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Guidelines for Aerospace Thermal Control Systems PCBA Development

Guidelines for Aerospace Thermal Control Systems PCBA Development

Tempo Automation
(https://www.tempoautomation.com/author/tempo/)
June 4, 2020 , in Aerospace (https://www.tempoautomation.com/category/aerospace/),
Blog (https://www.tempoautomation.com/category/blog/)

Just imagine one day humans traveling between planets just as we do now between countries. This may seem like
science ction, but recall that air travel was once thought to be a pie in the sky fantasy. And when you consider that
today space ights to and from the
International Space Station (ISS) (https://www.space.com/16748-international-space-station.html) where astronauts
stay for periods ranging from weeks to a year are considered routine, it brings interplanetary travel more into focus.
Space is, of course, a harsh environment where temperatures range from extremely cold to exceedingly hot. In order
to safely navigate through such an environment requires that spacecraft have reliable thermal management.

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Tempo
(https://www.tempoautomation.com/)

Managing or controlling the temperature is not simply necessary for humans, it is required for all vehicles or
platforms that pass through or operate in space. Although, the effects of external conditions are a major concern
they are no more so than the consequences; including mission failure and system shutdown, that may develop as a
result of not maintaining internal thermal stability. Therefore, the importance of the thermal control system and the
role of the electronics (https://www.tempoautomation.com/blog/the-role-of-electronics-in-aerospace-systems/) and
PCBs that comprise it cannot be overstated. First, let’s see how thermal control systems are used aboard spacecraft
and then how best to develop the boards that are critical to their successful operation.

Thermal Management Aboard Spacecraft

If you have ever been con ned to a windowless o ce or laboratory during the midst of summer without air
conditioning then you have an idea of the need for thermal management. As unbearable as this is for a day at work,
just imagine enduring this for months or longer in space. Ensuring this situation does not occur is the responsibility
of an aerospace thermal control system (TCS). However, this is probably the least important of the duties a TCS may
be tasked to perform. More critical is isolating internal compartments that require different thermal conditions from
each other and maintaining the temperature within an acceptable operating range for onboard equipment; especially
electronics and circuit boards.

Isolation is necessary to ensure that temperatures for different types of systems are maintained within the speci ed
ranges required for the elements, devices, and components that comprise the particular system under control. For
example, mechanical and electronic systems and (especially) optical systems typically have well-de ned and
different temperature windows in which they operate. Electronic systems aboard space vehicles are subject to a
number of threats. These include external radiation, mechanical stresses due to motion and vibration and
temperature swings. The use of
radiation-hardened electronics (https://www.tempoautomation.com/blog/developing-radiation-hardened-electronics-
for-space-environments/)
, test-supported
PCB material selection (https://www.tempoautomation.com/blog/pcb-material-selection-for-aerospace-electronics/)
, and thermal control systems are the most effective in mitigating these threats.

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 Thermal control systems can be
Tempo
passive or active (https://www.eetimes.com/thermal-control-systems-for-spacecraft-demand-passive-active-design-
(https://www.tempoautomation.com/)
techniques/)
and most spacecraft have both. Passive systems typically utilize a mechanical, chemical or other material property
to limit variation or achieve thermal equilibrium. Examples include piping, belts, thermal coating and layering; all of
which do not require an external power supply. Active systems, on the other hand, offer more precise control, quicker
response and extended temperature range beyond ambient. Achieving these objectives necessitates monitoring,
data acquisition, processing, conversion, and distribution by electronics and circuit boards.

Developing PCBAs for Aerospace Thermal Control Systems

The thermal management of a space ight vehicle is a dynamic series of actions that are initiated pre ight and
extend throughout the lifecycle of the mission. However, the considerations that impact thermal control system
operation vary for different stages, as listed below.

THERMAL CONTROL SYSTEM CONSIDERATIONS

Stage Thermal Concerns

Prelaunch Heat buildup from the engine

Launch Heat dissipation

In-Flight Power margin

In Orbit Sun and shade cycling

To ensure safe operation, the design and manufacturing of the thermal control system PCBAs must incorporate the
above concerns, while also adhering to the thermal limitations of their own deployment environment. Although these
may at times seem to be opposing objectives, your TCS board development can meet this challenge by following
guidelines, such as those listed below.

Aerospace Thermal Control System Development Guidelines

Optimize sensor design for a speci c environment

For sensors to be effective, they must be located in or near the targeted area. Therefore, it is important to build
sensors based on the speci c location where they will be used aboard the spacecraft.  Examples include having
a BMS near a battery, or a thermistor near the place where the temperature needs to be controlled using a
Thermoelectric Cooler (TEC).

Group components with similar thermal constraints, if possible

The thermal characteristics for components vary. For example, some passive components have a nearly linear
temperature-parameter pro le over some ranges. This must be incorporated into your board’s design as it will
affect performance. Therefore, it is best to utilize class-S (space-grade) components for maximal reliability and
durability.

Build boards for both manufacturing and operational thermal constraints

The thermal requirements for manufacturing and operation are not the same. Just as
PCB material selection (https://www.tempoautomation.com/blog/pcb-material-selection-for-aerospace-
electronics/)
must be optimized for the mechanical stresses of space ight, it is also important to make sure that thermal
constraints will not be violated.

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 Developing your thermal control system PCBAs with the above listing as a guide does not take the place of any
Tempo
regulatory requirements; nor are they alternatives to other good
(https://www.tempoautomation.com/)
aerospace board design tips (https://www.tempoautomation.com/blog/5-tips-for-developing-pcbs-for-aerospace-
electronics/)
. Instead, it is intended as an augmentation that speci cally targets the thermal control system.

The thermal control system is one of the most critical parts of your spacecraft as it seeks to ensure that all
operations can be performed under the most favorable conditions.

Tempo's Custom Avionics for PCB Manufacturing Service

AS9100D and IPC J-STD-001E with Space Addendum certi ed manufacturing processes.
ISO-9001, IPC-600 and IPC-610 commitment to quality certi cations.
Execute your full development cycle from proto to validation, NPI, and low volume production.
Accurate quote in less than a day.
DFX support, including DFM, DFA, and DFT from Day 1 of design.
Entire turnkey PCB manufacturing in as fast as 4 days.
Extreme space environment targeted manufacturing.
Use reputable components suppliers to ensure quality, security and traceability.
Performs multiple automated inspections during PCB assembly to ensure quality for prototyping.

Therefore, the development of boards that

comprise this system must incorporate special
considerations as listed above. At
Tempo Automation
(https://www.tempoautomation.com/)
, we have the experience and expertise to help you
build TCS boards that will meet your space
platform’s requirements.

And to help you get started on the best path, we

furnish information for your
DFM checks
(https://www.tempoautomation.com/dfm-
checks/)
and enable you to easily view and download
DRC les
(https://www.tempoautomation.com/tempo-
automation-stackup-and-drc- les-download)
. If you’re an Altium Designer or Cadence Allegro
user, you can simply add these les to your PCB
design software. For Mentor Pads or other design
packages, we furnish DRC information in other
CAD formats and Excel.

If you are ready to have your design

manufactured, try our
quote tool
(https://secure.tempoautomation.com/accounts/quote-
signup?next=/rfq/)
to upload your CAD and BOM les. If you want
more information on aerospace thermal control
systems and how to best develop boards for

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Tempo
contact us
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.

Get a Quote Today

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