Firmware Processor 36 Watt, 9-Output, Flyback Topology Power Supply for the NASA International Space Station ECLSS Urine Processor Assembly.

The Photograph above is a brass-board representation of said power supply at a Technology Readiness Level 5 (TRL5).  Temperature was tested beyond flight atmosphere and to the testing level requirements.  Full Engineering Development and Testing Documentation are available.  ECLSS flew in the Summer of 2008 to the International Space Station (ISS).

There was no up-screening necessary in this design.  The closest thing that could be considered to up-screening for this design was designing in MIL-STD-883B components only because other desired level of Military Standard Components was not procurable. All components used were to the Military Standard minimums required in the performance specification.  Radiation-Hardened parts were used where required and were procurable.  Given the function of this power supply, it was not susceptible to interruptions due to Radiation Events.  What mitigations that was necessary could be taken care of with RC time constant circuits. The following was published in NASA Tech Briefs as a result of this effort: http://www.techbriefs.com/content/view/1540/

The following are some of the past performance programs that PACER has provided support for.

ORGANIZATION: DRS Test & Energy Management, 110 Wynn Dr., Huntsville, AL 35805
PROGRAM: Abrams Integrated Management Situation Awareness Tank Development
CONTRACT NUMBER: W.O. W52H09-06-G-0001/FFP Award
DESCRIPTION: PACER has a multi-person team performing studies and design evaluations on Analog Circuits, Vehicle Power, EMI, Reliability, Analysis, Maintainability, Embedded Diagnostics, Vehicle Health Management and Testability, Lead-Acid Batteries, and a Wide Variety of Sensors.

ORGANIZATION: DRS Test & Energy Management, 110 Wynn Dr., Huntsville, AL 35805
PROGRAM: DSESTS Spares
CONTRACT NUMBER: W.O. DAAE20-03-G-0001-D.O.0109/FFP Award
DESCRIPTION: PACER designed out the obsolescence of 800 kHz deflection and 50 MHz video circuits for a CRT display for Thermal Imaging Applications.  The signal circuitry was made considerably smaller with the use of surface mount devices.  The deflection circuitry had a gain modification necessary because of having to design-in a new high-speed multiplier.  Another new High-Speed Video Amplifier was introduced; however, discrete classic transistor circuitry for the high-speed deflection and video had to remain because of being the best solution over modern-day integrated circuits in power dissipation and fidelity.

ORGANIZATION: DRS Test & Energy Management, 110 Wynn Dr., Huntsville, AL 35805
PROGRAM: DRS-TEM IRAD (PROPRIETARY, COMPETITION SENSITIVE)
CONTRACT NUMBER: 9XR01-005/FFP Award
DESCRIPTION: PACER partnered to provide support for an Internal Research and Development Program (IRAD).  This program was based on an existing client design of a PSM-ZVT DC/DC Converter.  This converter may be paralleled for higher current demands.  The Converter is a 300VDC to 28 VDC, 10 kW Power Supply compatible to MIL-STD-461E, MIL-STD-704F and MIL-STD-1275.  PACER was involved with the design of the control loop, over-current circuit design, current detection if an Insulated Gate Bipolar Transistor (IGBT) failed, custom magnetics, custom capacitors, and the design of the 28VDC 10 kW Output EMI filter.

ORGANIZATION: DRS Test & Energy Management, 110 Wynn Dr., Huntsville, AL 35805
PROGRAM: DSESTS Spares
CONTRACT NUMBER: W.O. DAAE20-03-G-0001-D.O.0084B/FFP Award
DESCRIPTION: PACER was tasked with designing out obsolescence of electronic circuitry.  Most circuitry are involved with driving and servo control of Gimbals, Gyros, Periscopes and Resolvers.  This work order completed the design, developed and verified the design on actual tank hardware, and validated the design in environmental testing.

ORGANIZATION: Intuitive Research and Technology Corporation, Huntsville, AL 35805
PROGRAM: Theater High Altitude Area Defense (THAAD) Tactically Ready Asset Condition Recorder (TRACR)
CONTRACT NUMBER: IRTC WBS-TRACR2006-02/Phase II SBIR/Outside Consultant/ FFP Award
DESCRIPTION: PACER assisted in the circuit development of RS-232 interface to sensors.  PACER selected RS-232 chip sets, real time clocks, microcontroller interfaces, 3-axis accelerometers, pressure sensors, temp sensors, humidity sensors, Mono-methyl Hydrazine (MMH) and Hypergolic Oxidizer (MON) sensors, and analog switches for circuitry.  PACER evaluated the electrical integration to Lockheed Martin Advanced Leak Sensor System (ALSS) and the MIL-STD-810F environmental and vibe compatibility. The Power Management System was analyzed and approved. PACER developed the Interface Control Documentation and kept a dialog with another subcontractor for Wireless Devices.  PACER wrote a White Paper as a guideline to direct their efforts for designing and specifying the build of a PWB as well as manage the procurement and manufacture of a Third Party PWB Vendor.  This White Paper also extended to selection criterion for the PWB Vendor as well as a Third Party Resource to build the Circuit Card Assembly (CCA).

Developed Wireless Sensors for use on the blades at the 4T and 16T Wind Tunnel Facilities at Arnold Engineering Development Center.

We have developed Power Conversion solutions for a small data acquisition firm in Huntsville, AL with an exciting new product accessible via all telephony standards as well as the internet.  We also provided a Power Management solution for a special Public Safety device being developed by this same firm.  This device has also been deployed in Operation Iraqi Freedom Operations.

We have also partnered with a Start-Up Internet Network Accessory Firm to help in the development of a patented Anti-Reconnaissance Protection Device.

We have supported a conglomerate of interest from The Army, The Air Force, DARPA, NASA, and firms in Huntsville and Florida supporting Advanced Propulsion for Space Vehicles.  PACER was tasked with electrical power concerns.

We also tested Lithium-Ion Battery Solutions for the application of Solid State Lasers as well as High Power Microwave Defense and Crowd Control Mechanisms.  Google: Active Denial System.  Client was a Defense Subcontractor. 

PACER was tasked with the Research, Analysis of Pros and Cons, Development of Concepts, and Feasibility Studies of Self-Prognostic, Self-Diagnostic Cable Techniques to enhance existing ground tactile vehicle systems.  PACER recommended a course of action through composition of White Papers submitted to Sub-Contractors and Prime-Item Developers.