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Abstract
The LION Navigator, as a standard product line of Airbus Defence and Space, has started a design for manufacturing initiative for switched mode power supplies in the year 2010.An analysis of the overall production effort of power supplies reveals that a high proportion is related to hand soldering of through-hole parts, integration of the PCB into the frame and conventional magnetics which are manufactured with low automatization. A concept study was originated to evaluate the technical prospects for an improved design for manufacturing strategy.The technical approach is related to substitution of remaining through-hole parts by SMD devices if it is economic, to cool Power-SMDs via PCB to structure and, last but not least, to replace conventional magnetics with planar ones, as main part of the study. The windings of planar magnetics are integrated into the PCB with a highly automated process. They provide advantages due to good cooling capability and a low component height but advanced calculation methods are necessary to succeed in the design. As a follow up to the study the development of the power converter for the LION Navigator was started in order to detail the hardware related to an improved design for manufacturing.
Highlights
The surface mount technology was developed by IBM in the 1960s and became widely used in the late 1980s
An analysis of the overall production effort of power supplies reveals that a high proportion is related to hand soldering of through-hole parts, integration of the PCB into the frame and conventional magnetics which are manufactured with low automatization
The technical approach is related to substitution of remaining through-hole parts by SMD devices if it is economic, to cool Power-SMDs via PCB to structure and, last but not least, to replace conventional magnetics with planar ones, as main part of the study
Summary
The surface mount technology was developed by IBM in the 1960s and became widely used in the late 1980s. Power applications were limited that time because PCB technology was not advanced as it is today. Multilayer PCB Technology is a standard with sufficient copper density for space applications as well. This offers the opportunity to integrate magnetics into the PCB. The manufacturing line gains in a reduced manufacturing effort compared to conventional magnetics where enamelled copper wires are wounded on U-, E-, Pot - or Toroid Cores. Planar magnetics have a low height but need more PCB area compared to wire wound standard magnetics. E-Planar cores allow the development of traditional transformers and chokes as well as integrated planar magnetics to achieve optimized core utilization. The development is more oriented towards a prediction of performance with a mathematical approach in order to limit the development time
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