Exxelia’s new solution is for PCDUs operating in constrained and demanding environments
Exxelia has created a new Smart Integrated Magnetics solution for advanced power conditioning and distribution units (PCDUs) operating in constrained, demanding environments such as space systems
The solution has been developed to meet specific electrical, thermal, and mechanical requirements defined at the system level and can be adapted to meet any set of customer specifications.
The new Smart Integrated Magnetics solution combines the transformer and the inductor of a Dual Active Bridge (DAB) in a single magnetic assembly. This approach aims to reduce volume, mass, and interconnection complexity while retaining electrical performance at high switching frequencies. The targeted application is isolated DC-DC power conversion in space-grade PCDUs.
The new solution is designed for a power level of 1 to 2kW at a switching frequency of 100 to 200kHz. The associated inductor provides an inductance of a few µH. The overall assembly can achieve an efficiency near 99% under nominal operating conditions due to optimisation of core materials, winding architecture, and magnetic coupling. Exxelia designed the solution with losses and thermal behaviour in mind, as these are critical in low-convection environments, and mechanical integration was also a key aspect of the development. The complete magnetic solution can fit into a low-profile/planar package, measuring 75 x 65 x 20mm, with a mass of around 250g. This compact form factor has been designed to enable integration into densely populated electronic modules while supporting resistance to mechanical stresses encountered during launch and operation.
The solution addresses environmental constraints, including thermal cycling and mechanical loads, common to space applications. Material selection, impregnation processes 1/2, and structural design were adapted to ensure long-term stability and compatibility with qualification requirements.
