RF Engineering Boosts VASIMR Efficiency from 40% to 98%
INDUSTRY:
Aerospace Industry
TYPE OF WORK:
Space product engineering, RF engineering services, spacecraft component design engineering
Enginuity’s diverse skills in RF engineering services, design, and manufacturing, along with their expertise in theoretical thermal dynamics, were crucial for this unique project, partly funded by the Canadian Space Agency. The team has been great to work with, and the experience has been overwhelmingly positive.
Tim Hardy
Chief Technology Officer (CTO), Aethera Technologies
About the Client
Aethera Technologies
Aethera Technologies is a leading Radio Frequency (RF) engineering company. Initially focused on custom hardware, software, and services for wireless communications, Aethera has expanded into R&D efforts across various industries.
Their core technology now drives innovations in space propulsion, fusion energy, pharmaceuticals, and materials transformation. With a global footprint, Aethera serves clients in North America, Europe, and Asia, delivering advanced RF solutions for diverse applications.
Understanding the Problem
The Challenge
Aethera Technologies, recognized for its expertise in Radio Frequency (RF) engineering, faced the challenge of designing a new power supply for Ad Astra Rocket Company’s VASIMR (Variable Specific Impulse Magnetoplasma Rocket) system. The VASIMR system, a fully magnetized plasma thruster for in-space propulsion, required an RF power processing unit that could deliver high-frequency power to heat the plasma exhaust.
This unit needed to be electrically efficient while meeting stringent specifications for form factor, mass, and volume. Aethera needed additional support for the mechanical engineering and design aspects of this project, leading them to seek Enginuity’s expertise.
Step 01: Initial Concept Development
Step 02: Design analysis and Stress Test
Step 03: Prototype Development
Step 04: TRL 7 Testing at NASA
Solving the Challenge
The Solution
Enginuity’s team of mechanical engineers and technologists collaborated with Aethera to develop a thermally and mechanically optimized design for the RF power processing unit. The solution involved creating a compact assembly of amplifiers, transformers, control boards, and conductive cooling systems within a magnetically shielded volume. This design met the stringent space propulsion requirements and achieved an impressive 98% energy efficiency.
A key challenge was designing a robust thermal system capable of managing heat in the vacuum of space, where small losses in power-electronics components could lead to system failure. Through several design iterations, the team balanced the mechanical layout, thermal design, and electrical design to converge on an optimal architecture. This ensured the unit’s functionality under the extreme conditions of space.
Summarizing the Outcome
The Conclusion
Enginuity’s innovative approach resulted in a Power Processing Unit (PPU) with 98% energy efficiency and a mass 40% lighter than the previous generation system. This optimized power processing system significantly enhanced the overall performance and cost-effectiveness of the VASIMR rocket. By maximizing power efficiency, the system improved thrust and reduced fuel costs, crucial for space missions where fuel is expensive to transport.
Key Takeaways
98% Energy Efficiency
Designed a PPU with 98% energy efficiency, enhancing the VASIMR electric rocket system’s performance.
Space-Optimized Design
Developed a compact, efficient PPU meeting strict space requirements for form factor, mass, and volume.
Successful Collaboration
Built and validated the PPU through partnership with Aethera, ensuring top performance and reliability.
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