High-Efficiency Multi-Mode Power-Processing Units for Hall-Effect Thrusters Using Electronically-Adjustable Step-Up Transformers

This Small Business Innovation Research Phase I project will address the technical and commercial feasibility of developing a dc-dc power processing unit with an electronically-adjustable step-up ratio (i.e. no moving parts) to achieve high conversion efficiencies (>94%) over a broad range of operating voltages (100-800V) and power levels (2-10kW). Plasma propulsion systems with dual-mode capability are currently under development for: (1) the ability to rapidly perform orbital transfers for protection and satellite repositioning, and (2) high propellant utilization for station keeping and attitude control. In order to become cost effective, a flexible power processing unit that can operate across a broad range, while remaining small in both size and volume (<3kg/kW), is needed. Starfire Industries has been researching Hall thruster technologies with improved efficiency, robust modeling capability and also new techniques for multi-mode operation across voltage ranges from 100-800V. Thus, Starfire is well aware of the needed capabilities and system requirements and is ideally suited for conducting additional research into PPU subsystem design. This SBIR proposal will explore the intellectual merit of the novel adjustable dc-dc converter concept and quantify its impacts on satellite design, mission planning, and overall cost. If successful, the broadband dc-dc converter could enable high-performance systems with significantly lower launch costs.