 V POL 2.5 V 1.0 V POL POL Reunant 100 V Prime V Back-Harness Distribution at: A Performance Centralize DRIBA Converter efficiency 75-85% 89-99% En-to-en power istribution efficiency 65% >85% Size reuction - >2x Proucibility Poor Goo Intermeiate bus with two-step conversion Testability Poor Goo 3 DRIBA Double regulate intermeiate bus architecture

4 Basic Architectures (a) Regulate Intermeiate Bus Vpri Input Stage (Non-Isolate) Vib Output Stage (Isolate) Vo1 C P C ib C o1 PGND (Non-Iso) SGND (b) Unregulate Intermeiate Bus Vpri Input Stage (Isolate) Vib Output Stage (Non-Isolate) Vo1 C P C ib C o1 PGND (Non-Iso) SGND (c) Double Regulate Intermeiate Bus Vpri Input Stage (Isolate) Vib Output Stage (Non-Isolate) Vo1 C P C ib C o1 PGND (Iso) (Non-Iso) SGND 4

5 Double Regulate: Input Power Stage Virtually nonpulsating input Virtually nonpulsating input current, requiring current, only small Cp at high voltage level (>24V) Double forwar, isolate, nonfixe uty ratio Virtually zero voltage ripple for Vib (c) Double Regulate Intermeiate Bus Vpri Input Stage (Isolate) Vib Output Stage (Non-Isolate) Vo1 C P C ib C o1 PGND (Iso) (Non-Iso) SGND Output current non-pulsating Vib regulate 5

6 Double Regulate: Bus Voltage Level Vib as a system esign parameter for performance optimization (c) Double Regulate Intermeiate Bus Vpri Input Stage (Isolate) Vib Output Stage (Non-Isolate) Vo1 C P C ib C o1 PGND (Iso) (Non-Iso) SGND Intermeiate bus voltage level is low (< 12V) 6

7 Double Regulate: Output Power Stage Single-ene, pointof-loa converter, non-isolate Output voltage Vo1 tightly regulate (c) Double Regulate Intermeiate Bus Vpri Input Stage (Isolate) Vib Output Stage (Non-Isolate) Vo1 C P C ib C o1 PGND (Iso) (Non-Iso) SGND Virtually nonpulsating input current Non-pulsating output current 7

8 Double Regulate: Thermal Property The output power stage is the most efficient at the point of loa (c) Double Regulate Intermeiate Bus Vpri Input Stage (Isolate) Vib Output Stage (Non-Isolate) Vo1 C P C ib C o1 PGND (Iso) (Non-Iso) SGND The bus converter can be off the boar, but in the vicinity, reucing further the heat flux Reuce heat flux at the point of loa, increasing reliability 8

9 Double Regulate: Regulation Typical loa an line regulation for Vo1 is ±3% by virtue of ouble regulation (c) Double Regulate Intermeiate Bus Vpri Input Stage (Isolate) Vib Output Stage (Non-Isolate) Vo1 C P C ib C o1 PGND (Iso) (Non-Iso) SGND No cross an back regulation since the output is regulate irectly 9

10 Double Regulate: Multiple Outputs ntermeiate Bus Vpri Excellent performance for one-rivesmultiples scheme with easy implementation Input Stage (Isolate) (c) Double Regulate Intermeiate Bus Vib Vib ntermeiate Bus b Output Stage (Non-Isolate) b Output Stage (Non-Isolate) Output Stage (Non-Iso) (Non-Isolate) (Non-Iso) Vo1 Von Vo1 C o1 Vo1 Vo2 SGND C o1 SGND C P C ib C o1 PGND (Iso) (Non-Iso) SGND Output voltage levels can be set continuously by uty ratio 10

11 Regulation Performance For a regulation of ±10%, the regulate intermeiate bus can be use For a regulation of ±5-7%, the unregulate intermeiate bus is recommene For a regulation of <±3% or less, high efficiency an small size, the ouble regulate intermeiate bus is preferre 11

12 Summary of Key Performance Parameters Input Power Stage Intermeiate Bus Voltage Level Output Power Stage Thermal Property Regulation Multiple Outputs System Stability & Output Impeance Regulate Single ene, Buck or Buck-Boost, Pulsating input current with large cap at bus voltage level (usually >24 V) Output current can be pulsating Regulate High, usually > 12V Double ene, push-pull, half or full brige Virtually nonpulsating input current Virtually nonpulsating output current Unregulate Most efficient power stage not at output Increase of point-of-loa heat flux Reuce reliability Typical loa/line regulation <±10% Cross regulation is large Back regulation is large Poor, >±10%, typical Favorable in stability Output impeance high Unregulate Double ene, half or full brige as bus converter Virtually nonpulsating input current Non-pulsating output current Unregulate with fixe uty ratio Low, usually < 12V Single ene point of loa (POL) Pulsating input current Non-pulsating output current Regulate Most efficient power stage at the output Reuce pointof-loa heat flux Increase reliability Typical loa/line regulation <±7% No cross regulation No back regulation Goo, ±5-7 %, typical Not favorable in stability Output impeance low Double Regulate Hybri Virtually nonpulsating input current Non-pulsating output current Virtually zero voltage ripple Output regulate Low, usually < 12V Value as a esign parameter for max system performance Hybri Virtually nonpulsating input current Non-pulsating output current Output regulate Most efficient power stage at the output Reuce pointof-loa heat flux Increase reliability Typical loa/line regulation <±3% No cross regulation No back regulation Excellent, <±5%, typical Favorable in stability Output impeance low 12

13 APOL Accomplishe its Goal Measure Best Efficiency at 1/3 Loa (%) Measure Min Efficiency at Full Loa (%) APOL EM APOL BCM EM En-to-En Near Aiabatic POL Power Converter POL CONVERTER The APOL Program We accomplishe all we accomplishe all we set out set out to o on the APOL to o! Program! Expecte Performance an Comparison to the State of the Art Vo1 ± 3% Require thermal removal (kw) AEHF TSAT (centralize power istribution) (intermeiate bus, unregulate) LINEAR REGULATOR Total payloa power (kw) LINEAR REGULATOR En-to-en efficiency (%) to V ± 3% Vin ± 50% POL CONVERTER + Bus LINEAR REGULATOR Bus Vo2 ± 3% + 5 V ± 3% High Efficiency Intermeiate Bus Converter Vo3 ± 3% V ± 3% LINEAR REGULATOR Vo4 ± 3% LINEAR REGULATOR (intermeiate bus, regulate) A total of 67% reuction in power issipation can be achieve V ± 3% LINEAR REGULATOR Efficiency: 92.0% En-to-en power issipation (kw) NextGen MAWFEA Efficiency: 92.5% A 78% increase of payloa capability for a given thermal esign Technical Reainess Levels (TRL) At three (3) at the start an greater than six (6) at the en An example of regulate intermeiate bus esign We have accomplishe the goal of reucing the power issipation by a total of 67% through the APOL Program 13

14 APOL Harware Development a) APOL Breaboar a) BCM Brassboar a) APOL Brassboar 14 c) APOL Engineering Moel b) BCM Engineering Moel

15 POL Converter Prototype A Point-of-Loa (POL) Converter prototype was then constructe using commercially available open-source PWB software an commercial parts Open space on PWB was reserve for future size growth for raiation harene esigns Front View Back View Figure 6 Photos of the prototype point-of-loa converter (POLC) 15

16 POL Prototype Measure Efficiency Efficiency was recore over wie loa, line, an temperature conitions A recor power efficiency of 98.99% was obtaine uring thermal cycling The efficiency was above 97.5% for all lines, loas an temperatures Efficiency (%) Temp = -30 C Temp = C Temp = -9.5 C Temp = 0.1 C Temp = 25.6 C Temp = 45.6 C Temp = 65.4 C Iout (A) 16 Figure 8 Measure POLC efficiency, emonstrating a recor power efficiency of 99% at 4V in, 3.3V out at about 3A

17 BCM Prototype Finally we like to share the measure efficiency from our bus converter moule (BCM) prototype Our BCM efficiency was measure to be a recor high of 95.47% Details can be the subject of a separate presentation Figure 14 Measure efficiency for the BCM prototype Figure 15 Front view of the BCM prototype 17

18 Measure Results on En-to-En Efficiency Measure En-to-En System Efficiency Efficiency (%) BCM/POL: LOWLINE (Vin = 65V) Prototype brassboar emonstrate that the en-toen system efficiency PRM/VTM: LOWLINE for (Vin the = 65V) ouble regulate bus is BCM/POL: NOMINAL (Vin = 70V) BCM/POL: HIGHLINE (Vin = 75V) PRM/VTM: NOMINAL (Vin = 70V) PRM/VTM: HIGHLINE (Vin = 75V) >13% better than that of the unregulate bus architecture Iout (A) Recor Efficiency Achieve for the POL Recor Efficiency Achieve for the BCM Efficiency (%) Temp = -30 C Temp = C Temp = -9.5 C Temp = 0.1 C Temp = 25.6 C Temp = 45.6 C Temp = 65.4 C A recor efficiency of 99% was obtaine for the POL esign Iout (A) A recor efficiency of 95.5% was obtaine for the BCM esign with Vo=3.3V 18

19 APOL EM Photos APOL POL EM with R7 MOSFETs (1.9 x2.2 x.46 /.14 lbs.) APOL BCM EM with R7 MOSFETs (3.0 x4.0 x.66 /.40 lbs.) APOL POL EM APOL POL EM emonstrate emonstrate efficiency of efficiency of 94.35% at 94.35% at1/3 1/3 of the of the loa loa an an 91.54% 91.54% at full at full loa loa when when teste teste to to 2x its 60W, 2x of esigne the esigne capability capability APOL BCM EM emonstrate efficiency of 92.64% at 1/2 the loa an 91.64% at full loa when teste to 120W, 2x of the esigne capability APOL POLC EFFICIENCY APOL BCM EFFICIENCY Efficiency (%) EFFICIENCY (%) Vin = 4.5V Vin = 65V Vin = 5V Vin = 5.5V Vin = 70V Vin = 75V Loa (%) per Channel LOAD (%) 19 APOL EM emonstrate recor efficiency for both the POL an the BCM esigns

20 APOL EM Photos POL EM Photos from Prouction 20

21 POL EM Test Set-Up 21

22 POL Measure Efficiency Before vib an thermal cycling After vib an thermal cycling The The measure POL measure efficiency efficiency virtually unchange virtually unchange after vibration after an vibration thermal an thermal cycling cycling tests tests 22

23 APOL EM Photos from Prouction BCM EM Photos from Prouction 23

24 BCM EM Test Set-Up 24

25 BCM Measure Efficiency The BCM measure efficiency is virtual unchange after the vibration an thermal cycling tests 25

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