From space to earth and back
Sunsensors on a detour
Background and expertise
Almost 65 years of accumulated experience in high reliability
optical equipment design, manufacturing and quality control
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Micro digital sunsensor
2003
2012
Autonomous wireless sunsensor
AWSS for Delfi-C3
Immersed sunsensor
ISS
2012
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IOPACS
µDSS
Mini-DSS
ESA Business Incubation program
TNO mini-FSS
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BiSon 6
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High reliability (>10.000 thermal cycles)
Cleanable (IP67W)
Easy mounting
Low albedo sensitivity
Low cost (target €100 @5000 pcs)
Significant space heritage
with mini-FSS
Mini-FSS
BiSon 6
±64 ˚
±6 ˚
accuracy
< 0,5 ˚ 3σ
< 0,15 ˚ 3σ
Albedo
sensitivity
acceptable
Low
Costs
≈ €13,500
≈€ 100
FOV
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@5000 pcs
Fine sunsensor principle
• 2 key parts
– Membrane
– 4 quadrant photodiode
• 2 key performance determining factors
– Relative positioning accuracy
– Straylight reduction
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Same reliability, different approach
High performance/Low cost
• Only 5 parts
(housing, ceramic , 4 quadrant photodiode, thermistor, membrane)
• Package with integrated connector
• (semi) Automated assembly
• Wirebonding interconnect
• Waferscale membranes and MEMS
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ESA-business incubation program
(using space technology for terrestrial applications)
• Waferscale
membranes
• Housing
integrated
connectors
• Pick and place
assembly
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Large scale housing manufacturing
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48 sensor housings per batch
(commonality of tooling)
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Connector mounting
(commonality of technology)
• Two sensor types,
one connector type
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Wafer scale membrane production
(differences in detailed implementation)
Terrestrial solar sensors
• 8” glass wafers for lower costs
• Dycing for lower cost
Space sunsensors
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• 4” sapphire wafers for
lower costs
• Laser cutting for higher
performance
Automated pick and place
(commonality of mounting principle)
Optical axis aligned with mounting reference
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wirebonding
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Straylight shield and Membrane
mounting
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Closure of the package
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Et Voila
BiSon 6
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BiSon 64
What happened to the BiSon 6
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BiSon 6 tests at Fraunhofer ISE
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Results
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Analysis ongoing
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Proposed for new project
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Promoted at several occasions
• CPV-9 2013 Myazaki (Japan)
• CPV-10 2014 Albuquerque (USA)
• CPV-11 2015 Aix les Bains (France)
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ESA power conference 2012
ESA power conference 2014
EU-PVSEC 2013 Frankfurt (Germany)
Hannover messe 2013 (Germany)
• No Sales (yet)
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What happened to the BiSon 64
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BiSon 64
Space grade sun sensors
at much lower costs
Mini-FSS
BiSon 64
±64 ˚
±56 ˚ (64 Diagonal)
accuracy
< 0,5 ˚ 3σ
< 0,5 ˚ 3σ
Albedo sensitivity
acceptable
less
size
50*46*17 mm³
49*49*10mm³
mass
50 grams
<22 grams
USA silicon
German silicon
≈13.500 Eur/pcs
3750Eur/pc
FOV
Remarks
Costs
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Key properties
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High reliability
Low cost
ITAR free
Fully space grade
– Radiation hardened photodiodes
– Sapphire membrane with ITO coating
– Axon micro-D based connectors
– Space approved assembly line(s)
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Radiation tolerance
Tested to high dose
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Messung 1 = reference
Messung 2= after 1.1015 1 MeV electrons
Messung 3= after 3.1015 1 MeV electrons
Messung 4= after 1.1016 1 MeV electrons
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Radiation insensitive algorithm
Radiation tolerance (2)
• Total dose testing performed at ESTEC
• Excellent dark current performance
• No change in quantum efficiency measurable
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Thermal testing
• 10 thermal cycles on each
unit
• 1000 cycles -45°C..+85°C
planned Q2 2015
• 30.000 cycle test range TBD
planned Q4 2015
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Particle Induced Noise Testing
• On each unit
• According to MIL-STD-883 method 2020A
– 4 times 20g random for 3 seconds
– 4 times three 1000g shocks
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Vibration qualification
30g sine
37.9g random
N.B. 6 units tested instead of only 1
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Liquid Nitrogen dip-testing
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3000 mate/de-mate cycles
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X-ray inspections
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Bonding, ball shear and pull strength
tests
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Result
Confidence
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Status and planning BiSon 64
• 4 prototypes produced (2012)
• 0-series of 10 devices produced.(2013)
• 12 units produced Dec 2014 (Non flight units due to deficiencies in
the diodes but mechanically representative and used for environmental testing)
• 10 units produced with flight standard diodes March
2015 for thermal cycling tests.
• 1000 thermal cycles planned Q2 2015
• Pyro shock test planned Q3 2015
• 30.000 thermal cycles planned Q4 2015
• TRL8 Q4/2015
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Calibration at ESA (SN44)
(Q2 2014)
55,2
Q1
Q2
Q3
Q4
1
1
1
1
10
0-5
1 3 5
7 9
11 13
15 17
19
-4
5
-5-0
-6
Series15
Series8
0
-5
-10
1
3
5
7
9
11 13
15
Series15
Series17
Series19
15
-2
Series13
0
5-10
Series9
0 gain
0
0
0
0
10-15
Series11
0
0
2
Series7
offset x
offset y
4
Series5
0
0
Series3
offset alfa
offset beta
Series1
max angle
-10--5
2-4
0-2
-2-0
-4--2
-6--4
Series1
17
19
cos alfa
cos beta
Q1raw(0,0)
Q2raw(0,0)
Q3raw(0,0)
Q4raw(0,0)
0
0
0
0
2
0
-0,2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
1
-0,4
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
-0,6
-1
-0,8
-1
-1,2
-1,4
-1,6
-1,8
-2
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Series1
-2
-3
Only pure formula
-4
-5
-6
Series1
Calibration at TNO
(in 2005 on precursor device)
• After calibration
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Calibration setup under constuction
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Promoted at several occasions
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ESA energy workshop 2012 (Noordwijk NL)
ICSO 2012 (Ajacio Fr)
ESA MNT workshop (Noordwijk NL)
Spacematch 2012 (Noordwijk NL)
AIAA smallsat Berlin 2013 (Ger)
NATO RTO expert meeting Karlstad (Swe)
ESA passive components days (Noordwijk NL)
NASA a human adventure (Utrecht NL)
Space match 2013 (Noordwijk NL)
ESA small satellites systems and services 2012 (Mallorca Spain)
ESTEC industry space days (Noordwijk NL)
ICSO 2014 (Tenerife Spain)
Microcentrum photonics event (Veldhoven NL)
ESA Guidance Navigation and Control conference (Oporto, Portugal)
Photonics West (San Diego USA)
CNES radiation workshop (Toulouse Fr)
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Sales and prospects
• 12 units sold to Luxspace for the ARTES21
Sat-AIS program (6 breadboard and 6 flight
units)
• 6 units in option for second satellite
• Listed on ESA harmonisation roadmap
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Conclusions
• Lens R&D is specialized in high reliability
sunsensors
• Cost optimisation for terrestrial
applications has led to attention for
space applications
• TRL8 expected by Q4/2015
• Good prospects for both BiSon 6 and
BiSon 64
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BiSon 6 BiSon 64
Ready for take-off
Thank you for your attention
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