Tech Briefs Magazine - March 2023 - 11

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Optimizing Connector Designs for Spaceborne Electronics
Low-Earth orbit (LEO) satellite systems are providing the world significant new methods of surveying, communicating, and sharing information.
With increased focus on LEO, a constant design evolution is occurring from deep space exploration to LEO-based constellations. Satellite
systems are moving rapidly from single units or devices to fully interconnected electronic networks operating on centralized computers. In
this interview, Travis Neumann, Special Project Manager at Omnetics Connector Corporation, discusses how connector designs are evolving to
meet the needs of spaceborne electronics.
Tech Briefs: New satellites and space electronics now require
interconnection design planning for each individual function and
where they will be performing. What are some of the key environmental
factors designers need to keep in mind while planning
circuitry for satellite systems?
Travis Neumann: We already know that in
satellite applications size and weight are a
big deal. We want the electronics to be small
and lightweight and the first thing to ask
as a designer is what do I need? When you
consider power and signals, there are really
two ways to slice this. It's in terms of the
current or voltage needs. Current will dictate
the size of the conductors where voltage can
affect spacing. Next question relates to how many of these connections
do we need? Using the number of connections you need, what
the voltage or current rating of those connections is, or signal in
terms of speed, and work from there to determine what's going to
be your best solution.
Tech Briefs: Satellites collect and transmit
data to a main system as well as
provide constant communication and information
back down to Earth. Increased
data volume often poses a challenge. How
are new materials and circuit designs
solving this problem?
Neumann: Increased data is definitely a
challenge. The other thing that's been happening
in the last couple of decades is data
compression. They process as much as they
can right at the sensor as there has been a
push to do as much processing as you can
locally. Increased data drives the movement
toward higher data rates in terms of transmission. Low loss board
materials are used for the high-speed digital data transmission we
see today. Spacing of the circuits through use of digital electronics
locates processing power near the sensor(s). Impedance controlled
traces and wires, surface finishes and the materials used have all
shifted to support our modern day data consumption needs.
Tech Briefs: As engineers design and build newer space devices
they are cramming additional functions and applications into
extremely tight spaces. How have connector and cable designs
evolved to meet the needs of spaceborne electronics?
Neumann: Omnetics has been small cable and connectors for quite
some time and we see customers moving down in size. Where they
might have used the traditional large military connectors, there is a
Tech Briefs, March 2023
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transition into high reliability micro and nano types. Technology like
that used in servers such as blade mount or stackable connections
promotes assembly for those looking to create large constellations.
Additionally, there are users of wired investigating flex circuit solutions
for their CubeSat for better management of the harness and
connections between boards.
Tech Briefs: Besides size, space, and weight what are additional
environmental effects to consider?
Neumann: A popular one is shielding. There is significant radiation
in space, and the further out you go, the more aggressive it
becomes. We get a lot of requests for back shells and plated braiding.
As shielding is an " in addition " type of solution, weight starts
to come into the play. Thermal cycling is another consideration.
Materials should be chosen with a wide enough operating range
they don't fatigue from repeated hot/cold cycles when orbiting the
Earth. Outgassing is another consideration to prevent deposition
of material onto optics and controls.
Tech Briefs: As the LEO-based space economy progresses, what's
the outlook for nano-connectors in space-grade electronics?
Neumann: I think we're on the front end of significant growth.
In 2015, there were 9,000 to 10,000 satellites in orbit. Today numerous
companies are sending up hundreds or even thousands
of satellites to create constellations to deliver images, high-speed
data, GPS, and more to the world. There are many connections from
board to board and board to component for power signal, flight
controls, communications, and far more uses than I can think of
that have need for small, ruggedized connectors.
Watch the full interview with Travis Neumann
11

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Tech Briefs Magazine - March 2023

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