Space power conversion applications.

A new Smart Integrated Magnetics solution designed for advanced power conditioning and distribution units (PCDUs) operating in constrained and demanding environments such as space systems has been developed by Exxelia. This solution is not a standard catalog product; it is the result of a custom development. It has been engineered to meet specific electrical, thermal and mechanical requirements defined at system level and can be adapted to meet any set of customer specifications.

This new Smart Integrated Magnetics solution combines the transformer and the inductor of a Dual Active Bridge (DAB) within a single, compact magnetic assembly. This integrated approach aims to reduce volume, mass and interconnection complexity while maintaining electrical performance at high switching frequencies. The targeted application is isolated DC-DC power conversion in space-grade PCDUs, where efficiency, reliability, and mechanical robustness are key design drivers.

From a technical standpoint, the Smart Integrated Magnetic is designed for a power level of 1 to 2kW at a switching frequency of 100 to 200kHz (example). The associated inductor provides an inductance of few µH. The overall assembly reaches an efficiency level close to 99% under nominal operating conditions, reflecting careful optimization of core materials, winding architecture and magnetic coupling. Particular attention has been paid to losses and thermal behavior, which are critical in low-convection environments.

Mechanical integration was a central aspect of the development. The complete magnetic solution fits into a low-profile / planar package measuring approximately 75 × 65 × 20 mm, with a total mass of around 250 g. This compact form factor is intended to facilitate integration into densely populated power electronics modules, while also supporting resistance to mechanical stresses typically encountered during launch and operation.

The design was carried out to address severe environmental constraints, including thermal cycling and mechanical loads, which are characteristic of space applications. Material selection, impregnation processes and structural design were adapted accordingly to ensure long-term stability and compatibility with qualification requirements.

While the solution presented here is specific to a given program and set of constraints, it reflects a broader approach that can be adapted to other high-reliability applications requiring compact, efficient and integrated magnetic designs.

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@Exxelia #Aerospace #PAuto

Simplifying bridge sensor measurements.

Software provides powerful signal conditioning capabilities for precise conversion of bridge inputs to process current or voltage control signals

Acromag’s new TT351 load cell and strain gauge signal conditioners use software to quickly select from a wide variety of sensor measurement options. A USB port simplifies setup on a Windows PC or Android mobile device with Acromag’s AgilityTM app. Software menus help users set the sensor type, bridge configuration, excitation source, filtering level, and input/output ranges. Advanced capabilities let users fine tune scaling of I/O signals, adjust excitation levels, and calibrate the bridge.

Universal output supports six ranges including 4-20mA, 0-10V and ±10V. Flexible power accepts a 9-32V DC supply at the terminals and a rail power bus option can supply multiple units from a single connection or establish redundant power. The narrow 17.5mm housing mounts easily on a DIN rail. Hazardous location approvals, high noise immunity, and a -40 to 70°C operating range make these transmitters ideal for use in harsh environments.

“These software-configured bridge sensor transmitters offer capabilities not possible with DIP switches or pot adjustments for a broad range of load cell, strain gauge, weight and force measurements,” stresses Robert Greenfield, Acromag’s Business Development Manager.

The TT351 input circuit allows true 6-wire bridge measurement and includes an adjustable bridge excitation supply (4 to 11V DC) with a remote sense feature. Sense wires ensure the programmed excitation voltage is applied at the sensor and enable lead-wire compensation. The differential input performs true ratiometric conversions for extremely stable measurements that remain accurate over time and temperature. Plus, lead break detection is inherent in the device. Three-way isolation between input, output and power increases safety and noise immunity.

Advanced signal processing capabilities, variable range input, and convenient USB programming make this instrument a very versatile strain/load measurement device. A single model can process strain gage, load cell, and millivolt input signals from 1-10mV/V. Initial bridge offsets or forces can be automatically removed with null compensation, tare, and zero balance bridge functions. An internal half-bridge can perform half and quarter bridge completion with precision resistor pairs or bias a floating millivolt input signal. A custom input signal linerarizer function supports up to 25 user defined signal breakpoints. Flexible scaling is independently adjustable on the input and output. To suppress noise effects, users can set a variable digital input filter level or average a number of samples. Shunt calibration tools with a simulation calculator enables rescaling of the transmitter’s indicated strain by modifying software gain and/or the instrument gauge factor. And to test or verify operation, a software diagnostics screen will poll the unit and display measured and computed values.

#PAuto @Acromag