R/T RESULTS ON STANDARD DC-DC CONVERTER MODULES

Transcription

1 R/T RESULTS ON STANDARD DC-DC CONVERTER MODULES ALCATEL SPACE INDUSTRIES- VALENCE L. GARRAUD - R. GRANJON SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

2 INTRODUCTION KEY REQUIREMENTS FOR SPACE DC-DC converters. Reduction of non recurring cost (objective 0 NRC for modules) Short schedule for the complete power supply function Low recurring cost STANDARD DC-DC CV MODULES Basic building block for the complete PS function Procured as a part, so anticipated high quantity production allowing to decrease cost SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

3 INTRODUCTION STANDARD DC-DC CV KEY TECHNICAL REQUIREMENTS. Module compatible with large range of use - large range of input voltage without any adaptation - large range of output power including no load without any adaptation Low volume and mass Easy to use - plug in module (implemented on PCB) - complete function included in the module Module fulfilling the environment requirements of parts implemented on boards (high vibration level..) SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

4 STANDARD DC-DC CV MODULES KEY ELECTRICAL SPECIFICATIONS INPUT VOLTAGE RANGE compatible of LEO,MEO and GEO applications 20.5 V to 126V, divided in two ranges (LV: 20.5Vto 56V,HV:50V to 126V) OUTPUT POWER AND VOLTAGES systematic need of several voltages,with output power range up to 41W single converter with several outputs (up to 4) and capacity to modify output voltages by simple transformer modification two output power range 15W and 41W. OUTPUT VOLTAGES PROTECTIONS INCLUDED SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

5 STANDARD DC-DC CV MODULES KEY ENVIRONMENT SPECIFICATIONS LARGE TEMPERATURE RANGE fixing lugs temperature range :-35 C up to 75 C full power available at 75 C with parts derating fulfilled HIGH VIBRATION AND SCHOCK LEVELS RADIATION EFFECTS FOR MEO and GEO applications total dose at die level 50 krads and heavy ions effects taken into account QUALITY REQUIREMENTS technologies compatible with 500 thermal shock cycles SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

6 TRADE OFF RESULTS SYNTHESIS CONVERTER TOPOLOGY HIGH OUTPUT VOLTAGES ACCURACY main output high accuracy,better than +/-2% (no load to full load) cross regulated outputs good accuracy +/-5% (no load to full load) HIGH EFFICIENCY to reduce dissipated power on board more than 50% of output power on low voltages outputs CAPACITY TO ADAPT OUTPUT VOLTAGES by simple modification SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

7 TRADE OFF RESULTS SYNTHESIS PACKAGING TECHNOLOGY MAIN SUBSTRATE very low resistance for power tracks and external pins (output current up to 10 A with output voltages down to 3.3V) low thermal resistance of the substrate capacity to include two levels of parts to optimise volume low recurring cost SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

8 TRADE OFF RESULTS SYNTHESIS PACKAGING TECHNOLOGY COMMAND AND CONTROL SUBSTRATE high density of interconnections low recurring cost alumina substrate with thick film technology SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

9 TRADE OFF RESULTS SYNTHESIS HERMETICITY HERMETIC SOLUTION: hermetic cavity verso including active parts and passive SMT parts on recto compatible with hirel level requirements(esa or MIL) NON HERMETIC SOLUTION: substrate verso supporting COTs and dies protected by glop top and passive SMT parts on recto parts not qualified and solution not compatible with most program requirements lower cost (parts and package) HERMETIC solution chosen to be compatible with all programs SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

10 CVSQ40 Ps max =41W 4 outputs: +5V ±1% 0A to 4A +15V ±5% 0A to 1.5A -15V ±5% 0A to 1.5A +32V ±5% 0A to 0.8A High efficiency (up to 87%) High level of protection (output overload, output overvoltage, primary under voltage lockout) Single Point failure free on input voltage line (input limiter included) ON/OFF standard command interface External synchronisation User adjustable main output Radiation hardened (50Krads) and heavy ions tolerant products Hermetic technology 96.5x81x20.5 mm200 g typ SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

11 CVSQ40 BLOCK DIAGRAM Power Bus Primary Interface Circuit LF Filter VS4 Ret_VS4 VS3 Limiter Output Filter VS2 VS1 Power Bus Return Start-up Circuit Ret VS1,VS2 VS3 TC ON/OFF Synchro PWM with Current Circuit Secondary Control Circuit Output Voltage Trimming Regulation loop Over voltage Detection SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

12 PROTECTIONS: CVSQ40 KEY PERFORMANCES No dissipative failure case Against output overload Against output overvoltage in failure case Primary under voltage lockout Single Point failure free on input voltage line (input limiter included) SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

13 CVSQ40 KEY PERFORMANCES EFFICIENCY: P(Vs1) = 40% of Ps P(Vs2) = 25% of Ps P(Vs3) = 25% of Ps P(Vs4) = 10% of Ps CVSQ40 efficiency versus Output Power and Primary Power Bus Efficiency (%) 86,00 85,00 84,00 83,00 82,00 81,00 80,00 79,00 78,00 77,00 76,00 75,00 74,00 73, Output Power (W) Vin = 20V Vin = 40V Vin = 56V SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

14 CVSQ40 KEY PERFORMANCES CROSS-REGULATION: Vs2 regulation versus Vs1 and Power Bus P(Vs3) = 1.5W P(Vs4) = 0W with Vs1 trimmed to 5,3V VS4 regulation versus Vs1 and Power Bus P(Vs2) = P(Vs3) = 0W 17,4 37 Vs2 voltage (V) 17, ,8 16,6 16,4 16, ,8 15,6 15,4 15, ,8 0W 5W 10W 15W 20W 24W Vs2 power (W) Ps1=0W/20V Ps1=1W/20V Ps1=5W/20V Ps1=10W/20V Ps1=15W/20V Ps1=0W/56V Ps1=1W/56V Ps1=5W/56V Ps1=10W/56V Ps1=15W/56V Vs4 voltage (V) 36, , , , , , , ,1 0,2 0,3 0,4 0,5 0,6 Vs4 output current (A) Is1=0A/20V Is1=0,5A/20V Is1=1A/20V Is1=2A/20V Is1=4A/20V Is1=0A/40V Is1=0,5A/40V Is1=1A/40V Is1=2A/40V Is1=4A/40V Is1=0A/56V Is1=0,5A/56V Is1=1A/56V Is1=2A/56V Is1=4A/56V SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

15 CVST15 Ps max =15W 3 outputs: +5V ±1% 0A to 2A +15V ±5% 0A to 0.7A -15V ±5% 0A to 0.7A High efficiency (up to 85%) High output voltages accuracy High level of protection (output overload, output overvoltage, primary under voltage lockout) ON/OFF standard command interface External synchronisation User adjustable main output Radiation hardened (50Krads) and heavy ions tolerant product Hermetic technology 78x70x19.5 mm 120 g typ SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

16 CVST15 BLOCK DIAGRAM Power Bus LF Filter VS3 Output Filter VS2 VS1 Power Bus Return TC ON/OFF Start-up Circuit Ret VS1,VS2 VS3 Synchro PWM with Current Control Circuit Secondary Control Circuit Output Voltage Trimming Regulation loop Over voltage Detection SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

17 CVSQ40 KEY PERFORMANCES PROTECTIONS: No dissipative failure case Against output overload Against output overvoltage in failure case Primary under voltage lockout SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

18 CVST15 KEY PERFORMANCES EFFICIENCY: Efficiency vs Load & Line at 25 C (P(Vs1) = 50% of Ps) 90,00 85,00 80,00 Efficiency (%) 75,00 70,00 65,00 Vin = 20,5V Vin = 40V Vin = 56V 60,00 55, Ps (W) SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

19 CVST15 KEY PERFORMANCES CROSS-REGULATION: VS2 cross regulation versus Vin & Vs1 power at 25 C (Vs1 trimmed to 5.3V) 16,5 Vs2 output (V) 16 15, , I(Vs1) 20,5V 20,5V 20,5V 20,5V 20,5V I(Vs1) 56V 56V 56V 56V 56V I(Vs2) ma SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

20 R/T CONCLUSION Standard DC-DC converters modules now available CVSQ40 and CVST15. CVSQ40, CVST15: 3.3V (Vs1) products adaptation possible with simple transformer adaptation. CVSQ40, CVST15 HV versions (50 to 126V), feasibility demonstrated with same external interfaces Development and qualification status Technologies qualification completed end T CVSQ40, CVST15: LV products development completed end 2001 SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

21 R/T CONCLUSION Flight models delivering CVSQ40, CVST15 (LV) first EMs delivered end 2001 FMs manufacturing in progress (delivery foreseen T3 2002) Flight models quality level two levels available Long life mission: quality level K ( in accordance with MIL PRF 38534) Short life mission: quality level H ( in accordance with MIL PRF 38534) SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN

22 R/T CONCLUSION Documents available (for each module type) Data sheet User manual Technical Specification Study report including part stress analysis and failure modes at external interfaces SEMINAIRE CONVERTISSEURS DC-DC CNES JUIN