selection of switch mode power supply (smps) for reliability slides...power supply (smps) for...
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1 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection of Switch Mode Power Supply (SMPS) for Reliability By Ron Wunderlich, PhD
DfR Solutions Open House March 16, 2015
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2 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
History
o The following is a history of Switch Mode Power Supplies:
o SMPS were developed back in the late 70’s and early 80’s
o This technology helped to significantly reduce the size of
power supplies by switching at high frequency compared to
line frequency
o Previous designs were linear regulators, ferro-resonant
transformers and even motor-generators with phase control
(IBM Mainframes)
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History
o Back in the late 80’s there was a shift in the industry
o SMPS were becoming a commodity no different than a
resistor or capacitor that you buy
o So, costs and profit margins were driven down over the
years
o Profit margins for a power supply is less than a few percent
while IC chips are 30% to 70%
o Almost all power supply design and manufacturing is now
overseas
o However, SMPS are still required
o They have become a “Necessary Evil”
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Complexity
o Even though SMPS are treated like a commodity, they are
in some cases more complex than the final product they go
in
o Let’s look at some of the technology that is involved in a
SMPS
o Industry has shifted to making SMT parts but many power
components have to be PTH so there is a need to deal with a
mix of SMT/PTH components
o Need high voltage components like MOV’s to handle up to
4KV surges
o Heavy copper boards (2oz or higher) to handle high current
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Complexity
o Need large amount of capacitance but with high ripple
current or else you can dry out aluminum electrolytics
o Need fuses that can open easily under faults yet survive
shock/vibe
o Inductors and transformer’s themselves are difficult
handmade sub-assemblies with ferrite material that have
complex behavior
o Semiconductors that must handle both high voltage and high
current and yet act as ideal as possible
o To cool devices need thermal cooling like heatsinks
o Need to operate at high temperature
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Complexity
o Then there are regulations that need to be met
o For AC/DC’s there’s UL 60950 and others for safety specs
o To meet safety you need safety approved components
and the required spacing's between primary-secondary
o If there are safety issues in the field, this will result in a
recall
o Worse if someone gets shocked
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7 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Complexity
o Conducted and Radiated EMC
o Used to be just conducted noise was an issue
o Now with faster switching converters, radiated noise has
become an issue
o DfR has seen cases where the switching power supply
generated more noise than the high end processor and
FPGAs
o Layout and switching speeds are critical
o Require ferrite beads, Toshiba spike killers, common
mode chokes
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8 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Complexity
o Then there are standards (for AC/DC’s)
o IEC61000-4-2 ESD
o IEC61000-4-3 RF Immunity
o IEC61000-4-4 Electrical Fast Transient
o IEC61000-4-5 Surge
o IEC61000-4-6 Conducted Immunity
o IEC61000-4-8 Power Frequency Magnetic Field Immunity
o IEC61000-4-11 Dips and Sags
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Complexity
o We are just scratching the surface
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Selection
o Unless you do a full detail analysis, you won’t know
exactly how good the power supply is
o However, there are some guidelines that can help you in
your selection process
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11 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o Load current
o You know exactly what voltage you need but the load
current is not as well identified
o The common practice is to add up all the worst case currents
from all the devices in the circuit
o This will give you the worst case load current
o Do you select a power supply that is rated for the worst
case load current or 1.5X or even 2X ?
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12 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o My suggestion is to pick a power supply that is designed for
2X the worst case load
o Just like components, power supplies must be de-rated
o Why choose 2X ?
o In the OEM power supply market there is a dirty little secret
o They assume that customers typically run the power supply
at ½ load so some OEM’s will base their reliability on 50%
load
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13 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o Standards
o As discussed before, there are standards (for AC/DC’s) and
each standard has a level
o The higher the level, the more robust the product will be
o IEC61000-4-2 ESD
o IEC61000-4-3 RF Immunity
o IEC61000-4-4 Electrical Fast Transient
o IEC61000-4-5 Surge
o IEC61000-4-6 Conducted Immunity
o IEC61000-4-8 Power Frequency Magnetic Field Immunity
o IEC61000-4-11 Dips and Sags
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14 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o For example, IEC61000-4-5 Surge
o A product that meets Level/Class 4 will be more robust than
a product that meets Level/Class 3
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Selection
o Fans for cooling
o For high power converters, a fan is required for cooling
o Fans are mechanical systems that wear out due to the
bearings
o They are limited by the number of revolutions
o There are many bearing types but all have their pluses and
minuses
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16 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o There are tricks for increasing fan life
o Use a large fan but run it at a lower speed (less
revolutions)
o Run the fan only when needed for cooling
o Variable speed fan based on cooling requirements
o N+1 fan cooling system
o Sometimes how the cooling system works will be specified in
the datasheet or else you have to ask
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17 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o Aluminum Electrolytics
o These type of caps have a liquid which can dry up over time
o The life of an aluminum electrolytic is determine by
o Lr = rated lifetime of the capacitor at rated ripple
current
o Tr = rated temperature of the capacitor
o TE = actual temperature of the electrolyte
o This formula is based on the evaporation of a liquid
102Er TT
rLL
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Selection
o Here’s some interesting things
o The life decreases exponentially with temperature
o The rated life is performed at rated ripple current
o For SMT caps and some PTH, the rated ripple current is 0A
o That means as soon as you apply any ripple current, the life
decreases
o If the caps have rated ripple current > 0A and if you run
them at a lower ripple current, the life increases
o Capacitors with 85C rated temperature are usually made
by 3rd Tier vendors
o First Tier vendors have outsourced these caps but still have
their names on them
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19 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o The larger the capacitor, the higher the rated lifetime is
o Watch for local hotspots
o The transformer below is heating up the capacitor
o DfR has seen in one product a resistor running at 200C next
to the cap
o
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20 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o When looking over a power supply, you would like to have
a 105C/1000Hr minimum capacitor rating
o If possible, ask the vendor for the temperature profile of the
power supply and the ripple current
o This way you can calculate the life of the capacitors your
self
o Instead of life testing to see when the capacitor fails, DfR
has developed a method of using weight loss due to
evaporation as a method of determining life time
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21 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o Parts Position on the PCB
o If the parts are too close to the board edge, they can crack
because of the depanelization process
o If they are placed along the same axis as the bend in the
card, they can also crack
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22 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o Below shows the preferred axis of bending
o There are some components that are close to the edge but
the orientation is such that it minimizes the cracking
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Selection
o In this case, parts marked in red are in wrong orientation
o Bend the board and they can crack
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Selection
o Board Cleanliness
o You can tell a lot about the company from the construction of
the power supply
o A clean board shows the company is meticulous and has
good processes in place
o A dirty board can put you at risk with abnormal circuit
behavior and arcing
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25 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o This is a nice clean board
o No flux
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Selection
o Hand solder flux left on board
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Selection
o No clean solder flux left on board
o This is a problem with high impedance analog circuits
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Selection
o More solder flux left on the board
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Selection
o Solder Workmanship
o Because of mixed technologies (SMT and PTH), certain
components have to be hand soldered
o If you are going to hand solder, make sure its soldered
properly
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Selection
o Poor solder workmanship
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Selection
o Glue
o For high density converters glue will be required
o Its used to hold components together for shock/vibe
o It's also used as an insulating material to meet primary-
secondary isolation
o However, this needs to be put in by hand which can result in
mistakes
o Safety spacing is most critical
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32 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o Here’s an example with minimum amount of glue and not
used for critical safety areas
o This is a good design
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33 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o Poor glue operation
o Not only is this sloppy but they had to coat high voltage
wires to meet safety requirements
o This cannot be done consistently
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Selection
o Tape
o Another method for decreasing the safety spacing's for high
density power supplies is to use tape
o Again, like glue, tape has to be put on manually and
mistakes can happen
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35 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o Here’s an example where only the transformer has tape for
safety requirements
o This is a good design
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36 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o In this example there is a significant amount of tape used
o Hopefully they don’t make a mistake
C01
Heatsink
C01
Transformer
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Selection
o Assembly
o Overall look at how the power supply is constructed
o Ask yourself questions
o Are components being force fit ?
o Can you get a screw driver to mount a device to a
heatsink without slipping and causing other damage ?
o If there are problems in the assembly, most likely you will
see issues later on
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38 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Selection
o C4, Q6 and Q2 are pressed against each other
o The parts can crack over time with thermal cycling
C4
Q6
Q2
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39 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Final Word
o Final Word
o This presentation will give you enough information to choose
a power supply
o Also give an overview on checking the quality of the power
supply
o At DfR Solutions, we take it one step further where a
detailed analysis consisting of a paper/hardware review of
the circuit is performed next
o Also if there are issues with the power supply, we can help
diagnose the problem and suggest corrective actions
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40 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o The electrical review process entails the following
o Review of specifications
o This gives an understanding of the product but also if
there is sufficient information and are levels and ranges
correct
o Such as
o Is the operating temperature range sufficient
o Are there appropriate standards and high enough levels
Review Process
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41 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o The electrical review process entails the following (cont)
o Review of the circuit
o Understand and review the functionality of the circuit
o Make sure the circuit functions as is
o Sometimes suggest improvements in functionality or cost
o Check the robustness of the circuit
o Look at EMC and ESD aspect of the circuit
o Check the de-rating of components
o Power dissipation, voltage rating (even on resistors)
o dV/dt rating of FETs for LLC
o VGS breakdown of FETs
o Temperature rating
Review Process
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42 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o The electrical review process entails the following (cont)
o Stability
o Circuits with feedback loops like power supplies
o Even LDOs (like using low ESR ceramics where high ESR aluminum electrolytics are needed to be stable)
o Life of aluminum electrolytics
o Half of all design reviews run into issues
o Use temperature variation over seasons to be as accurate as possible
o Magnetics
o Transformer documentation and strcture
o Saturation current of magnetics
o Core loss
Review Process
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43 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o The electrical review process entails the following (cont)
o Component Risk
o Flag components that may have known issues or possibly be
discontinued
o Layout
o Placement of components
o Power flow
o Check for sufficient spacing's
o Software
o Averaging routines for noise signals
Review Process
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44 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Thanks
Any Questions? Contact Ron Wunderlich
The End
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