High-performance, miniaturized and configurable power and control unit for electrospray thrusters

Electrospray thrusters offer remarkable efficiency at low power levels and compact form factor, positioning them as promising propulsion systems for small satellite platforms. This paper introduces the design of a miniaturized Power and Control Unit for electrospray thrusters. The system fits within the pocketsat form factor while ensuring high-performance, high-voltage power conversion and effective thrust generation in this propulsion technology. The paper goes through the architecture of the Power and Control Unit and its different subsystems, where the high-performance power converter is studied in detail. The system is built in a 42 \(\times\) $\times$ 42 \(\times\) $\times$ 25 mm³ and 39 g weight stacked hardware unit, achieving a configurable bipolar voltage output with the implemented control algorithm. The system undergoes experimental verification, where a power conversion efficiency over 90% was measured within the output range of 2-10W and 1-2kV, validating soft-start, thruster voltage alternation, and variation of the thruster set point in real time. The final milestone is the successful 7-hour emission test with electrospray thrusters under vacuum conditions, ensuring the system’s suitability for real-world applications related to electrospray propulsion for small satellites.