Crossover Power Processing for Satellite Thruster Redundancy

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Solution Overview

Problem

Existing satellite thruster systems often fail to provide adequate redundancy in power processing units, leading to potential system failures when one unit ceases to function.

Innovation Solution

A spacecraft propulsion system is designed with a crossover switching unit that connects two power processing units to two thruster strings, allowing each power processing unit to control both thruster strings in case of failure, thereby providing crossover redundancy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wholly redundant systems with two distinct sets of thrusters and power processing units are used, then reliability is improved, but device complexity increases

Engineering Contradiction:
Improvesystem reliabilityVSAvoidsystem complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements a universal power processing architecture where a single power processing unit can serve multiple thruster strings through crossover capability. The controller is designed to dynamically allocate power processing resources across different thruster strings, allowing one unit to take over another's function if needed, thereby providing redundancy without requiring completely separate dual systems.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the power processing functions by allowing a single power processing unit to control multiple thruster strings. The controller integrates the management of multiple thrusters and power processing units into a unified system, enabling resource sharing and flexible allocation while maintaining system redundancy.

Inventive Principle:
Principle #5Merging (Combining)

2Device complexity

If power processing units are designed to cease functioning upon power supply failure, then device complexity is reduced, but reliability deteriorates

Engineering Contradiction:
Improvepower processing unit complexityVSAvoidthruster system reliability
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent implements beforehand cushioning by designing power processing units with the capability to handle power supply failures in advance. The units are equipped with fault detection and recovery mechanisms that allow them to maintain operation or seamlessly transfer control to another unit when power supply issues occur, preventing complete system failure.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent employs parameter changes by allowing power processing units to dynamically adjust their operational parameters based on power supply conditions. When faced with power supply failures, the units can change their operating mode, reduce power consumption, or redistribute resources to maintain critical functions, rather than simply ceasing operation.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS12286244B2Satellite including crossover power processing units for electric thrusters
Publication Date: 2025.04.29 AEROJET ROCKETDYNE INC
  • US12286244B2 patent drawing
  • US12286244B2 patent drawing
  • US12286244B2 patent drawing

AI summary

A spacecraft propulsion system including a first thruster system including a first power processing unit connected to a first thruster string via a crossover switching unit and connected to a second thruster string via the crossover switching unit. A second thruster system including a second power processing unit connected to the second thruster string via the crossover switching unit and to the first thruster string via the crossover switching unit. A controller is connected to each of the first power processing unit, the second power processing unit, and the crossover switching unit.