MEMS-based Reconfigurable Manifold Update Presentation at MAPLD 2005

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

2Wilson MAPLD 2005/P223

Motivation for Reconfigurable Systems

• Maximizes utilization of space assets to allow:

– Recovering from faults (fault-tolerance)

– Reconfiguration after deployment

• Reconstituting / “refocusing” assets for current 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


Role of Adaptive Wiring in Reconfigurable Systems

AdaptiveManifold of

Reconfigurable Interconnections

componentsockets

Reconfigurabledigital

Reconfigurableanalog

A/D

D/A Reconfigurablemicrowave

A/D

D/A

connectors

Reconfigurablepower

discretecomponentpatchboard

MA

TR

IX O

F E

MB

ED

DE

D S

WIT

CH

ES

MA

TR

IX O

F E

MB

ED

DE

D S

WIT

CH

ES


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


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


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, permit agile manipulation of radio protocols for transceivers


C & DHProcessor

Interface Card

Interface Card

Interface Card

Interface Card

B

u s

COMM

GNC

GNC

GNC

PMAD

telemetry

Payload (s)

Conventional Spacecraft Avionics

8Wilson MAPLD 2005/P223Command & Data Handling

AdaptiveWiring

Manifold

MSP

Sp

aceWire

Sp

aceWire

Sp

aceWire

Sp

aceWire

Sp

aceWire

Optical Sensor

Optical Sensor

C&

DH

Inte

rfac

e

Inte

rfac

e

CO

MM

Compact PCI bus

comp. comp.

Legacy components

Software Radio

Software Radio

SensorSensor

SensorSensor

SensorSensor

SensorSensor

SensorSensor

SensorSensor

SensorSensor

SensorSensor

SensorSensorSensorSensor

SensorSensor

SensorSensor

SensorSensor

MSP

MSP

MSP

MSP

Space-wire

FP

FP

FP

FP

FPFPFP

FP

FP

FP

FPFP

MSP = Malleable Signal ProcessorFP = Fusion Processor

Plug-and-play network

Reconfigurable Spacecraft Avionics


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-and-play

– where choice of each pin location and its impedance characteristics could be re-definable at will


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


Conventional vs. Adaptive Wiring Manifold

Box

Box

Box

Box

Box Box

Box

Box

Box

Box

open closed


Programmable Connections

• AWM combines wiring, switches, and control to make arbitrary terminal-to-terminal connectivity possible in a wiring system

• Program switches using routing heuristics

ABCD

EFGH

IJKL

MNOP

QRST

UVWX

switchboxswitch

ABCD

EFGH

IJKL

MNOP

QRST

UVWX

switchboxswitch

ABCD

EFGH

IJ

MNOP

QRST

UVWX

ABCD

EFGH

IJ

MNOP

QRST

UVWX

ABCD

EFGH

IJKL

MNOP

QRST

UVWX

ABCD

EFGH

IJKL

MNOP

QRST

UVWX

Program A-P connection

Program A-P,C-K, F-Q-S connections


Adaptive Manifolds

• Approaches to embed large 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 extensibility

• Disciplines for design and application of reconfigurable systems

28VDC

5VDC

-15VDC

ProgramVDC

Analog_2

Diagnostic

COMM_1

COMM_2

+15VDC

Analog_1

Smart-wiring based avionics system

Dockable-assemblies Satellite-as-a-device


Payload Attachment Pointsand Switch Resource Distribution

• Mounting sites contain terminals connected to one of six types of wiring resources

– Four wiring types (volatile and non-volatile, MEMS, non-MEMS)

– Fixed (common connections)

– Configuration (future)

• Wiring resources contained in switchboxes

Digital (FPID) – 75%

MEMS – 10%

Solid state power – 10%

Latching

Macro EM – 5%

Example population strategy

switchbox

switchbox

switchbox

switchbox

switchbox

switchbox

switchbox

switchbox

switchbox

Mou

ntin

g si

teM

ount

ing

site

fixed

fixed

switchbox


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


Latching Relay Requirements

Design Goals Logic Switch Manifold Configuration Switch Manifold

Power Bus Switch Manifold

Constriction resistance < 1 Ω < 50 mΩ < 8 mΩ

Configuration SPST, switchyard SPDT, SPMT, switchyard SPST

Switch density (#/mm2) > 100 > 10 > 1

Energy to switch

0 ↔ 1

< 0.1 mJ < 1 mJ < 1 mJ

Hot switching capabilities TTL levels 15V @ 100 mA 10 V @ 1 A

Current handling capabilities

TTL levels 1 A 10 A

Lifetime (cycles) > 107 > 106 > 104

Time to switch

0 ↔ 1

< 100 μs < 1 ms < 10 ms


Fixed contact

pad

Moving contact

(teeter-totter)

Coil contracts

Torsion suspensions

Moving contact

pad

Magfusion’s RF Latching Relay


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


Circuit design for demo AWM

• Circles represent connections

– Open: selectable connections

– Filled: fixed connections

• Each line represents a set of individually switched circuits elements

– 2 power, 10 RF, and logic

– Compromise configuration

• Limitation on number of MEMS RF switches available

– N(N-1)/2 = >2,000 switches

• N = (3+4)*10

– Demo configuration used only 260 MEMS RF latching switches

North

Payload 1

East

Payload 2

South

Payload 3

West


Implementation of AWM demo

• 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

– MEMS switches

– 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

Switchbox

Panel

CPUCPU

PAYLOADSITE

PAYLOADSITE

PAYLOADSITE

SwitchboxASIC

(ATK/MRCunder AFRL

Support)

Magfusion Switch

Other MEMSSwitches


Video Capture over SPA-S, Video-PC_TV over SPA-U, Space-Cube and GPS Demonstration on One

Panel: Meets Transfer Rates!

AWM Components

R-USB configuration network

ASIM (Appliqué Sensor Interface Module)Payload Interface (USB, xTEDS)

Front/back sides of Switchcard


AWM Panel Configuration with Payload Cards

Input for configuration and spacecraft power

One of 13 Switch Module Cards(using 10 latching Magfusion relays, 2 latching macro power switchesrelays mounted on underside of card)

AWM USB Configuration Interface (bottom side)

Payload Interface Card

SpaceWirePort

USBPort

Panel to panel Connector


Back View AWM Panel Configuration

Switch Module Card(10 Magfusion Switches)(Total of 4 installed on bottom)

AWM USB1.1 Configuration Interface

USB1.1 Hub card for on and off panel enumeration/control


AWM Demo

NI Frame Grabber

1st Space Wire BoardSPACEBALL 3DM-GX1

DVD player

3DM-GX1Inclinometer &

Orientation Sensor

Display:SPACEBALL rotating cube

2nd PC running Display2

2nd Space Wire Board

Display:DVD movie

PC running AWM CONFIG. SW (not needed once system configured)

Display:AWM CONFIGURATION GUI

OPC NORTH

TEDS

Panel 1

OPC SOUTH

OP

C E

AS

T

OP

C W

ES

T

PA

Y 2

PAY 3

PAY 1

OPC NORTH

TEDS

Panel 2

OPC SOUTH

OP

C E

AS

T

OP

C W

ES

T

PAY 1

Optional TEDS Port

1 Distinct SpaceWire interconnect routed via AWM for payload to payload interconnect2 Distinct USB routes:TEDS – USB 1.1 TEDS interface used for enumeration and controlUSB – USB 1.1 (2.0 capable) interface routed via AWM for payload to payload interconnect

All panels, switch cards and hub cards are identicalPayload cards are similar but haveunique ID for function identification

(host)

(slave)

PA

Y 2

PAY 3


RF Characteristics of AWM

2.7 GHz Diff Eye thru Switchcard and 15 inch of PCB


RF Characteristics of AWM

2.7 GHz Diff Eye Cables Alone


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


• 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

Take Away Items from AWM Demo


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

• 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


Concept: A software-definable wiring system•Pre-built (into structures), rapidly-programmable•Can be modified in orbit

Benefits:

•Rapid integration on ground

•Debug support (temporary probe wires)

•On-orbit rewiring (fault, defect rectification)

•Reliability and utility of MEMS switches

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

RE-CONFIGURABLE/ADAPTIVE MANIFOLD

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)

Spacecraft busSubsystems

28VDC

5VDC

-15VDC

ProgramVDC

Analog_2

Diagnostic

COMM_1

COMM_2

+15VDC

Analog_1

payloadattachmentpoint

Switch boxes

high densityinterconnectbetweenswitchboxes

CMP

configurationmanagement processor

Generic Adaptive Wiring Manifold Architecture

MEMS-based Reconfigurable Manifold Update Presentation at MAPLD 2005

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