Unlocking 400kW+ High-Power Applications! NGI Empowers High-Power Ground Testing for Spacecraft

As commercial aerospace has been included in China’s government work report, industries such as launch vehicles and satellites are entering a period of rapid growth. According to third-party data, since China’s commercial aerospace industry first exceeded RMB 1 trillion in 2020, it has reached RMB 2.3 trillion by 2024, with a compound annual growth rate of 22%.

Ground testing, often regarded as the “real combat rehearsal” of spacecraft, is a critical step in the R&D and production process. Among these, high-power, high-stability, and programmable DC power systems have become indispensable core equipment. By simulating the power bus, power supply modules, and loads, these systems enable a comprehensive evaluation of the spacecraft’s power supply reliability.

In this article, we will share how NGI’s high-power, high-reliability DC power system has been successfully applied in ground testing for a global top-tier spacecraft manufacturer.

Customer Requirements

Customer A is a global leading manufacturer in spacecraft R&D and production, covering multiple frontier fields such as flight vehicles and satellite electronic systems.

To build a ground test power system for satellites and space stations, the customer planned to deploy a high-power DC power system with a total power capacity of 400kW. The system is designed to simulate the primary powerof solar arrays or energy storage batteries, and to perform ground validation for power controllers, power distribution units, and high-power DC-DC converters.

Core test items include electrical performance (efficiency, line/load regulation, ripple and noise) and protection features (overvoltage, overcurrent, short-circuit protection, input overvoltage/undervoltage protection). The customer’s preliminary requirements are summarized as follows:

High-Power Supply Capability

Ground testing requires comprehensive verification of spacecraft systems, including payload testing, space power management and distribution system testing, component aging testing, and auxiliary system testing.

These operations depend on a stable and continuous power supply, requiring the input power of the primary power bus to reach 400kW, with scalability to MW-level capacity to meet the trend of increasing spacecraft power demand.

Wide-Range High-Voltage Output

Common voltage levels for satellites and space stations are 28V, 50V, and 100V. As power levels increase, higher voltage buses such as 120V and 280V will be adopted.

High-voltage supply enables the same power output with lower current, reducing transmission losses and improving energy efficiency. Therefore, the DC power source must support a programmable 0–280V output to accommodate multiple voltage standards.

Output Redundancy

The continuity of power supply is crucial during ground testing. The system must therefore feature redundant power supply capability, ensuring that even if one module fails, the system can continue supplying power and maintain uninterrupted test operation.

Comprehensive Safety Protection

Safety is a top priority. The power supply must include overvoltage (OVP), overcurrent (OCP), overpower (OPP), overtemperature (OTP), and undervoltage (UVP) protection. Once any abnormal condition occurs, the system should immediately shut down the output to prevent equipment damage or safety incidents.

NGI’s High-Power, High-Reliability Power System

After multiple rounds of technical discussions and prototype testing, the customer selected the NGI N35500 high-reliability high-power DC power system, which perfectly met the ground test requirements.

High Integration

The system adopts a modular architecture, with a single module delivering 3U/42kW power density. A single cabinet can output up to 420kW, with scalability to MW-level power.

It supports an output voltage range of 0–360V, with voltage accuracy up to 0.02% + 0.02% F.S., fully meeting high-power and high-precision supply needs.

High Redundancy

Supports N+1 redundancy configuration. When a fault occurs in any single module, the system automatically identifies and isolates the faulty unit while redistributing the remaining capacity within the total power range, ensuring uninterrupted power delivery.

High Safety

Equipped with OVP, OCP, OPP, OTP, and UVP protection mechanisms, the system immediately cuts off output in the event of an abnormality, providing comprehensive safety protection for personnel and equipment.