Rugged Power Supply Design
Overview
Design Engineering Capability
Military Experience With High-Efficiency Switch-Mode Converter
- >200 kHz Converter Operation
- Half And Full Bridge For Off Line
- Buck And Boost
- FET Power Switching
- Magnetic Amplifier Post-Regulators For Higher Power
- Linear Post Regulators For Low Power Outputs
Spacecraft Experience With Inherent Radiation Hard Topologies
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Current-fed Push-Pull
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Current-fed Forward
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Current-fed Flyback
System Enhancements
- Built-In Test Signals
- Redundancy
- Control And Status Input/Output
Conservative Mechanical Design
- Full Thermal Analysis, Modeling, Thermal Mapping
- Analysis And Testing For Dynamic And Other Environments
- Hybrids, Surface Mount And Special Packages For High Density
Established EMI Control Procedures
- Full EMI Filtering
- Functional Partitioning And Extensive Shielding
Radiation Hardness Design
Experience With Long Term Radiation Levels
- Designs To Work Through Single Level Upsets
- Neutron, Prompt Gamma, Total Dose And EMP
- Shielding Analysis Including Effect Of Spacecraft
- Tradeoff Between Case Shielding And Component Shielding
Special Protection Against SGEMP
- Case Material Selection
- Low Z Coated Internal Surfaces
Extensive Radiation Database On Components
Component Testing And Circuit Analysis
- Results Of Special Characterization Tests Incorporated In Survivability Analysis
Hardness Verification Testing
- Electronic Box Level
- System Level
Hardness Assurance
- Lot Sampling Of Production Units
- Neutron / Total Dose / Dose Rate / Latch-Up
Computer Aided Design
Electronic Design
- P-Spice For Circuit Simulation
- Syscap With View Logic For Circuit Simulation, Including Radiation Effects
Mechanical Design
- T-Snap For Thermal Analysis
- NISA Finite Element Analysis, Including Stress, Vibration, Shock And Thermal
Engineering Documentation and Control
Documentation Preparation
- Running AutoCad R13 And PADS Power PCB
- Drawing Standards To MIL-STD-100 And MIL-T-31000
- Documentation System (DE-116) And Drawing
- Preparation (DE-108)
Documentation Control
- Documentation Control And Configuration Management Meets MIL-STD-973
- Drawing Release And "Controlled" Distribution Covered By DE-105 And DE-114
- Drawing Change Procedures Covered By DE-100, DE-101 And DE-110
Experience
Recent Programs |
Reliability Experience |
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Manufacturing
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Each test is performed using approved Test Procedures For specific test process see Mfg. Flow Charts |
Quality
Quality Assurance Program
- ISO9001:2001 Certified
- ISO10012-1 Calibration Control Program
- Babcock maintains an advanced Quality Assurance Program that is tailored for high reliability military and aerospace applications. The program is continually reviewed and improved based on new technologies, customer feedback, and active preventive action / lessons-learned programs.
Customer Approvals
Following Customers Have Approved Babcock Quality Program
- Northrop Grumman
- Allied Signal
- Boeing
- Honeywell
- Orbital Sciences Corporation
- Lockheed Martin
- ITT
- Raytheon
Quality Program Highlights
- Quality Assurance organization independent of other functions and active in contract review, design development, manufacturing, end-item delivery, and post delivery support
- Quality Assurance Program emphasizes prevention methodologies, includes on-going supplier qualification, part, material, and process validation, design for manufacturing, continuous training, and utilization of process metrics for continual improvement
- Automated system provides forward and backward traceability of parts and materials to end-item application and provides electronic search and immediate "As-Built" data generation
- Automated in-house calibration system provides electronic tracking, recall, and control of calibration system requirements
Examples
Space Products
Model Number | Description | Program |
EM247/8/9 | DC/DC Converter | MILSTAR |
EM259 | Dual Redundant Data Control Power Supply | DSP |
EM274 | High Density 100 Watt Space Converter | SDI Brilliant Pebbles |
EM274-2 | High Density 100 Watt Space Converter | ROCSAT |
EM282 | HSCC Low Voltage Power Supply | EOS |
EM283 | Thermal Control Subsystem (TCS) Power Supply | DSP |
EM285 | Standard Onboard Space Computer Power Supply | A2100 |
EM286 | Rate Gyro Processor (RGP) HVPS | THAAD |
EM287 | High Voltage Power Supply | IUS |
EM288 | Low Voltage Power Supply | NEAR |
EM290 | Second Color Unit (SCU) Power Supply | DSP |
EM292 | Infrared Processing Unit (IRPU) Power Supply | DSP |
EM293 | High Voltage Power Supply | IUS/SDI |
EM294 | High Voltage Power Supply | PAC-3 |
EM295 | HV/LV Power Supply | MILSTAR II |
EM296 | CTCU Low Voltage Power Supply | P81 |
EM297 | MIMU High Voltage Power Supply | P81 |
EM299 | Tie Converter | ROCSAT |
EM300 | High Density 50 Watt Space Converter | SMTS |
EM304 | TKE Space Converter | EOS |
EM305 | High Density 50 Watt Space Converter | EOS |
EM311 | DC/DC Converter | P81 |
EM314 | Fiber Optic Gyro DC/DC Converter | - |
EM315 | DC/DC Converter | P81 |
EM317 | DC/DC Converter | P81 |
EM318 | DC/DC Converter | P81 |
EM319 | DC/DC Converter | P81 |
EM320 | DC/DC Converter | P81 |
EM328 | DC-DC Converter | - |
Military
Model Number | Description | Program |
EM243 | Avionics AC/DC Converter | F-111 |
EM245 | Transponder DC/DC Converter | B-2 |
EM253 | Multi Output AC-DC Interrogator Power Supply | AB/TPX-54 |
EM259 | Dual Redundant Data Control Power Supply | DSP |
EM278 | Heads Up Display Power Supply | Japan FS-X |
EM280 | RIMU High Voltage Power Supply | Trident Missile |
EM281 | RIMU Low Voltage Power Supply | Trident Missile |
EM284 | IMU High Voltage Power Supply | THAAD |
EM286 | Rate Gyro Processor (RGP) HVPS | THAAD |
EM294 | High Voltage Power Supply | PAC-3 |
EM355 | Computer Power Supply | THAAD |
Custom - DC to DC Brick Converters
Model Number | Description | Output Power | Size (in) |
Weight (gm) |
EM274 | High Density 100 Watt Space Converter | 100 W | 3.75 x 2.90 x 0.65 | 300 |
EM300 | High Density 50 Watt Space Converter | 43.6 W | 3.75 x 2.90 x 0.65 | 215 |
EM305 | High Density 50 Watt Space Converter | 48 W | 3.75 x 2.90 x 0.65 | 215 |
EM314 | Fiber Optic Gyro DC/DC Converter | 35.25 W | 3.50 x 2.75 x 0.75 | 225 |
EM315 | DC/DC Converter | 28.38 W | 3.21 x 2.61 x 0.51 | 150 |
EM317 | DC/DC Converter | 16.09 W | 3.21 x 2.61 x 0.61 | 160 |
EM318 | DC/DC Converter | 41.15 W | 4.00 x 2.75 x 1.25 | 400 |
EM319 | DC/DC Converter | 18.05 W | 3.81 x 2.91 x 0.53 | 190 |
EM320 | DC/DC Converter | 26.86 W | 3.31 x 2.91 x 0.53 | 170 |
EM328 | DC-DC Converter | 2.4 W | 2.50 x 2.00 x 0.50 | 70 |
Custom High Voltage Converters
Model Number | Description | Program |
EM280 | RIMU High Voltage Power Supply | Trident Missile |
EM281 | RIMU Low Voltage Power Supply | Trident Missile |
EM284 | IMU High Voltage Power Supply | THAAD |
EM286 | Rate Gyro Processor (RGP) HVPS | THAAD |
EM287 | High Voltage Power Supply | IUS |
EM293 | High Voltage Power Supply | IUS/SDI |
EM294 | High Voltage Power Supply | PAC-3 |
EM295 | HV/LV Power Supply | MILSTAR II |
EM297 | MIMU High Voltage Power Supply | P81 |
Custom Power Supply Systems
Model Number | Description | Program |
EM247 | DC/DC Converter | MILSTAR |
EM253 | Multi Output AC-DC Interrogator Power Supply | AB/TPX-54 |
EM259 | Dual Redundant Data Control Power Supply | DSP |
EM281 | RIMU Low Voltage Power Supply | Trident Missile |
EM283 | Thermal Control Subsystem (TCS) Power Supply | DSP |
EM290 | Second Color Unit (SCU) Power Supply | DSP |
EM292 | Infrared Processing Unit (IRPU) Power Supply | DSP |
Slice Converters
Model Number | Description | Program |
EM282 | HSCC Low Voltage Power Supply | EOS |
EM285 | Standard Onboard Space Computer Power Supply | A2100 |
EM288 | Low Voltage Power Supply | NEAR |
EM296 | CTCU Low Voltage Power Supply | P81 |
EM304 | TKE Space Converter | EOS |
Legacy Custom Products
Model Number | Description | Output Power | Output Voltages | Size (in) |
Weight (gm) |
EM274 | High Density 100 Watt Space Converter | 100 W | +5, +29, +46, +120 | 3.75 x 2.90 x 0.65 | 300 |
EM300 | High Density 50 Watt Space Converter | 43.6 W | +5.2, +7 | 3.75 x 2.90 x 0.65 | 215 |
EM305 | High Density 50 Watt Space Converter | 48 W | +5, +5.5, +13.5, -13.5, +15, -15 | 3.75 x 2.90 x 0.65 | 215 |
EM314 | Fiber Optic Gyro DC/DC Converter | 35.25 W | +5.3, -5.3 | 3.50 x 2.75 x 0.75 | 225 |
EM315 | DC/DC Converter | 28.38 W | +5.05, -5.05 | 3.21 x 2.61 x 0.51 | 150 |
EM317 | DC/DC Converter | 16.09 W | +7.4, +9.8, -9.8 | 3.21 x 2.61 x 0.61 | 160 |
EM318 | DC/DC Converter | 41.15 W | -2, +5.1, -5.25 | 4.00 x 2.75 x 1.25 | 400 |
EM319 | DC/DC Converter | 18.05 W | +5, -5, -5.9, +6, +11.8 | 3.81 x 2.91 x 0.53 | 190 |
EM320 | DC/DC Converter | 26.86 W | +5, -5, +12 | 3.31 x 2.91 x 0.53 | 170 |
EM328 | DC-DC Converter | 2.4 W | +12, -12 | 2.50 x 2.00 x 0.50 | 70 |
EM329 | DC-DC Converter | 150 W | +5.32 | 5.25 x 4.50 x 0.80 | 600 |