Introduction of DLR EEE-Working Group. “The usage of automotive components in space applications - EEE Parts Database | doEEEt.com (2024)

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