Design of Wide Range Input and Output Beam Power Supply for Ion Electric Propulsion

Abstract

The power processing unit（PPU）of ion electric propulsion system on the deep space detector needs to adapt to wide range voltage input，wide range voltage output and wide range power output，which results in the increase of component stress， volume and weight and decrease of efficiency of PPU. According to the requirements of grid power supply for ion electric propulsion PPU of small objects detector in China，the input voltage is 60 ~ 110 V，the output voltage is 420 ~ 1 260 V，and the output current is 0.3 ~ 2.1 A. In this paper, the design of grid power supply is studied from the aspects of power module decomposition，soft switching topology selection，single-stage power converter topology design and two-stage power converter topology design. A comprehensive optimization scheme in efficiency，volume and reliability is proposed. The physical verification of the design of single power module of grid power supply is carried out. The results show that the optimized module decomposition and fixed output voltage can effectively reduce the component stress，optimize the efficiency of the converter working point and improve the reliability of the converter；when using the single-stage phase shifted full bridge and full bridge LLC to design wide range input converters，there are still some problems，such as high stress of semiconductor power components，high capacitance stress，and difficult processing of magnetic components；the buck / boost + full bridge LLC two-stage topology scheme can simplify the stress of high-voltage rectifier circuit and adapt to wide range input. It is a preferred scheme for wide range input and output Beam power supply.

Keywords

deep space explorer / electric propulsion / power processing unit / PPU / beam power supply

References

[1] 叶培建,彭兢. 深空探测与我国深空探测展望[J]. 中国工程科学,2006,8(10):13-18
YE P J,PENG J. Deep space exploration and its prospect in China[J]. Engineering Science,2006,8(10):13-18
[2] 雷英俊,朱立颖,张文佳. 我国深空探测任务电源系统发展需求[J]. 深空探测学报,2020,7(1):35-40,46
LEI Y J,ZHU L Y,ZHANG W J. Research on power system development of Chinese deep space exploration[J]. Journal of Deep Space Exploration,2020,7(1):35-40,46
[3] 汤海滨，刘宇. 深空探测主推进——电推进选择及其关键技术[C]//2002年深空探测技术与应用科学国际会议论文集. 北京：中国宇航学会，中国科学院，2002.
[4] 杭观荣,康小录. 电推进在深空探测主推进中的应用及发展趋势[J]. 火箭推进,2012,38(4):1-8+48
HANG R G,KANG X L. Application and development trends of electric propulsion in deep-space primary propulsion[J]. Journal of Rocket Propulsion,2012,38(4):1-8+48
[5] 牛厂磊,罗志福,雷英俊,等. 深空探测先进电源技术综述[J]. 深空探测学报,2020,7(1):24-34
NIU C L,LUO Z F,LEI Y J,et al. Advanced power source technology of deep space exploration[J]. Journal of Deep Space Exploration,2020,7(1):24-34
[6] 王文强,杨洪东,杨广,等. 太阳电池阵深空探测适应性设计概论[J]. 深空探测学报,2020,7(1):41-46
WANG W Q,YANG H D,YANG G,et al. Solar cell array design for deep space exploration missons[J]. Journal of Deep Space Exploration,2020,7(1):41-46
[7] 李宗良,高俊,刘国西,等. 小行星探测电推进系统方案研究[J]. 深空探测学报,2018,5(4):347-353
LI Z L,GAO J,LIU G X,et al. Study on the electric propulsion system for asteroid detection[J]. Journal of Deep Space Exploration,2018,5(4):347-353
[8] 杨福全,赵以德,李娟,等. 主带小行星采样返回任务中的离子电推进应用方案[J]. 深空探测报,2015,5(2):168-173
YANG F Q,ZHAO Y D,LI J,et al. Application scheme of ion electric propulsion system for main-belt asteroid sample and return mission[J]. Journal of Deep Space Exploration,2015,5(2):168-173
[9] 孙小菁,张兴民,田立成,等. 小行星探测及采样返回任务电推进系统方案设计[J]. 真空,2018,55(1):40-45
SUN X J,ZHANG X M,TIAN L C,et al. Scheme design of electric propulsion system for asteroid sample and return mission[J]. Vacuum,2018,55(1):40-45
[10] 郑茂繁,耿海,梁凯,等. 用于小行星探测的离子推力器技术研究[J]. 深空探测学报,2015,2(3):236-240
ZHENG M F,GENG H,LIANG K,et al. Research on ion thruster technology for asteroid exploration[J]. Journal of Deep Space Exploration,2015,2(3):236-240
[11] 赵以德,张天平,黄永杰,等. 40 cm离子推力器功率宽范围工作实验研究[J]. 推进技术,2018,39(4):942-947
ZHAO Y D,ZHANG T P,HUANG Y J,et al. Experimental study of 40 cm ion thruster over a wide range of input power[J]. Journal of Propulsion Technology,2018,39(4):942-947
[12] 朱立颖,刘治钢,张晓峰. 国外小天体探测器电源系统设计分析[J]. 航天器工程,2018,27(1):130-136
ZHU L Y,LIU Z G,ZHANG X F. Analysis on power system design of probe for small celestial body[J]. Spacecraft Engineering,2018,27(1):130-136
[13] GOLLOR M，BOSS M，HERTY F，et al. Generic High Voltage Power Supplies （HVPS） with optimum efficiency and multi-range[C]//30^th International Electric Propulsion Conference. Florence， Italy：[s. n.]，2007.
[14] PINTó F，PALENCIA J. Airbus defence and space power processing units：new HET and GIT PPU developments qualification status[C]// The 35th International Electric Propulsion Conference. USA：[s. n.] ，2017.
[15] BOURGUIGNON E，FRASELLE S，SCALAIS T，et al. Defise. Power processing unit activities at Thales Alenia Space Belgium （ETCA）[C]//The 34th International Electric Propulsion Conference. Hyogo-Kobe， Japan：International Electric Propulsion Conference，2015.
[16] KOMURASAKI K. Overview of electric propulsion activities in Japan[C]//43rd AIAA/ASME/SAE/ASEE Joint Propulsion Conference & Exhibit. Cincinnati. Ohio，USA，American： AIAA，2007.
[17] KUNINAKA H，PAKHOMOV A V. Microwave discharge ion engines onboard Hayabusa asteroid explorer[J]. Aeronautical & Space Sciences Japan, 2008，997：572-581.
[18] KUNINAKA H,FINK W,KAWAGUCHI J. Deep space flight of Hayabusa asteroid explorer[J]. Proceedings of SPIE —the International Society for Optical Engineering,2008,6960:696002
[19] NAKAYAMA Y,FUNAKI I,KUNINAKA H,et al. Experimental evaluation of miniaturized ion thruster with microwave discharge[J]. Journal of the Japan Society for Aeronautical & Spaceences,2005,53(621):461-466
[20] KENICHIKA H，OSUGA H，TERUKINA I，et al. Development status of high voltage power supply for a 20 mN class ion thruster：IEPC-2011-183[R]. [S.l.]：IEPC，2011.
[21] POLK J，KAKUDA R，ANDERSON J，et al. Validation of the NSTAR ion propulsion system on the Deep Space Onse mission - overview and initial results[C]//Joint Propulsion Conference & Exhibit. Los Angeles，California，USA：AIAA，1999.
[22] RAWLIN V，SOVEY J，HAMLEY J，et al. An ion propulsion system for NASA's Deep Space missions[C]// Space Technology Conference & Exposition. San Diego，California，USA：AIAA，2013.
[23] BOND T A，BENSON G，CARDWELL G I，et al. NSTAR Ion engine power processor unit performance：ground test and flight experience[C]//37th Aerospace Sciences Meeting and Exhibit. Reno，Nevada，USA：AIAA，1999.
[24] BROPHY J. The Dawn ion propulsion system[J]. Space Science Reviews,2011,163(1-4):251-261
[25] BROPHY J R，MARCUCCI M G，GANAPATHI G B，et al. The ion propulsion system for Dawn[C]//41st AIAA Aerospace Sciences Meeting. Reno，Nevada，USA：AIAA，2003.
[26] 阮新波. 脉宽调制DC/DC全桥变换器的软开关技术[M]. 北京：科学出版社，2013.
[27] YANG B，LEE F C，ZHANG A J，et al. LLC resonant converter for front end DC/DC conversion[C]// APEC. Seventeenth Annual IEEE Applied Power Electronics Conference and Exposition. [S.l.]：IEEE，2002.
[28] SONG T T,HUANG N C,IOINOVICI A. A family of Zero-Voltage and Zero-Current-Switching (ZVZCS) three-level DC–DC converters with secondary-assisted regenerative passive snubber[J]. IEEE Transactions on Circuits and Systems,2005,52:2473-2481
[29] KIM E S,KIMY H. A ZVZCS PWM FB DC/DC converter using a modified energy-recovery snubber[J]. IEEE Transactions on Industrial Electronics,2002,49:1120-1127
[30] CHO J G,BAEK J W,JEONG C Y,et al. Novel zero-voltage and zero-current-switching full-bridge PWM converter using a simple auxiliary circuit[J]. IEEE Transactions on Industrial Electronics,1999,35:15-20
[31] CHOI H S. Design consideration of half-bridge LLC resonant converter[J]. Journal of power electronics,2007,7(1):13-20
[32] 吴中民,刘威,吕征宇. LLC全范围满载软开关优化设计[J]. 浙江大学学报(工学版),2014,48(12):2223-2229
WU Z M,LIU W,LV Z Y. Optimal design of zero voltage switch of LLC in full range and full load[J]. Journal of Zhejiang University (Engineering Science),2014,48(12):2223-2229
[33] 钟运平,程小华,张勇,等. 半桥LLC谐振变换器参数优化设计[J]. 磁性材料及器件,2014(2):53-57
ZHONG Y P,CHENG X H,ZHANG Y,et al. Optimal design of parameters of half-bridge LLC resonant converter[J]. Journal of Magnetic Materials and Devices,2014(2):53-57