Magnetics solution for space power conversion applications

Exxelia has developed 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.

This solution is not a standard catalogue 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.

Exxelia 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, this 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 optimisation of core materials, winding architecture and magnetic coupling. Particular attention has been paid to losses and thermal behaviour, 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 × 20mm, with a total mass of around 250g. 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.