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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Grid-Connected Modular Soft-Switching Solid State Transformers (M-S4T)

The objective of this project is to develop and verify the concept of a flexible and modular soft-switching solid-state transformer (M-S4T) for direct grid-connected applications. The ability to directly connect power electronics converters to the medium voltage grid (4 kV – 13 kV), and to potentially replace the passive and bulky, but ubiquitous 60 hertz service transformer in the 25 kVA to 100 kVA range, with a more flexible and controllable device, has been regarded as the ‘holy grail’ in grid control. However, this has proven to be extremely difficult. This project has developed the solutions to several key challenges of the direct grid-connected power electronics and realized a 7.2 kV M-S4T prototype. First, a protection method to protect the M-S4T from the high voltages (110 kV for the 13 kV system) that occur on the grid due to transients and lightning strikes have been developed and experimentally verified. Second, the realization and the operation of the M-S4T based on high-voltage SiC devices (>3.3 kV) and a medium-frequency medium-voltage low-leakage transformer in a single-stage solid-state transformer with zero-voltage switching, low dv/dt, and low electromagnetic interference has been successfully demonstrated up to 7.5 kV peak. Third, an oil-cooling system and stable communication and distributed control system for converter module voltage sharing have been developed and experimentally verified. The developed M-S4T has realized a modular universal high-performance power conversion system. This conversion system is scalable to different voltage and power levels and adaptable to four-quadrant bidirectional operation. Moreover, the use of passive cooling techniques meets the equipment life requirements, and the lightning protection scheme fulfills the basic insulation level specifications for direct grid connection. Such power conversion system opens up near-term opportunities, including energy storage, solar PV, or electric vehicle charging with significant cost and footprint savings. In the longer term, the possibility of replacing the utility distribution transformer with an M-S4T will be transformative for future distribution grids with a compact footprint and full controllability to enable high renewable energy and storage penetration. In addition to the main project, this report expands on the Plus-Up projected including as part of the main award. This project developed and demonstrated the technology for autonomous collaborative inverters that can be connected in an ad hoc manner to the grid. The aim of the project was to: (1) evaluate the existing techniques for grid-connected inverters and find their limitations; (2) develop detailed requirements for grid-connected inverters in the modern grid with millions of active nodes; (3) design a unified control strategy that brings more autonomy and intelligence to grid-connected inverters, and addresses parts of the issues with the existing techniques. The proposed technique, called UniCon, enables inverters to 1) connect/disconnect to/from the grid in an ad hoc manner; (2) work based on local sensing. Slow communication could be used for a more optimized behavior; (3) work automatically in both grid-forming/grid-following mode; (4) handle large disturbances, e.g., big load step and fault, in an oscillation-free manner; (5) work collaboratively with other inverters in steady-state and during transients. UniCon can be implemented in the middle-level control; hence it is agnostic to the vendor and to the implementation of the inner voltage/current and protection loops. Furthermore, a new synchronization scheme, based on deep learning, was developed that can extract the grid voltage phase and amplitude in a stable manner. The method is cheap to implement can improve the dynamic performance of the grid-connected inverters during fast transients, e.g., fault. The proposed control scheme was validated by (1) MATLAB/Simulink; (2) hardware-in-the-loop results, and; (3) experimental results using three inverters that form a microgrid in a down-scaled feeder. Lastly, both the M-S4T and UniCon have achieved promising tangible paths to markets. In the case of the M-S4T, the underlying technology — the Soft Switching Solid State Transformer (S4T) developed at the Georgia Tech Center for Distributed Energy (GT-CDE) has been licensed by GridBlock from the Georgia Tech Research Corporation, and GridBlock has been working with manufacturing partner Jabil (one of the largest US-based contract manufacturers) and system integrator Power Secure (largest deployer of microgrids in the US with 4.7 GW under management), to meet the strong initial demand. Similarly, GridBlock has an exclusive license to the UniCon technology, developed under this award by GT-CDE. The UniCon provides an intermediate control layer that enables the implementation of the higher-level ‘transactive’ control commands for the system. The architecture of the system - slow communications with the cloud for system optimization and setpoints, and the use of locally measured quantities for real-time control, provide a very robust and secure way of implementing a real-time must-run grid that is also secure and stable. This is a brand-new functionality that is critical for the future grid and key to GridBlock’s business model.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Interconnection and Interoperability Requirements of Hydrogen Assets to Enable Grid Integration

Traditionally, the inverters used for distributed energy resources (DERs) including solar, energy storage and hydrogen fuel cells are grid following assets. Grid following assets track real power and reactive power setpoints decided by either a local autonomous controller or a remote controller like a microgrid controller. In the past five years, multiple challenges have increased the need for grid forming inverters that can interface to a wide variety of energy resources. These grid forming inverters are becoming critical assets for power systems to enable the replacement of existing rotational machines and provide grid services such as grid resiliency services and black-start. Hydrogen assets (fuel cells) have the potential to successfully replace rotating machines and act as voltage and frequency master by leveraging the long-duration and seasonal energy storage capabilities of hydrogen technologies. This poster presents the progress made in budget period 1 of the proposed work. We will leverage an existing ARIES platform experimental setup to run power-hardware-in-the-loop and controller-hardware-in-the-loop experiments with grid forming fuel cell inverters to develop and document the standardization requirements.

electrolyzer↗
DOE OSTI2022

Logic operations with active topological defects

Logic operations performed by semiconductor-based transistors are the basis of modern computing. There is considerable interest in creating autonomous materials systems endowed with the capability to make decisions. In this work, we introduce the concept of using topological defects in active matter to perform logic operations. When an extensile active stress in a nematic liquid crystal is turned on, +1/2 defects can self-propel, in analogy to electron transport under a voltage gradient. By relying on hydrodynamic simulations of active nematics, we demonstrate that patterns of activity, when combined with surfaces imparting certain orientations, can be used to control the formation and transport of +1/2 defects. We further show that asymmetric high- and low-activity patterns can be used to create effective defect gates, tunnels, and amplifiers. The proposed active systems offer the potential to perform computations and transmit information in active soft materials, including actin-, tubulin-, and cell-based systems.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS2004

Event-Driven Random-Access-Windowing CCD Imaging System

A charge-coupled-device (CCD) based high-speed imaging system, called a realtime, event-driven (RARE) camera, is undergoing development. This camera is capable of readout from multiple subwindows [also known as regions of interest (ROIs)] within the CCD field of view. Both the sizes and the locations of the ROIs can be controlled in real time and can be changed at the camera frame rate. The predecessor of this camera was described in High-Frame-Rate CCD Camera Having Subwindow Capability (NPO- 30564) NASA Tech Briefs, Vol. 26, No. 12 (December 2002), page 26. The architecture of the prior camera requires tight coupling between camera control logic and an external host computer that provides commands for camera operation and processes pixels from the camera. This tight coupling limits the attainable frame rate and functionality of the camera. The design of the present camera loosens this coupling to increase the achievable frame rate and functionality. From a host computer perspective, the readout operation in the prior camera was defined on a per-line basis; in this camera, it is defined on a per-ROI basis. In addition, the camera includes internal timing circuitry. This combination of features enables real-time, event-driven operation for adaptive control of the camera. Hence, this camera is well suited for applications requiring autonomous control of multiple ROIs to track multiple targets moving throughout the CCD field of view. Additionally, by eliminating the need for control intervention by the host computer during the pixel readout, the present design reduces ROI-readout times to attain higher frame rates. This camera (see figure) includes an imager card consisting of a commercial CCD imager and two signal-processor chips. The imager card converts transistor/ transistor-logic (TTL)-level signals from a field programmable gate array (FPGA) controller card. These signals are transmitted to the imager card via a low-voltage differential signaling (LVDS) cable assembly. The FPGA controller card is connected to the host computer via a standard peripheral component interface (PCI).

Monacos, Steve↗
DOE OSTI2024

Analysis of Grid-Forming Inverter Controls for Grid-Connected and Islanded Microgrid Integration

Autonomous grid-forming (GFM) inverter testbeds with scalable platforms have attracted interest recently. In this study, a self-synchronized universal droop controller (SUDC) was adopted, tested, and scaled in a small network and a test feeder using a real-time simulation tool to operate microgrids without synchronous generators. We presented a novel GFM inverter control adoption to better understand the dynamic behavior of the inverters and their scalability, which can impact the distribution system (DS). This paper provides a steady-state and transient analysis of the GFM power inverter controller via simulation to better understand voltage and frequency stabilization and ensure that the critical electric loads are not affected during a prolonged power outage. The controllers of the GFM inverter are simulated in HYPERSIM to examine voltage and frequency fluctuations. This analysis includes assessing the black start capability for photovoltaic microgrids, both grid-connected and islanded, during transient fault conditions. The high photovoltaic PV penetration levels open exciting opportunities and challenges for the DS. The GFM inverter control demonstrated appropriate response times for synchronization, connection, and disconnection to the grid. The DS has become more resilient and independent of fossil fuels by increasing the penetration of inverter-based distributed energy resources (DERs).

Ward, Laura (ORCID:0000000345501581)↗
DOE OSTI2023

Analytical Large-Signal Modeling of Inverter-Based Microgrids With Koopman Operator Theory for Autonomous Control

The microgrid (MG) plays a crucial role in the energy transition, but its nonlinearity presents a significant challenge for large-signal power systems studies in the electromagnetic transient (EMT) time scale. In this paper, we develop a large-signal linear MG model that considers the detailed dynamics of the primary and zero-control levels based on the Koopman operator (KO) theory. Firstly, a set of observable functions is carefully designed to capture the nonlinear dynamics of the MG. The corresponding linear KO is then analytically derived based on these observables, resulting in the linear representation of the original nonlinear MG with observables as the new coordinate. The influence of external input on the system dynamics is also considered during the derivation, enabling control of the MG. We solve the voltage control problem using the traditional linear quadratic integrator (LQI) method to demonstrate that textbook linear control techniques can accurately control the original nonlinear MG via the developed KO-linearized MG model. Our proposed KO linearization method is generic and can be easily extended for different control objectives and MG structures using our analytical derivation procedure. Here, we validate the effectiveness of our methodology through various case studies.

25 ENERGY STORAGE↗
DOE OSTI2025

Efficient and Selective Chemical Transformations in Highly Charged and Confined Nanodroplets

The acceleration of chemical reaction rates and the increased product selectivity in microdroplets compared to that in bulk solutions has become a topic of increasing interest that has been extensively characterized by electrospray ionization mass spectrometry (ESI-MS). However, the sources of this acceleration and the detailed relationships between droplet properties and resulting reaction rate acceleration are still under debate. Moreover, droplet properties are governed by multiple interrelated experimental parameters, i.e., electrospray voltage, solution flow rate, etc., which makes it difficult and time-consuming to explore this diverse parameter space using traditional manual experimental or computational approaches. In this work, we developed an automated experimental platform integrating reactions in controlled charged microdroplet environments with ESI-MS characterization and sequential hybrid Bayesian modeling, as well as an optimal experimental design framework, to achieve multidimensional parameter optimization for higher reaction turnover rates, based on a model reaction of tetraethylenepentamine (TEPA) with carbon dioxide. With the current platform, we have achieved automated scans with a range of electrospray voltages and solution flow rates, and determined and optimized parameter settings to achieve increased reaction turnovers. We have also linked this platform to the underlying properties of droplets via a hybrid model incorporating physics, high-level theoretical calculations, and machine learning (ML) approaches. The autonomous platform is broadly applicable to a range of chemical reactions relevant to DOE’s mission in chemical separations, catalysis, and materials synthesis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Machine Learning-Assisted Stability Boundary Determination of Multiport Autonomous Reconfigurable Solar Power Plants

The multiport autonomous reconfigurable solar (MARS) power plant is a promising solution to integrate renewable resources and energy storage systems into the alternating current (ac) power grid and an high-voltage direct current (HVdc) link. In the MARS system, various input power sources are connected to the individual submodules (SMs) through direct current (dc)–dc converters. However, the presence of external power sources can result in unbalanced capacitor voltages of SMs, thereby violating stability constraints under multiple/diverse operating conditions. This article aims to address the gap by accurately determining the stability boundary of the MARS system. As such, a novel machine learning (ML)-assisted energy balancing control (EBC) criterion is proposed. Further, in conjunction with a refined EBC, this approach ensures balanced capacitor voltages across various types of SMs, significantly enhancing the overall system efficiency. The proposed EBC criterion effectively controls EBC activation and deactivation, achieving remarkable accuracy. Both power systems computer aided design (PSCAD)/electromagnetic transients including direct current (EMTDC) simulations and control hardware-in-the-loop (cHIL) tests are conducted to validate the feasibility and efficiency of the proposed method. By combining the EBC and ML-assisted EBC criterion, efficient energy management is achieved for systems featuring multiple input power sources, such as MARS. This approach enables the system to fully exploit its potential across an expanded operational range while upholding high-efficiency standards.

14 SOLAR ENERGY↗
NASA NTRS1980

A propulsion and steering control system for the Mars rover

The design of a propulsion and steering control system for the Rensselaer Polytechnic Institute prototype autonomous Mars roving vehicle is presented. The vehicle is propelled and steered by four independent electric motors. The control system must regulate the speeds of the motors so they work in unison during turns and on irregular terrain. An analysis of the motor coordination problem on irregular terrain, where each motor must supply a different torque at a different speed is presented. A procedure was developed to match the output of each motor to the varying load. A design for the control system is given. The controller uses a microprocessor which interprets speed and steering commands from an off-board computer, and produces the appropriate drive voltages for the motors.

Turner, J. M.↗
NASA NTRS1990

Control of multiple resonant power processors in a multi-source system

Analysis and test results show that phasor-regulated, Mapham-derived resonant inverters can be paralleled to provide standardizing interfaces for multiple sources on a utility-type, aerospace power distribution bus. The basic sources do not require matching in any way, and may have grossly different characteristics. Fully stable system architectures with multiple sources, parallel/redundant distribution buses, and a wide variety of loads can be easily constructed and controlled. The commands and parameters available for system control allow for tight tolerance bus voltage control, and absolute power-sharing control from the various sources over the full range of possible source and load variations. That level of control enables simplified load power processing hardware and the distribution of losses to optimally load the source thermal control system. Positive control of all system performance and allocation of losses are not required by all missions or vehicles, and overall vehicle considerations do not always require the loads on vehicle energy sources and thermal control systems to be balanced. In those cases, power system control can be simplified, and a hierarchical set of defaults can be substituted for computer-generated or supervisory input commands to allow for stable, fully autonomous system operation.

Mildice, James↗
NASA NTRSDate not supplied

Firmware Architecture of the ARMADAS Bolting Robot

The Automated Reconfigurable Mission Adaptive Digital Assembly Systems (ARMADAS) project, under development at NASA Ames Research Center, has demonstrated on-ground autonomous robotic assembly of extensive digital structures, and it is now moving forward towards in-space demonstration. The ARMADAS system comprises of the operation software, the operation user interface (opsUI), and a swarm of robots. The robotic system consists of a multitude of collaborative agents specifically designed to transport, place and bolt the building blocks, called voxels (volumetric pixels). This paper focuses on the bolting robot, referred to as Mobile Metamaterial Internal Co-Integrator (MMIC-I). MMIC-I is a battery-powered crawling robot. It navigates the structure through extension, contraction and gripping. Two distinct controller boards operate the robot's two symmetric modules, referred to as module A and B. Board A is the master board: it coordinates motion planning and motion primitives execution, hosts the WiFi client, performs periodic self-assessment and system idle check and triggers faults if anomalies are detected. Board B periodically sends a heartbeat to board A, through a wired communication channel that uses the Serial protocol. Additionally, board A's WiFi client receives heartbeat packet requests or motion/bolting commands from a dedicated server board, and acknowledges reception sending back a response heartbeat packet containing information about the overall robot status, e. g. electrical current and voltage values, target and actual angles, operating mode, fault status. Whenever a motion command is sent, the motion planning section of the firmware determines the current robot configuration, using Inertial Measurement Unit readings and the motors Pulse Width Modulation values. Afterwards, it calculates the list of primitives needed to reach the target state, and controls their execution in the proper order. MMIC-I can receive and execute motion and bolting commands only when it is in operational mode. MMIC-I has three operating modes: standby, operational and safed. Standby mode is automatically entered upon startup. While in standby mode, all motors are powered off, and the only accepted commands are the ones relative to a change of mode and heartbeat packet request. Fault detection causes the robot to automatically enter safed or standby mode. Whenever the detected fault occurs within a motion and requires immediate intervention, e. g. an over-current situation, the robot enters safed mode. Safed mode powers off all motors except for the locomotion module, thus preventing the robot from collapsing. Conversely, when the detected fault doesn't require immediate intervention (low battery warning, for instance), the robot enters standby mode after completing the ongoing motion. This paper provides a detailed discussion of MMIC-I's firmware architecture. It accurately describes the implementation approach for each module: sensor data reading, motor control and actuation, WiFi server-client communication, intra-boards Serial communication, operating modes and autonomous fault detection, motion planning, coordination and execution, etc. Moreover, in support of the software description, this paper includes a thorough characterization of MMIC-I's hardware and avionics.

In-space assembly↗
NASA NTRS2015

A Wirelessly Powered Micro-Spectrometer for Neural Probe-Pin Device

Treatment of neurological anomalies, places stringent demands on device functionality and size. A micro-spectrometer has been developed for use as an implantable neural probe to monitor neuro-chemistry in synapses. The microspectrometer, based on a NASA-invented miniature Fresnel grating, is capable of differentiating the emission spectra from various brain tissues. The micro-spectrometer meets the size requirements, and is able to probe the neuro-chemistry and suppression voltage typically associated with a neural anomaly. This neural probe-pin device (PPD) is equipped with wireless power technology (WPT) enabling operation in a continuous manner without requiring an implanted battery. The implanted neural PPD, together with a neural electronics interface and WPT, allow real-time measurement and control/feedback for remediation of neural anomalies. The design and performance of the combined PPD/WPT device for monitoring dopamine in a rat brain will be presented to demonstrate the current level of development. Future work on this device will involve the addition of an embedded expert system capable of performing semi-autonomous management of neural functions through a routine of sensing, processing, and control.

Choi, Sang H.↗
DOE OSTI2023

A Peer-to-Peer Market-Based Control Strategy for a Smart Residential Community with Behind-the-Meter Distributed Energy Resources

This paper presents a distributed peer-to-peer market control strategy to manage and to enable resource sharing of behind-the-meter distributed energy resources in a residential community. In the proposed strategy, each consumer or prosumer determines the flexibility of their point of connection to the power network such that the obtained flexibility is network-feasible. Based on the feasible flexibility, the consumers and the prosumers trade power among each other at each time instance to fulfil their preferred load requirements while maximizing their payoffs and helping to regulate node voltages inside the community. Because the problem to be solved is non-convex, a distributed particle swarm optimization algorithm is used to coordinate the consumers/prosumers in a fully autonomous manner without any centralized or hierarchical coordination. Numerical simulations performed on a community of 48 homes demonstrate the efficacy of the proposed approach.

distributed energy resource↗
DOE OSTI2025

Thermomagnetic generators for ultra-low-grade marine thermal energy harvesting

Low-grade thermal gradients in marine environments represent an underexploited energy source for autonomous sensing and monitoring. Converting such small temperature differences into usable electrical power remains a key challenge for ocean-deployed systems. We present a deployable thermomagnetic generator thoroughly characterized for marine-relevant energy harvesting. The device powers an internet-connected sensor and harvests ultra-low temperature differences akin to those at the ocean surface. It draws heat from water and rejects it to ambient air, operating optimally at a temperature difference (ΔT) of ~7.5 °C. Laboratory prototypes generated up to 6.7 mW at ΔT ~ 10 °C with gentle airflow (~1 m s -1 ). A separate controlled wave-tank demonstration validated stable operation and sensor powering under marine-like boundary conditions. Given its voltage and power margins, the generator could sustain multiple sensor nodes. Scalability and material assessments identify modular deployment and non-rare-earth alternatives as pathways toward practical marine energy harvesting and low-grade waste-heat recovery.

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Multi-Port Autonomous Reconfigurable Solar Power Plant

As the penetration level of power electronics increases and remote photovoltaic (PV) generation is integrated into the alternating current (ac) grid, the short-circuit ratio (SCR) at the point of interconnection of a hybrid PV–energy storage system (ESS) plant may be low. Additionally, the inertia of the alternating current (ac) grid may be low. The low SCRs and inertias can lead to reliability challenges in the power grid. These operating conditions require additional reinforcements, such as synchronous condensers, static var compensators, static synchronous compensators, and high-voltage direct current (HVdc) links/grids. HVdc links or grids may also provide the additional capability of connecting the plant to asynchronous grids and/or connecting asynchronous grids, among others. This scenario leads to discrete development of solar inverters, energy storage inverters, HVdc converters, and several transformers. Some of the problems associated with this discrete development and inverter-based generation include increased cost, lower reliability, and reduced efficiency associated with duplication of power electronics (PEs); competing controls of several individual discrete inverter-based generators due to the presence of multiple PEs, which leads to derating of the system; and transient stability problems arising from inverter-based generation, such as voltage/frequency events leading inverter shutdowns, voltage instability and control interactions in the formed weak grid, and harmonics caused by resonances of multiple inverters.

14 SOLAR ENERGY↗
DOE OSTI2024

A Neural Network-Based Power Mismatch Elimination Strategy for Integrated Solar and ESS AC/DC Systems (MARS)

The multiport autonomous reconfigurable solar power plant (MARS) is a promising concept for the integration of photovoltaic (PV) and energy storage system (ESS) to the transmission ac grid and a high-voltage direct current (HVdc) link. The presence of PV and ESS in each arm of the MARS results in uneven distribution of active power among different submodules (SMs), thereby leading to unbalanced SM capacitor voltages and potentially compromising the system stability. Moreover, in the case of partial shadings, shaded PV SMs will suffer from decreased power injections causing power mismatch in the MARS system. To address this issue, a neural-network-based power mismatch elimination (NNPME) strategy is proposed in this article. The proposed NNPME strategy optimizes ESS usage and leverages both dc and ac circulating currents to facilitate power transfer among the SMs, arms, and phases of the MARS system. Simulation and control hardware-in-the-loop (cHIL) experiments demonstrate the effectiveness of the proposed NNPME strategy. Compared with the traditional approaches, the proposed NNPME strategy can significantly enhance system efficiency and ensure stable and continuous operation, even in the presence of uneven power distribution within the MARS system.

14 SOLAR ENERGY↗
NASA NTRS2001

A Study on a Microwave-Driven Smart Material Actuator

NASA s Next Generation Space Telescope (NGST) has a large deployable, fragmented optical surface (greater than or = 2 8 m in diameter) that requires autonomous correction of deployment misalignments and thermal effects. Its high and stringent resolution requirement imposes a great deal of challenge for optical correction. The threshold value for optical correction is dictated by lambda/20 (30 nm for NGST optics). Control of an adaptive optics array consisting of a large number of optical elements and smart material actuators is so complex that power distribution for activation and control of actuators must be done by other than hard-wired circuitry. The concept of microwave-driven smart actuators is envisioned as the best option to alleviate the complexity associated with hard-wiring. A microwave-driven actuator was studied to realize such a concept for future applications. Piezoelectric material was used as an actuator that shows dimensional change with high electric field. The actuators were coupled with microwave rectenna and tested to correlate the coupling effect of electromagnetic wave. In experiments, a 3x3 rectenna patch array generated more than 50 volts which is a threshold voltage for 30-nm displacement of a single piezoelectric material. Overall, the test results indicate that the microwave-driven actuator concept can be adopted for NGST applications.

Choi, Sang H.↗
NASA NTRS2014

SpaceCube v2.0 Space Flight Hybrid Reconfigurable Data Processing System

This paper details the design architecture, design methodology, and the advantages of the SpaceCube v2.0 high performance data processing system for space applications. The purpose in building the SpaceCube v2.0 system is to create a superior high performance, reconfigurable, hybrid data processing system that can be used in a multitude of applications including those that require a radiation hardened and reliable solution. The SpaceCube v2.0 system leverages seven years of board design, avionics systems design, and space flight application experiences. This paper shows how SpaceCube v2.0 solves the increasing computing demands of space data processing applications that cannot be attained with a standalone processor approach.The main objective during the design stage is to find a good system balance between power, size, reliability, cost, and data processing capability. These design variables directly impact each other, and it is important to understand how to achieve a suitable balance. This paper will detail how these critical design factors were managed including the construction of an Engineering Model for an experiment on the International Space Station to test out design concepts. We will describe the designs for the processor card, power card, backplane, and a mission unique interface card. The mechanical design for the box will also be detailed since it is critical in meeting the stringent thermal and structural requirements imposed by the processing system. In addition, the mechanical design uses advanced thermal conduction techniques to solve the internal thermal challenges.The SpaceCube v2.0 processing system is based on an extended version of the 3U cPCI standard form factor where each card is 190mm x 100mm in size The typical power draw of the processor card is 8 to 10W and scales with application complexity. The SpaceCube v2.0 data processing card features two Xilinx Virtex-5 QV Field Programmable Gate Arrays (FPGA), eight memory modules, a monitor FPGA with analog monitoring, Ethernet, configurable interconnect to the Xilinx FPGAs including gigabit transceivers, and the necessary voltage regulation. The processor board uses a back-to-back design methodology for common parts that maximizes the board real estate available. This paper will show how to meet the IPC 6012B Class 3A standard with a 22-layer board that has two column grid array devices with 1.0mm pitch. All layout trades such as stack-up options, via selection, and FPGA signal breakout will be discussed with feature size results. The overall board design process will be discussed including parts selection, circuit design, proper signal termination, layout placement and route planning, signal integrity design and verification, and power integrity results. The radiation mitigation techniques will also be detailed including configuration scrubbing options, Xilinx circuit mitigation and FPGA functional monitoring, and memory protection.Finally, this paper will describe how this system is being used to solve the extreme challenges of a robotic satellite servicing mission where typical space-rated processors are not sufficient enough to meet the intensive data processing requirements. The SpaceCube v2.0 is the main payload control computer and is required to control critical subsystems such as autonomous rendezvous and docking using a suite of vision sensors and object avoidance when controlling two robotic arms.

Xilinx FPGA↗