Transcript 223_wilson_pp

MEMS-based Reconfigurable
Manifold Update
Presentation at MAPLD 2005
Warren Wilson‡, James Lyke‡
Joseph Iannotti* and Glenn Forman*
‡Space Vehicle Directorate/Air Force Research
Laboratory
*General Electric Global Research
Motivation for Reconfigurable
Systems
• Maximizes utilization of space assets to allow:
– Recovering from faults (fault-tolerance)
– Reconfiguration after deployment
• Reconstituting / “refocusing” assets for current
•
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mission
• Reconfiguring / “refocusing” assets for
new missions
• Single platform and distributed functionality
Accelerates the possibility of “space-on-demand” by
enabling plug-and-play spacecraft
– Adaptive interfaces to dramatically reduce the time for
development, integration
– Space logistics / remote servicing
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Role of Adaptive Wiring in
Reconfigurable Systems
component
sockets
99.00
Adaptive
Manifold of
Reconfigurable
Interconnections
A/D
3
3000
97.00
2500
Reconfigurable
power
Primary and
Secondary winding
96.00
2000
95.00
1500
94.00
1000
93.00
500
92.00
91.00
E section of
Ferrite core
0
50
100
150
200
250
150
200
250
b
c
MATRIX OF EMBEDDED SWITCHES
a
MATRIX OF EMBEDDED SWITCHES
Height (mils)
Low Profile Magnetics
a. Disk-type transformer
b. Tube-type transformer
c. Power density/Efficiency
vs. height for 50W transformer
at 1MHz switching frequency
(footprint = 0.3in2)
A/D
Reconfigurable
D/A
analog
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3500
disk-type
tube-type
98.00
I section of
Ferrite core
Efficiency (%)
Reconfigurable
digital
Power density (W/in )
connectors
Reconfigurable
D/A microwave
3
discrete
component
patchboard
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Reconfigurable analog
•
Programmable analog architectures
– Configurable process chains
• Alter gain, offset, filtration characteristics
– Configurable analog blocks
• Permits flexible arrangement of some analog
building blocks
•
Limitations
– Frequency of operation
– Ranges of resistances, capacitances require
supplemental, external, non-programmable discrete
components
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Reconfigurable Power
•
Permit alteration of input voltage, output voltage, and
load conditions under software control
– maintain optimal electrical efficiency under
variations
• Industry practice
– Some configurable power technologies permit
modular power supplies by manual arrangement of
discrete building blocks (e.g., Lambda)
– Smart-power approaches in microprocessors and
FPGAs to permit different supply and I/O voltage
levels
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Reconfigurable Microwave
•
Emergent techniques
– Direct digital synthesis (generated modulated
carrier directly in real-time)
– Reconfigurable antenna
• Electronically steerable antenna
• MEMS-based antenna reshaping
• Other techniques to modify dielectric / conductor
configurations of antenna under software control
– Software radio
• Minimize non-digital content of RF systems,
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permit agile manipulation of radio protocols for
transceivers
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Conventional Spacecraft Avionics
C & DH
Processor
Interface Card
Payload (s)
COMM
Bus
GNC
GNC
Interface Card
Interface Card
GNC
PMAD
telemetry
Interface Card
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Reconfigurable Spacecraft Avionics
FP
MSP
MSP
MSP
SpaceWire
Adaptive
Wiring
Manifold
SpaceWire
Plug-and-play
network
FP
FP
FP
FP
FP
FP
FP
SpaceWire
MSP
Software
Radio
SpaceWire
Optical
Sensor
FP
FP
FP
FP
Legacy components
comp.
comp.
Space
-wire
Sensor
Sensor
Sensor
Sensor
Sensor
Sensor
Sensor
MSP
SpaceWire
Sensor
COMM
Sensor
Interface
Sensor
Interface
Sensor
C&DH
Sensor
Sensor
MSP = Malleable Signal Processor
FP = Fusion Processor
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Compact PCI bus
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Command & Data Handling
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Adaptive Manifold
•
Reconfigurable switch manifold used to program front
end electronics and signal/processing paths of a
satellite
– Enabling the ability to break or make conductive pathways at
will
– Permit maximal use of a scarce satellite resource
– Effectively re-route the signal paths to optimize the
extractable data
– Correct defects found during construction/integration/mission
•
Applied as the interface of self-configuring systems,
the idea would be equivalent to an advanced plug-andplay
– where choice of each pin location and its impedance
characteristics could be re-definable at will
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Adaptive Manifold II
• Such a manifold would required
– Locally embedded relays: hundreds or thousands of switches
distributed among a circuit's interconnections
– A configuration control system: which would set the “0s” and “1s”
of each particular relay
•
E.g., programmed by a bitstream generation process
–
Currently used in certain digital field programmable gate array (FPGA)
system
• A MEMS-based “smart substrate” can handle signals with extreme
excursions in amplitude and frequency
–
The complete separation of the switched circuit from the switching circuit
is an advantage when cascading switches within the manifold
–
The MEMS switches can operate under voltage constrains that would take
a transistor switch out of saturation, or worse, cause device breakdown
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Conventional vs. Adaptive Wiring
Manifold
Box
Box
Box
Box
Box
Box
Box
Box
Box
Box
open
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closed
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Programmable Connections
A
B
C
D
M
N
O
P
A
B
C
D
M
N
O
P
E
F
G
H
Q
R
S
T
E
F
G
H
Q
R
S
T
I
J
K
L
U
V
W
X
I
J
U
V
W
X
switchbox
Program A-P connection
switch
A
B
C
D
M
N
O
P
E
F
G
H
Q
R
S
T
I
J
K
L
U
V
W
X
•
AWM combines wiring, switches,
and control to make arbitrary
terminal-to-terminal connectivity
possible in a wiring system
•
Program switches using routing
heuristics
Program A-P,C-K, F-Q-S connections
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Adaptive Manifolds
• Approaches to embed large
28VDC
5VDC
+15VDC
-15VDC
Program
VDC
COMM_1
COMM_2
Analog_1
Analog_2
Diagnostic
numbers of micro-relays into
packages, boards, and wiring
harness
• Strategies for reconfiguration
• Algorithms for altering system
configurations
– Satellite itself becomes a
large “field programmable
device”
• Concepts for repair-ability and
Smart-wiring based avionics system
extensibility
• Disciplines for design and
application of reconfigurable
systems
Dockable-assemblies
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Satellite-asa-device
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Payload Attachment Points
and Switch Resource Distribution
Mounting site
Latching
Digital (FPID) – 75%
switchbox
MEMS – 10%
switchbox
Solid state power – 10%
switchbox
switchbox
Macro EM – 5%
fixed
•
switchbox
Mounting site
switchbox
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Example population strategy
Mounting sites contain terminals
connected to one of six types of
wiring resources
–
Four wiring types (volatile and
non-volatile, MEMS, nonMEMS)
–
–
Fixed (common connections)
switchbox
switchbox
switchbox
switchbox
fixed
•
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Configuration (future)
Wiring resources contained in
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switchboxes
Summary of switch requirements
for an adaptive manifold
• Bistable / multistable
• Electrical performance
–
–
–
Low resistance
High bandwidth
High-isolation (low
crosstalk)
• Hot-switching
–
High melting contacts
Mechanical performance
• 50 micron gap
•Sets maximum switching voltage
• 2 micron thick gold alloy contracts
•Sets lifetime under hot switching
• 0.2 m/s contact velocity
•Related to hot switching lifetime
• 70 mΩ constriction resistance
•Sets maximum cold current
• 50/200 μs lag open/close time
•Sets maximum relay duty cycle
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Latching Relay Requirements
Design Goals
Logic Switch Manifold
Configuration Switch
Manifold
Power Bus Switch
Manifold
Constriction resistance
<1Ω
< 50 mΩ
< 8 mΩ
Configuration
SPST, switchyard
SPDT, SPMT, switchyard
SPST
Switch density (#/mm2)
> 100
> 10
>1
Energy to switch
< 0.1 mJ
< 1 mJ
< 1 mJ
Hot switching capabilities
TTL levels
15V @ 100 mA
10 V @ 1 A
Current handling
capabilities
TTL levels
1A
10 A
Lifetime (cycles)
> 107
> 106
> 104
Time to switch
< 100 μs
< 1 ms
< 10 ms
0↔1
0↔1
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Magfusion’s RF Latching Relay
Fixed contact
pad
Moving contact
pad
Torsion suspensions
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Coil contracts
Moving contact
(teeter-totter)
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Design of Avionics Manifold
• Design is to arbitrarily connect among 3 payloads and 4 ports
– The ports connect to additional panels
– Each payload allows 12 connections: 10 RF, 2 power
• Construct a macro-relay version of a simple manifold
– 260 latching MEMS RF metal-to-metal relays in a “mesh”
configuration
– 10 latching macro DC metal-to-metal relays to supply high current
power
– Circuit board on printed wiring board (10 layers)
• Expected benefits
– Development of control circuitry
– Establish software algorithms and user-interface
– Examine scaling issues
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Circuit design for demo AWM
•
Circles represent connections
–
–
North
Payload 1
•
East
Payload 2
•
West
Filled: fixed connections
Each line represents a set of
individually switched circuits
elements
–
–
South
Payload 3
Open: selectable connections
2 power, 10 RF, and logic
Compromise configuration
Limitation on number of MEMS
RF switches available
–
N(N-1)/2 = >2,000 switches
•
–
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N = (3+4)*10
Demo configuration used only
260 MEMS RF latching
switches
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Implementation of AWM demo
Magfusion Switch
Switchbox
ASIC
(ATK/MRC
under AFRL
Support)
Other MEMS
Switches
•
Manifold is a panel based on
flexible circuitry
•
“Payload sites” serve as
points to mount subsystems
or complex components
•
Switchboxes are small
circuit boards containing
–
–
Switchbox
PAYLOAD
SITE
CPU
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Panel
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Control ASIC
•
Microcontroller (CPU) used
to manage switchbox
configurations (e.g. JTAG
interface or Robust USB)
•
Multiple panels can
communicate partial
configurations to form
composite adaptive wiring
assemblies
PAYLOAD
SITE
PAYLOAD
SITE
MEMS switches
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AWM Components
ASIM (Appliqué Sensor Interface Module)
Front/back sides of Switchcard
Payload Interface (USB, xTEDS)
Video Capture over SPA-S, VideoPC_TV over SPA-U, Space-Cube
and GPS Demonstration on One
Panel: Meets Transfer Rates!
R-USB configuration network
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AWM Panel Configuration with
Payload Cards
AWM USB Configuration Interface (bottom side)
Input for
configuration
and spacecraft
power
Payload Interface Card
Panel to panel
Connector
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One of 13 Switch Module Cards
(using 10 latching Magfusion relays,
2 latching macro power switches
relays mounted on underside of card)
SpaceWire
Port
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USB
Port
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Back View AWM Panel Configuration
USB1.1 Hub card
for on and off panel
enumeration/control
Switch Module Card
(10 Magfusion Switches)
(Total of 4 installed on bottom)
AWM USB1.1 Configuration Interface
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AWM Demo
Display:
SPACEBALL rotating
cube
NI Frame Grabber
1st Space Wire Board
SPACEBALL 3DM-GX1
1 Distinct SpaceWire interconnect routed via AWM for
payload to payload interconnect
DVD 2 Distinct USB routes:
player TEDS – USB 1.1 TEDS interface used for enumeration and control
USB – USB 1.1 (2.0 capable) interface routed via AWM
for payload to payload interconnect
2nd PC running Display2
OPC NORTH
Display:
DVD movie
PAY 1
OPC EAST
PAY 2
OPC WEST
Display:
AWM
CONFIGURATION
GUI
Panel 1
PAY 3
TEDS
(host)
OPC SOUTH
2nd Space Wire Board
OPC NORTH
PAY 1
3DM-GX1
Inclinometer &
Orientation Sensor
OPC EAST
Panel 2
PAY 2
OPC WEST
PC running AWM
CONFIG. SW (not
needed once system
configured)
PAY 3
Optional TEDS Port
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All panels, switch cards and
hub cards are identical
Payload cards are similar but have
unique ID for function identification
TEDS
(slave)
OPC SOUTH
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RF Characteristics of AWM
2.7 GHz Diff Eye thru Switchcard and 15 inch of PCB
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RF Characteristics of AWM
2.7 GHz Diff Eye Cables Alone
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Take Away Items from AWM Demo
•
All passive (Relay) AWM will have length limitations
that impact desired high speed SpaceWire
performance
•
Latching switches are desirable but have seen issues
with available array density
•
“Electronic” (FPIDS, FPGA’s, etc...) can provide
configurable I/O’s and signal regeneration while
providing adaptive routing features
•
System architecture may include optical interconnect
for “Long Hauls”; thru an entire panel, acts as repeater
as well
•
All passive backplane gives flexibility and
producibility
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Take Away Items from AWM Demo
•
Physical location/orientation of panels provide
challenge in AWM routing
•
USB1.1 is convenient but has issues in this
application with respect to upstream-downstream
•
At high speeds, un-terminated stubs due to unused
routes are not tolerated
•
Higher density switching hardware minimizes stub
length and as such minimizes number of switches
needed
• SpaceWire standard needs more work in the area of:
– Tx and Rx mask spec
– Acceptable Interconnect Degradation spec
– Interoperability spec
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Summary
•
Hopefully, AWM may do for spacecraft what FPGAs do
for digital microelectronics
•
AWM is a ready consumer of MEMS relays
– Excellent vehicle to study large-scale reliability
• AWM will provide a meaningful set of ground and
space experiments
– Not limited to RF
– Expected to have many non-space applications
•
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The AWM concept is to be included and further
developed in the responsive technology test cell
located in the Responsive Space Testbed at the AFRL
Space Vehicle Directorate, Kirtland AFB, NM
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RE-CONFIGURABLE/ADAPTIVE
MANIFOLD
28VDC
payload
attachment
point
5VDC
+15VDC
-15VDC
Switch
boxes
Program
VDC
high density
interconnect
between
switchboxes
Spacecraft
bus
Subsystems
COMM_1
configuration
management
processor
CMP
COMM_2
•Debug support (temporary probe wires)
Analog_1
•On-orbit rewiring (fault, defect rectification)
Analog_2
•Reliability and utility of MEMS switches
Diagnostic
Phase 1 – Construct exerciser panel; establish
specs for switchboxes compatible with testable
switches
Phase 2 – Create space MEMS switch reliability
experiment with diagnostics; require several
hundred switches; 12-month spaceflight / Tacsat 4
(2007 launch)
Phase 3 – Create non-toy space experiment
based on adaptive wiring manifold; include at
least four payload attachment sites; 12-month
spaceflight / Tacsat 5 (2008 launch)
Generic Adaptive Wiring Manifold Architecture
Objective is to Demonstrate:
•Rapid payload integration
•Space system reconfiguration
•Systems on-orbit protection
•Self-organizing sensor network
•Adaptive MEMS-based wiring manifold
•Reconfigurable RF system
•Self-aware cognitive software
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Concept: A software-definable wiring system
•Pre-built (into structures), rapidly-programmable
•Can be modified in orbit
Benefits:
•Rapid integration on ground
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