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The Design Process – EMC Considerations for Successful
Development and Delivery
Paul Stover, NCE
Compliance Test Engineer
ADTRAN
February 16, 2012
- Delivery of the final product along with compliant EMC performance can be
challenging.
- We’ll examine several points associated with the development process that can
lead to successful delivery – or to disaster.
- Presented will be cause and effect examples of these points and how disaster can
be prevented.
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Topics
• Design Process overview
• Where compliance fits
• Concept through delivery
• Examples of gotchas that could have been avoided
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Target market
• Market requirements
Concept
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Target market
• Market requirements
Concept
• Design
• Hardware
• Software
• Documentation (manuals etc..)Development
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Target market
• Market requirements
Concept
• Design
• Hardware
• Software
• Documentation (manuals etc..)Development
• Testing
• Mitigation
• Approvals
• DocumentationQualification
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Target market
• Market requirements
• Design considerations
• Can we do it?Concept
• Design
• Hardware
• Software
• Documentation (manuals etc..)Development
• Testing
• Mitigation
• Approvals
• DocumentationQualification
• Revenue
• $$$$$$
Sales
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Target Market
• Industry Specific
• Commercial
• Automotive
• ITE
• Defense/Aerospace/Government
• Domestic• Domestic
• US/Canada
• International
• European Union
• Eastern Europe/Russia
• Mexico/Latin America/Asia Pacific
• Market Requirements
• Testing affected heavily – can affect the overall success
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Compliance role during Conceptual Phase
• Understanding of the requirements for a given
market or industry
• Testing, documentation and marking/labeling
• You want to sell it where?!
• Based on these requirements, what are the potential • Based on these requirements, what are the potential
ramifications to the overall design?
• Hardened for immunity
• Levels and type
• Costs
• Hardware implementation
• Testing/Market entry
• Payola, payola
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• So we know what we want to make and where we’d like to sell
it, what’s next?
• Development
• Hardware
• Software (Really?)• Software (Really?)
• Documentation (may be language specific)
• Time to Market (ever present concern)
• Varies with complexity of product and industry
• Affects the bottom line
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
Executive
ManagementCompliance
Mid-Level
Management
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Development - Where we should spend most of our time
• Unfortunately this isn’t always the case (testing and mitigation)
• New Product considerations
• Physical/Mechanical
• Shielded/unshielded enclosure
• Circuit board design
Schematic review• Schematic review
• Artwork review
• Interconnecting cabling
• Shielded/unshielded
• Length and construction /UTP vs. Cat 5e
• Installation Environment/Application
• Residential/industrial
• Indoors/outdoors
• Hot/cold
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Compliance Role during Development
• Based on device conceptual result
• Provide guidance with regard to physical arrangement, construction,
bonding and grounding
• Review schematics and provide guidance early in the process
• Component placement/selection
• Compartmentalization• Compartmentalization
• PCB stack up
• Review PCB artwork revision (a) prior to prototype construction
• Verify stack up and PDN design
• Signal routing/termination
• As appropriate address cabling and environmental issues
• This may be industry driven
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Example # 1
• AC/DC converter
• 120V/60Hz in 48VDC out at 48W
• Metal housing
• 2 attaching cables
• AC mains unshielded ~3ft* = 1/4λ@ 80MHz
• DC output unshielded ~2ft** = 1/4λ @ 125MHz• DC output unshielded ~2ft** = 1/4λ @ 125MHz
• Approximate size 1.5”H x 3”W x 4.5”L
• SMPS in the 100-200kHz range
• Class A Device
• Not reviewed by Compliance Engineering – processes were not in
place for ready review.
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
Example #1 = +26dB pk over the Class A Limit
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
Comfortable margin to Class A limit
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Example # 1
• Resolved with
• 100+ plots later……
• Addition of common mode filtering in the form of a wire-wound
choke and ferrite beads
• Layout change to PCB (x2-3)
• Minor construction changes
• Functional design was great but development at this time did not
include Compliance schematic/artwork review
• Later this device was successfully developed into a 100W and
greater version w/o significant difficulty.
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Example # 2
• Telecom service delivery platform
• -48VDC
• Sealed metal housing with shielded direct burial cables
• Four PCB’s internally connected with header pins
• Original approximate size is 6”L x 24”W x 30”H
• Class A Device
• The original device was compliant with the Class A limits
• Conversion of the device to a 2U high 19” rack mount configuration
with unshielded cables and two PCB’s internally.
• Was the ‘same’ schematically
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
Previous unit performance
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
Example #3 = ~+18dB pk over the limit; Does it look the same?
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
Comfortable margin to Class A limit – looks more like the original
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Example # 2
• Resolved with
• Removal of 3-4 components
• Relocation of Common mode filter closer to EUT input (board spin)
• Design Engineering did not include Compliance in the schematic
review as it was derived (copied) from a compliant product.
• Compliance engineering was not included in the mechanical
design or board layout phase of development.
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Example # 3
• Custom high-end computer
• Built from a combination of off-the-shelf devices (compliant)
• Metal housing/dual display
• 120V/60Hz – 240/50Hz auto-ranging supply
• Attaching cables
PC peripherals• PC peripherals
• AC input cable
• Approximate size 18”W x 24”L x 18”H
• Class A Device
• In-house compliance resource with no test capability
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
Example #1 = ~+6dB pk over the Class A Limit
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
Comfortable margin to the Class A limit
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Example # 3
• Resolved with
• Replacement of off-the-shelf power supply with a compliant power
supply.
• Treatment of shielded monitor cabling
• Power supply provided by Vendor A was thought to comply but in
actuality did not.
• “Trust, but verify” – Ronald Reagan
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Example # 4
• Custom computing/measuring device
• Built from a combination of off-the-shelf devices and custom PCB’s
• 120V/60Hz AC to 12VDC wall-wart converter
• Off the shelf 12VDC to 5VDC converter internally
• Plastic housing w/touch screen
• Attaching cables
• Custom measuring device in plastic housing
• PC peripherals
• AC/DC input cable
• Approximate size 8’ cube
• Class A Device
• Start-up company with no in-house Compliance resource
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
Example #1 = +10dB pk over the Class A Limit
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
Marginally passes EU limit = ~3dB for USA
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Example # 4
• Resolved with
• Re-positioning of internal components
• Replaced off-the shelf DC-DC converter with PCB mounted regulator
(this saved ~$80 in parts)
• Used CE Mark approved lump-in-line for AC-DC conversion
• Layout changes to custom PCB’s
• Added a plethora of ferrite cores to internal peripheral cabling
• Compliance involvement didn’t begin until the unit was ‘ready’
for qualification prior to sale.
• No
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Problem solved; what now?
• Qualification
• Mitigation
• If one falls through the cracks during development, work with the lab
• Testing
• Relationship with accredited, competent laboratory facilities• Relationship with accredited, competent laboratory facilities
• Approvals
• Test plan should be developed to gain the widest reach of approvals
in the most cost efficient way
• Documentation
• Accurate Test reports
• Declaration of Conformity/Labeling
• Registration and Payola
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Example # 5
• Testing of product
• A2LA Accredited Test facility
• OATS with 3 and 10m capability
• Documented compliant NSA data
• Site registered and approved with the FCC
• Class A Device
• Established company with in-house testing facilities
• Significant variation from expected result – variation from 3m
distance to the 10m to great.
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
Laboratory Variations at 10m test distance - Vertical
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Example # 5
• Resolved with
• Repair of discontinuity in ground plane at ~4m distance
• Anomaly had gone undetected at test facility – use of a noise • Anomaly had gone undetected at test facility – use of a noise
source for site validation demonstrated the issue.
• Other issues detected at laboratories
• Excessive moisture in Ground Plane structure
• Cabling issues
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Compliance Role in Qualification/Approval
• Mitigation
• Emission/Immunity failure resolution
• Testing
• Coordination and monitoring of services provided
• Approvals and Documentation• Approvals and Documentation
• Accurate Test reports
• Correct representation of the product and how it was tested
• Declaration of Conformity/Labeling
• CE MARK
• Registration and Payola
• NOM/VCCI and others
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
• Summary
• Compliance processes aren’t a hurdle to jump over but an
engineering resource for success
• Involvement early in the process will shorten time to market and • Involvement early in the process will shorten time to market and
improve reliability – the earlier the better
• Compliance costs overall will be reduced
• Compliance people really aren’t so bad after all
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The Design Process –EMC Considerations for Successful Development and Delivery
February 16, 2012
What a day!