It has been designed to meet specific electrical, thermal, and mechanical requirements defined at the system level and can be adapted to meet any set of customer specifications.
Exxelia's new Smart Integrated Magnetics solution combines the transformer and inductor of a double active bridge (DAB) into a single, compact magnetic assembly. This integrated approach aims to reduce the volume, mass, and complexity of interconnections while maintaining electrical performance at high switching frequencies. The intended application is isolated DC-DC power conversion in space-grade PCDUs, where efficiency, reliability, and mechanical robustness are key design factors.
From a technical standpoint, this Smart Integrated Magnetic solution is designed for a power level of 1 to 2 kW at a switching frequency of 100 to 200 kHz (example). The associated inductor provides an inductance of a few µH. The assembly achieves an efficiency level close to 99% under nominal operating conditions, reflecting careful optimization of the core materials, winding architecture, and magnetic coupling. Particular attention has been paid to losses and thermal behavior, which are critical in environments with low convection.
Mechanical integration was a key aspect of the development. The complete magnetic solution fits into a flat, low-profile package measuring approximately 75 × 65 × 20 mm, with a total weight of around 250 g. This compact form factor is designed for easy integration into densely populated power electronics modules, while also providing the necessary resistance to the mechanical stresses typically encountered during launch and operation. The design was tailored to meet the severe environmental constraints, including thermal cycling and mechanical loading, characteristic of space applications. Material selection, impregnation processes, and structural design were all adapted accordingly to ensure long-term stability and compliance with qualification requirements.
Although the solution presented here is specific to a particular program and set of constraints, it reflects a broader approach that can be adapted to other high-reliability applications requiring compact, efficient, and integrated magnetic designs.
