Introduction of DLR EEE-Working Group. “The usage of automotive components in space applications

DLR EEE-Components Division
New Space, Motivation

As space industry is facing a process of renewal, the possible usage of non-space parts in space missions to reduce overall costs, improve availability, reduce lead time and increase flexibility (functionality, new technologies) is getting more and more of crucial importance.

Way forward: Usage of automotive EEE components in space applications

Why focus on Automotive parts?

• •  Strategy in automotive industry (e.g. Standardization, Designed for Manufacturing, Product Roadmaps, Life-Cycle Management, established processes etc. ) 
  •  More recent technologies and features
  •  Significantly lower costs, shorter lead times, better availability
  •  Guaranteed reliability and temperature ranges
  • Many German Automotive parts manufacturers have also Space Productions

DLR EEE-Components Division
Introduction, Space2Motion Working Groups 

DLR initiative: “Space sector meets automotive industry” 

Exchange platform for automotive and space sector not only for EEE-Components

Working Group : Usage of Automotive Components in Space Applications

•  Kick-off Meeting in January 2019
•  Finalization of Terms of Reference in July 2019

Scope (finalised)

• •  Phase 1 – Identification
  •  Phase 2 – Analysis
  •  Phase 3 – Concept Development 
  •  Phase 4 – Concept Verification 
  •  Phase 5 – Development of an exchange platform/ Data Base

Participants (finalisation ongoing) for each Phase

• •  EEE-Components manufacturers (Automotive and Space)
  •  EEE-Components users
  •  Automotive OEMs

New Space – Working Group

“Usage of Automotive Components in Space Application” 

Phase 1 – Identification

Target: Understand the past and define the most critical parts (user needs)

• Which parts are needed:
  • Consolidate future need of German users, focus on critical space parts (e.g. long lead times, high costs, quality issues, new functions/technologies)

•  Lessons Learned:

• •  Experiences from previous programs using non-space grade parts (e.g. TET-1)
  •  Studies related the usage or evaluation and qualification of non-space grade parts 

• Participants: (incomplete list)
  • More than 20 companies/institution/university are already part of the WG

Phase 2 – Analysis

Target: Understand the Delta and identify the challenges

• Market Analysis: Overview of automotive parts from Germany which are potential replacements for identified critical space parts

• Perform a GAP-Analysis:
  Differences between ESCC/MIL qualified parts and AEC-Q parts
  • Analyze based on documentation, specifications 
  • Consider 
    • Class 1,2,3 per ECSS-Q-ST-60
    • Evaluation and qualification philosophies
    • Mission profiles of automotive parts

• Data collection for selected automotive parts qualification

• Identify the challenges resulting from use of automotive parts (some examples)

• • Pure tin – mitigate whisker growth 
  • Risk assessment – Assess: reliability, failure mechanisms, drift calculations
  • Traceability, “lot” definition, radiation: (non-)hardness
  • High minimum order quantities, high non-recurring costs , smart/lean procurement process, storage and sales strategy
•  Participants: (incomplete list)
  • Subgroup active parts: Fraunhofer Institute, RoodMicrotec, BERNS Engineers, Hostmi, Infineon
  • Subgroup passive parts: Isabellenhütte, Vishay Beyschlag, RoodMicrotec, Hostmi, BERNS Engineers

Phase 3 – Concept Development

Target: Develop a concept and verification methods to demonstrate suitability of  AEC-Q parts in space applications

• Develop a concept per part type/ technology which considers different programe levels to reduces the necessary testing (Initial/evaluation, lot acceptance) cost to a minimum

• Classification of mission profiles (parameters, requirements, …)
• Define approach to way forward for identified challenges
• Test Concept Option 1: Systematic on ground testing
  • Develop concept – which tests have to be performed
  • Optimize concept – how to save resources, e.g. board level tests?

     

• Test Concept Option 2: On-Orbit Verification
  • Develop concept 
    •  Use of small satellites & Cube-Sats, maybe Sample return mission (?)
    •  Data transfer during mission time, „real-time“ analysis
    •  Extrapolation of data, assessment of perimeter and risk

      What kind of data could be gained?
      To which extent is extrapolation possible?
      Which operational conditions/missions can be covered?

•  Usage: 

• •  Detection early failures 
  •  Launch conditions provide information about resistance to shock and vibration
  •  Radiation related data  on DD and TID or maybe on SEE? 
•  Participants: (incomplete list)
• • Subgroup active parts: Fraunhofer Institute, RoodMicrotec, BERNS Engineers, Hostmi, DLR Research and Technology, German Orbital Systems
  • Subgroup passive parts: Isabellenhütte, Vishay Beyschlag, RoodMicrotec, Hostmi, BERNS Engineers, Fraunhofer Institute, DLR Research and Technology, German Orbital Systems

Phase 4 – Verification

 Target: Implementation of the developed concept and testing

• Concept Option 1: Perform defined tests in lab, assess results

• Concept Option 2: OOV-mission slot, manufacturing of test boards, analysis of transferred real-time data, data evaluation

• Comparison of test data gained by the two options, assess validity of Option 2 data, define and optimize concept for future investigations

•  Participants: (incomplete list)

• • Subgroup active parts: Fraunhofer Institute, RoodMicrotec, Hostmi, DLR Research and Technology, German Orbital Systems, University Würzburg
  • Subgroup passive parts: RoodMicrotec, Hostmi, Fraunhofer Institute, DLR Research and Technology, German Orbital Systems

Phase 5 – Development of an exchange platform/ Data Base

Target: To support German industry and institution

•  Developing concept and programming
•  Test results, documentation and all other component related information
• Participants: (incomplete list): Cheyenne-IT consulting, German Orbital Systems, RoodMicrotec, Hostmi, Fraunhofer Institute, Vishay Beyschlag

New Space – Working Group “Usage of Automotive Components in Space Application” Preliminary Schedule