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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 • Wilson 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 2 MAPLD 2005/P223 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 Wilson 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 MAPLD 2005/P223 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 Wilson 4 MAPLD 2005/P223 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 Wilson 5 MAPLD 2005/P223 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, Wilson permit agile manipulation of radio protocols for transceivers 6 MAPLD 2005/P223 Conventional Spacecraft Avionics C & DH Processor Interface Card Payload (s) COMM Bus GNC GNC Interface Card Interface Card GNC PMAD telemetry Interface Card Wilson 7 MAPLD 2005/P223 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 Wilson Compact PCI bus 8 Command & Data Handling MAPLD 2005/P223 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 Wilson 9 MAPLD 2005/P223 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 Wilson 10 MAPLD 2005/P223 Conventional vs. Adaptive Wiring Manifold Box Box Box Box Box Box Box Box Box Box open Wilson 11 closed MAPLD 2005/P223 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 Wilson 12 MAPLD 2005/P223 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 Wilson Satellite-asa-device 13 MAPLD 2005/P223 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 Wilson 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 • 14 Configuration (future) Wiring resources contained in MAPLD 2005/P223 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 Wilson 15 MAPLD 2005/P223 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 Wilson 16 MAPLD 2005/P223 Magfusion’s RF Latching Relay Fixed contact pad Moving contact pad Torsion suspensions Wilson 17 Coil contracts Moving contact (teeter-totter) MAPLD 2005/P223 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 Wilson 18 MAPLD 2005/P223 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 • – Wilson 19 N = (3+4)*10 Demo configuration used only 260 MEMS RF latching switches MAPLD 2005/P223 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 Wilson Panel 20 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 MAPLD 2005/P223 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 Wilson 21 MAPLD 2005/P223 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 Wilson One of 13 Switch Module Cards (using 10 latching Magfusion relays, 2 latching macro power switches relays mounted on underside of card) SpaceWire Port 22 USB Port MAPLD 2005/P223 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 Wilson 23 MAPLD 2005/P223 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 Wilson All panels, switch cards and hub cards are identical Payload cards are similar but have unique ID for function identification TEDS (slave) OPC SOUTH 24 MAPLD 2005/P223 RF Characteristics of AWM 2.7 GHz Diff Eye thru Switchcard and 15 inch of PCB Wilson 25 MAPLD 2005/P223 RF Characteristics of AWM 2.7 GHz Diff Eye Cables Alone Wilson 26 MAPLD 2005/P223 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 Wilson 27 MAPLD 2005/P223 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 Wilson 28 MAPLD 2005/P223 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 • Wilson 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 29 MAPLD 2005/P223 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 Wilson Concept: A software-definable wiring system •Pre-built (into structures), rapidly-programmable •Can be modified in orbit Benefits: •Rapid integration on ground 30 MAPLD 2005/P223