For advanced power conditioning and distribution units (PCDUs) operating in constrained and demanding environments, including space systems, Exxelia developed a new Smart Integrated Magnetics solution.
This solution is the outcome of a custom development rather than a typical catalog product. It can be adapted to meet any set of customer specifications and has been built to fulfill specific electrical, thermal, and mechanical requirements specified at the system level.
The transformer and inductor of a Dual Active Bridge (DAB) are combined into a single, compact magnetic assembly in Exxelia’s innovative Smart Integrated Magnetics solution. The aim of this integrated approach is to maintain electrical performance at high switching frequencies while reducing volume, mass, and interconnection complexity.
The intended use is isolated DC-DC power conversion in space-grade PCDUs, where mechanical robustness, efficiency, and reliability are important design factors. Technically speaking, this Smart Integrated Magnetic is intended for a power level of 1 to 2kW at a switching frequency of 100 to 200kHz (for instance). An inductance of a few µH is provided by the associated inductor.
Under nominal operating conditions, the assembly’s overall efficiency approaches 99%, a result of careful optimization of the winding architecture, magnetic coupling, and core materials. Losses and thermal behavior, which are crucial in low-convection conditions, have received particular attention.
A key component of the development was mechanical integration. The entire magnetic solution weighs around 250 g and fits into a low-profile, planar package that measures about 75 × 65 × 20 mm. In addition to supporting resistance to mechanical stresses commonly experienced during launch and operation, its compact form factor is designed to make integration into densely populated power electronics modules easier.
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.
This Smart Integrated Magnetics solution illustrates Exxelia’s capability to deliver fully customised magnetic components, developed in close interaction with system architects and power electronics engineers. 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.
For Further Info, CLICK HERE
