power developer: january 2016
DESCRIPTION
The Move Towards Software-defined Power: CUI Ushers in the New Age of Digital PowerTRANSCRIPT
CUI Ushers in the New Age of Digital Power
New Automotive PMICs from Cypress
Power Supply Safety
Considerations
The Move Towards Software-defined Power
JANUARY 2016
Interview with Mark Adams
Senior VP of CUI
EEWeb
Power Developer CONTENTS
3
TECH SERIES
DC/DC Book of KnowledgeChapter 6: Safety Considerations
PRODUCT WATCH
Arrow Product InsightsDC-DC Step-down Converters from OnSemi, Murata, and Linear Technology; JFET-based Products from Infineon and GeneSic
ROHM’s BD9G341AEFJ DC-DC Converter
ZMDI’s ZSSC1750 System Basis Chip
TECH REPORT
Designing and Managing Custom Battery Pack Plastic Enclosures
INDUSTRY INTERVIEW
The Move Towards Software-defined PowerInterview with Mark Adams of CUI
EEWeb FEATURENew Automotive PMICs from Cypress Offer Benefits in Every Detail
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EDITORIAL STAFFContent EditorAlex Maddalena [email protected]
Digital Content ManagerHeather Hamilton [email protected] Tel | 208-639-6485
Global Creative DirectorNicolas Perner [email protected]
Graphic DesignerCarol Smiley [email protected]
Audience DevelopmentClaire Hellar [email protected]
Register at EEWebhttp://www.eeweb.com/register/
Published byAspenCore
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Boise, Idaho 83702 Tel | 208-639-6464
Victor Alejandro Gao General Manager Executive Publisher
Cody Miller Global Media Director
Group Publisher
4
Power Developer
KNOWLEDGE
By Steve Roberts Technical Director for RECOM
RECOM´s DC/DC Book of Knowledge is a detailed
introduction to the various DC/DC converter
topologies, feedback loops (analogue and digital),
test and measurement, protection, filtering,
safety, reliability, constant current drivers and
DC/DC applications. The level is necessarily
technical, but readable for engineers,
designers and students.
DC/DC
Chapter 6
SafetyBook of
TECH SERIES
5
KNOWLEDGE
By Steve Roberts Technical Director for RECOM
RECOM´s DC/DC Book of Knowledge is a detailed
introduction to the various DC/DC converter
topologies, feedback loops (analogue and digital),
test and measurement, protection, filtering,
safety, reliability, constant current drivers and
DC/DC applications. The level is necessarily
technical, but readable for engineers,
designers and students.
DC/DC
Chapter 6
SafetyBook of
6
Power Developer
The main aims of the various safety standards and regulations are to prevent injury, loss of life, or damage to property by defining levels of protection against dangers like electric shock, hazardous energy, fire and smoke, physical injury, and radiation and chemical hazards.
The terms “danger” and “hazard” are often used interchangeably. One way to differentiate is to think of a danger as a potential hazard. For example, a mains cable may carry a dangerous voltage, but the cable is still safe to handle because the wires are insulated. However, if the insulation was damaged or inferior, the cable would then be hazardous to touch.
One important use for DC/DC converters is to enhance the safety of the applications they are used in. If the DC/DC converter is a safety certified product, the application designer can treat the converter as a “black box” and rely on the DC/DC converter manufacturer to provide adequate internal safeguards to meet the safety regulations.
This does not mean that the application designer is therefore no longer responsible for user safety in their designs as they must still show due diligence in identifying potential hazards and taking the necessary steps to safeguard against them, but this task is made easier if the DC/DC converter is already certified. For example, if a DC/DC converter fails due
to an internal short circuit fault, it can overheat but should not burn.
The materials used in the converter construction must therefore be non-flammable and self-extinguishing. However, if the application designer omits to provide adequate protection against this kind of fault (e.g. by failing to limit the input current to the converter), then the DC/DC converter could still get hot enough to cause another component or material to ignite and start a fire. The designer is therefore still responsible for the consequences of a component failure, even if the component is itself safety certified.
The tendency in safety certification regulations is to emphasize this responsibility on the application designer by including hazard-based safety engineering (HBSE) and risk management (RM) as part of the general safety certification process.
This is a major change in approach compared with the traditional electrical safety standards such as 60950 or ETS300, which concentrate purely on the DC/DC converter safety without considering the consequent risk should it fail in the end-application. This is also a reason why most DC/DC converter manufacturers state that their products are generally not suitable for use in safety-critical applications.
The HBSE process follows four main steps:
1. Identify sources of hazard in the product (e.g. energy sources)
2. Classify the seriousness of the hazards (e.g. Class 1: not painful and ignition unlikely, Class 2: painful but no injury, ignition possible, or Class 3: injury and ignition likely)
3. Identify appropriate safeguards (e.g. make hazardous voltages inaccessible, current limiting)
4. Qualify the safeguards (e.g. ensure that tools are needed to access hazardous voltages; maximum currents are safe during normal and fault conditions)
Electric ShockMost isolated DC/DC converters are used in applications with mains-powered AC/DC primary supply. If this primary power supply fails in such a way that hazardous voltages are present on its output terminals, it is the function of the DC/DC converter to protect the user from an electric shock. In other words, if the main isolation across the AC/DC transformer fails then the secondary isolation across the DC/DC converter should protect the user from an electric shock. This concept of two independent forms of protection is the bedrock for many safety standards. In general, if the circuit is inaccessible (tools required for access), then a single isolation barrier is acceptable; otherwise at least two levels of protection are required.
Insulation ClassThree main insulation classes are defined in the safety standards.
1. Functional Insulation: The isolation is sufficient for the converter to function, meets the appropriate requirements for safety separations and will not provide a fire hazard during a fault, but the insulation is not sufficient to provide protection from an electric shock.
Most DC/DC converters are in this class as they are powered from non-hazardous voltages. A functionally insulated converter will provide limited protection from an electric shock in the event of a primary power supply failure, but they are not classed as reliable protection from a permanently hazardous input voltage. Fig. 6.1 shows an example of a functionally insulated converter. The input and output windings are wound on top of each other and rely on the wire coating for insulation. Despite this simple form of construction, isolation voltages of up to 4kVdc can be achieved.
Figure 6.1. Example of functional insulation
TECH SERIES
7
The main aims of the various safety standards and regulations are to prevent injury, loss of life, or damage to property by defining levels of protection against dangers like electric shock, hazardous energy, fire and smoke, physical injury, and radiation and chemical hazards.
The terms “danger” and “hazard” are often used interchangeably. One way to differentiate is to think of a danger as a potential hazard. For example, a mains cable may carry a dangerous voltage, but the cable is still safe to handle because the wires are insulated. However, if the insulation was damaged or inferior, the cable would then be hazardous to touch.
One important use for DC/DC converters is to enhance the safety of the applications they are used in. If the DC/DC converter is a safety certified product, the application designer can treat the converter as a “black box” and rely on the DC/DC converter manufacturer to provide adequate internal safeguards to meet the safety regulations.
This does not mean that the application designer is therefore no longer responsible for user safety in their designs as they must still show due diligence in identifying potential hazards and taking the necessary steps to safeguard against them, but this task is made easier if the DC/DC converter is already certified. For example, if a DC/DC converter fails due
to an internal short circuit fault, it can overheat but should not burn.
The materials used in the converter construction must therefore be non-flammable and self-extinguishing. However, if the application designer omits to provide adequate protection against this kind of fault (e.g. by failing to limit the input current to the converter), then the DC/DC converter could still get hot enough to cause another component or material to ignite and start a fire. The designer is therefore still responsible for the consequences of a component failure, even if the component is itself safety certified.
The tendency in safety certification regulations is to emphasize this responsibility on the application designer by including hazard-based safety engineering (HBSE) and risk management (RM) as part of the general safety certification process.
This is a major change in approach compared with the traditional electrical safety standards such as 60950 or ETS300, which concentrate purely on the DC/DC converter safety without considering the consequent risk should it fail in the end-application. This is also a reason why most DC/DC converter manufacturers state that their products are generally not suitable for use in safety-critical applications.
The HBSE process follows four main steps:
1. Identify sources of hazard in the product (e.g. energy sources)
2. Classify the seriousness of the hazards (e.g. Class 1: not painful and ignition unlikely, Class 2: painful but no injury, ignition possible, or Class 3: injury and ignition likely)
3. Identify appropriate safeguards (e.g. make hazardous voltages inaccessible, current limiting)
4. Qualify the safeguards (e.g. ensure that tools are needed to access hazardous voltages; maximum currents are safe during normal and fault conditions)
Electric ShockMost isolated DC/DC converters are used in applications with mains-powered AC/DC primary supply. If this primary power supply fails in such a way that hazardous voltages are present on its output terminals, it is the function of the DC/DC converter to protect the user from an electric shock. In other words, if the main isolation across the AC/DC transformer fails then the secondary isolation across the DC/DC converter should protect the user from an electric shock. This concept of two independent forms of protection is the bedrock for many safety standards. In general, if the circuit is inaccessible (tools required for access), then a single isolation barrier is acceptable; otherwise at least two levels of protection are required.
Insulation ClassThree main insulation classes are defined in the safety standards.
1. Functional Insulation: The isolation is sufficient for the converter to function, meets the appropriate requirements for safety separations and will not provide a fire hazard during a fault, but the insulation is not sufficient to provide protection from an electric shock.
Most DC/DC converters are in this class as they are powered from non-hazardous voltages. A functionally insulated converter will provide limited protection from an electric shock in the event of a primary power supply failure, but they are not classed as reliable protection from a permanently hazardous input voltage. Fig. 6.1 shows an example of a functionally insulated converter. The input and output windings are wound on top of each other and rely on the wire coating for insulation. Despite this simple form of construction, isolation voltages of up to 4kVdc can be achieved.
Figure 6.1. Example of functional insulation
http://www.recom-power.com/downloads/book-of-knowledge
8
Power Developer
2. Basic of Supplementary Insulation: Satisfies the requirements of functional insulation but contains additional insulation to provide basic protection from electric shock, which is at least 0.4mm thick and also has larger internal safety separations than functional insulation.
Basic insulated DC/DC converters typically have a physical layer of insulation so that the insulation is not just dependent on the transformer wires’ lacquer. The example shown in Fig. 6.2 has a toroidal core fitted inside a plastic case which also incorporates a “bridge” that physically separates the input and output windings from each other. The ferrite core is considered conductive, so the case must also insulate each winding from the core as well as keeping the primary and secondary wings separate.
3. Double or Reinforced Insulation: The isolation satisfies the requirements of basic insulation but contains multiple physical insulation barriers to provide
enhanced protection from electric shock. Each barrier must be at least 0.4mm thick and the internal safety separations are also made larger.
Fig. 6.3 shows an example of a reinforced insulation converter. The output windings use triple insulated wires and the Mylar film provides increased creepage separation between input and output as well as offering a physical insulation barrier. Such DC/DC converters are able to withstand long-term hazardous AC voltages across them (working voltage = 250Vac) and provide up to 10kVdc isolation.
So far, Chapter 6 of the DC/DC Book of Knowledge has covered the various safety certifications needed when designing a power supply. The chapter goes on to highlight some additional safety ratings for medical and failure probability as well as risk management assessment. To read the chapter in its entirety, visit: http://www.recom-power.com/downloads/book-of-knowledge
Fig. 6.2. Example of basic insulation.
Fig. 6.3. Example of reinforced insulation.
10
Power Developer
For this Arrow New Product Insights, we will discuss three DC-to-DC step-down converters from OnSemi, muRata, and Linear Technology. We will also take a look at three JFET based products—two from Infineon and one from GeneSic.
OnSemi’s NCP1529 is an adjustable voltage step-down DC-to-DC converter, using a constant frequency, current mode step-down architecture. Using external resistors to set the output voltage, this IC can output a voltage range between point nine and three point nine volts and can source at least one amp. For greater efficiency, the NCP1529 employs two modes of operation, pulse width modulation for high efficiency with greater current and pulse frequency modulation for higher efficiency with lighter current loads. It also includes features such as soft-start, undervoltage protection, thermal shutdown protection, and current overload protection.
muRata’s LXDC3EP33A-107 is a step-down DC to DC converter with a small 3.5 by 3.2 millimeter footprint due to its inductor embedded ferrite substrate. Using synchronous rectifier technology and an automatic pulse width or pulse frequency modulation selection, this IC achieves up to ninety four percent efficiency. Accepting anywhere from two point five to five point five volts with an output between one and three point three volts, this also has been specially designed for reduced EMI.
Linear Technology’s LTC3251 DC-to-DC step-down converter uses a dual phase switched capacitor charge pump in order to drop the input voltage. The voltage is regulated by detecting the output voltage through an external resistor network and adjusting the output current based off of those readings. Linear Technology has also implemented its Spread Spectrum Operation technology, smoothing peaks in the frequency domain and decreasing overall EMI.
Infineon’s 1EDI30J12C family is a single-driver IC for a normally-on JFET. Using a JFET in conjunction with a low voltage P-channel MOSFET, switching losses are minimized while allowing a high voltage capability of up to 17.5V. This IC provides the Direct Drive JFET Topology, an optimized cascode operation that keeps the JFET in a safe off-state during the startup of the application. When the supply voltage reaches an acceptable level, the MOSFET is permanently turned on and the JFET is driven directly by the input signal.
I N S I G H T SPR DUCT
Linear Technology has implemented its Spread Spectrum Operation technology, smoothing peaks in the frequency domain and decreasing overall EMI.
This IC provides the Direct Drive JFET Topology, an
optimized cascode operation that keeps the JFET in a
safe off-state during the startup of the application.
∨
∨
PRODUCT WATCH
11
For this Arrow New Product Insights, we will discuss three DC-to-DC step-down converters from OnSemi, muRata, and Linear Technology. We will also take a look at three JFET based products—two from Infineon and one from GeneSic.
OnSemi’s NCP1529 is an adjustable voltage step-down DC-to-DC converter, using a constant frequency, current mode step-down architecture. Using external resistors to set the output voltage, this IC can output a voltage range between point nine and three point nine volts and can source at least one amp. For greater efficiency, the NCP1529 employs two modes of operation, pulse width modulation for high efficiency with greater current and pulse frequency modulation for higher efficiency with lighter current loads. It also includes features such as soft-start, undervoltage protection, thermal shutdown protection, and current overload protection.
muRata’s LXDC3EP33A-107 is a step-down DC to DC converter with a small 3.5 by 3.2 millimeter footprint due to its inductor embedded ferrite substrate. Using synchronous rectifier technology and an automatic pulse width or pulse frequency modulation selection, this IC achieves up to ninety four percent efficiency. Accepting anywhere from two point five to five point five volts with an output between one and three point three volts, this also has been specially designed for reduced EMI.
Linear Technology’s LTC3251 DC-to-DC step-down converter uses a dual phase switched capacitor charge pump in order to drop the input voltage. The voltage is regulated by detecting the output voltage through an external resistor network and adjusting the output current based off of those readings. Linear Technology has also implemented its Spread Spectrum Operation technology, smoothing peaks in the frequency domain and decreasing overall EMI.
Infineon’s 1EDI30J12C family is a single-driver IC for a normally-on JFET. Using a JFET in conjunction with a low voltage P-channel MOSFET, switching losses are minimized while allowing a high voltage capability of up to 17.5V. This IC provides the Direct Drive JFET Topology, an optimized cascode operation that keeps the JFET in a safe off-state during the startup of the application. When the supply voltage reaches an acceptable level, the MOSFET is permanently turned on and the JFET is driven directly by the input signal.
I N S I G H T SPR DUCT
Linear Technology has implemented its Spread Spectrum Operation technology, smoothing peaks in the frequency domain and decreasing overall EMI.
This IC provides the Direct Drive JFET Topology, an
optimized cascode operation that keeps the JFET in a
safe off-state during the startup of the application.
∨
∨
Arrow.com
12
Power Developer
Infineon’s IJW120R070T1 JFET combines the material properties of silicon carbide with the normally-on JFET concept, allowing for higher performance and ruggedness. To reduce switching losses compared to other conventional cascodes, the JFET is directly switched on and off by applying a negative gate voltage and 0V respectively, with the MOSFET always in an ON state except during start-up and power loss. Both the 1EDI30J12C and IJW120R070T1 are on an Infineon evaluation board, the Eval 1200V CoolSIC for easy prototyping.
GeneSiC’s GA05JT12 is a normally off Silicon Carbide JFET that is compatible with existing silicon gate-drivers. With a max operating temperature of 175 degrees Celsius, high efficiency, and the ability to withstand short circuits, this JFET is ready for usage in applications ranging from uninterruptible power supplies to down hole oil drilling.
For more info on the latest products, join us for the next Arrow New Product Insights, or look to Arrow.com.
Infineon’s IJW120R070T1 JFET combines the material properties of silicon carbide with the normally-on JFET concept, allowing for higher performance and ruggedness.
∨
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Power Developer
BD9G341AEFJ DC-DC Converter
This EEWeb Tech Lab looks at ROHM’s BD9G341AEFJ, a single-channel buck converter with an integrated FET, a wide input voltage range, and output voltage that is variable from 1V to Vcc at 3A.
The BD9G341AEFJ implements current mode architecture, providing fast transient response and simple phase compensation setup. Design is further simplified by integrating an 80V, 3.5A, 150 mΩ N-channel MOSFET. The input range of 12V to 76V allows the device to be used in distributed power applications and eliminates intermediate conversions and the associated loss in total conversion efficiency. In addition, a standby current of 0 µA makes it well-suited for battery powered applications, while a switching frequency of up to 750 kHz supports smaller inductors and provides high efficiency variable output voltage (from 1V to Vcc) at 3A.
The device comes with an evaluation kit to see how simple the implementation actually is. The board contains the converter, the output diode, and the output inductor. There is also a 47kΩ resistor that sets the clock to 200
From
ROHM’s BD9G341AEFJ DC-DC Converter
reduces design effort due to its integrated
FET and current-mode architecture.
kHz. If you decrease this resistor, you increase the clock frequency, which allows you to reduce this inductor, which ultimately allows you to reduce the size of your implementation.
ROHM’s BD9G341AEFJ DC-DC Converter reduces design effort due to its integrated FET and current-mode architecture. To watch a video demonstration of the BD9G341AEFJ, click the image below.
For more information, visit ROHM.com.
CLICK
rohm.com
PRODUCT WATCH
15
BD9G341AEFJ DC-DC Converter
This EEWeb Tech Lab looks at ROHM’s BD9G341AEFJ, a single-channel buck converter with an integrated FET, a wide input voltage range, and output voltage that is variable from 1V to Vcc at 3A.
The BD9G341AEFJ implements current mode architecture, providing fast transient response and simple phase compensation setup. Design is further simplified by integrating an 80V, 3.5A, 150 mΩ N-channel MOSFET. The input range of 12V to 76V allows the device to be used in distributed power applications and eliminates intermediate conversions and the associated loss in total conversion efficiency. In addition, a standby current of 0 µA makes it well-suited for battery powered applications, while a switching frequency of up to 750 kHz supports smaller inductors and provides high efficiency variable output voltage (from 1V to Vcc) at 3A.
The device comes with an evaluation kit to see how simple the implementation actually is. The board contains the converter, the output diode, and the output inductor. There is also a 47kΩ resistor that sets the clock to 200
From
ROHM’s BD9G341AEFJ DC-DC Converter
reduces design effort due to its integrated
FET and current-mode architecture.
kHz. If you decrease this resistor, you increase the clock frequency, which allows you to reduce this inductor, which ultimately allows you to reduce the size of your implementation.
ROHM’s BD9G341AEFJ DC-DC Converter reduces design effort due to its integrated FET and current-mode architecture. To watch a video demonstration of the BD9G341AEFJ, click the image below.
For more information, visit ROHM.com.
16
Power Developer
ZMDIZSSC1750System Basis Chip
“Using a shunt, this device is capable of measuring
charging and discharging battery current with a huge
dynamic range from milliamps to thousands of amps.”
In today’s EEWeb Tech Lab, we will be reviewing ZSSC1750 Data Acquisition System Basis Chip (SBC) from ZMDI (now IDT). A system basis chip is a system on a chip that integrates multiple ECU functions into a single die and the ZSSC1750 does this by integrating a high voltage circuit, sigma delta ADCs, analog input stage, digital filtering, and a LIN transceiver into one IC. It is designed for use with any microcontroller with an SPI interface.
PRODUCT WATCH
17
ZMDIZSSC1750System Basis Chip
“Using a shunt, this device is capable of measuring
charging and discharging battery current with a huge
dynamic range from milliamps to thousands of amps.”
In today’s EEWeb Tech Lab, we will be reviewing ZSSC1750 Data Acquisition System Basis Chip (SBC) from ZMDI (now IDT). A system basis chip is a system on a chip that integrates multiple ECU functions into a single die and the ZSSC1750 does this by integrating a high voltage circuit, sigma delta ADCs, analog input stage, digital filtering, and a LIN transceiver into one IC. It is designed for use with any microcontroller with an SPI interface.
CLICKzmdi.com
18
Power Developer
With the ADCs, the ZSSC1750 can measure
lead-acid battery voltage and current at a
rate of 1 kHz or more, as well as resolution
of up to 18 bits with no missing codes while
concurrently measuring temperature.
Simultaneous measurement of voltage
and current allows for inner resistance
calculations often used for battery state
of health estimation. Using a shunt, this
device is capable of measuring charging
and discharging battery current with a huge
dynamic range from milliamps to thousands of
amps. Accumulator registers allow accurately
calculating state of charge even in operating
modes when the microcontroller is asleep.
Click the image below to watch a video
demonstration of the ZSSC1750 evaluation kit:
KEY BENEFITS
» On-chip voltage reference
» Robust power-on-reset for harsh automotive environments
» On-chip low-power oscillator
» AEC-Q100 qualified solution
» Industry’s smallest footprint
The ZSSC1750 is an extremely small form factor, ultra-low power consumption IC that will help in any situation, automotive, medical, or industrial, that requires real time monitoring and control of battery systems. To learn more about the ZSSC1750 go to ZMDI.com.
“Using the ZSSC1750, you can do a large amount of the testing in your lab—
you can get a very good review of exactly how this IC is going to work inside of your system.”
– Josh Bishop, EEWeb Tech Lab
PRODUCT WATCH
19
With the ADCs, the ZSSC1750 can measure
lead-acid battery voltage and current at a
rate of 1 kHz or more, as well as resolution
of up to 18 bits with no missing codes while
concurrently measuring temperature.
Simultaneous measurement of voltage
and current allows for inner resistance
calculations often used for battery state
of health estimation. Using a shunt, this
device is capable of measuring charging
and discharging battery current with a huge
dynamic range from milliamps to thousands of
amps. Accumulator registers allow accurately
calculating state of charge even in operating
modes when the microcontroller is asleep.
Click the image below to watch a video
demonstration of the ZSSC1750 evaluation kit:
KEY BENEFITS
» On-chip voltage reference
» Robust power-on-reset for harsh automotive environments
» On-chip low-power oscillator
» AEC-Q100 qualified solution
» Industry’s smallest footprint
The ZSSC1750 is an extremely small form factor, ultra-low power consumption IC that will help in any situation, automotive, medical, or industrial, that requires real time monitoring and control of battery systems. To learn more about the ZSSC1750 go to ZMDI.com.
“Using the ZSSC1750, you can do a large amount of the testing in your lab—
you can get a very good review of exactly how this IC is going to work inside of your system.”
– Josh Bishop, EEWeb Tech Lab
20
Power Developer
Custom Battery Pack
By Anton Beck, Battery Product Manager Epec Engineered Technologies
Customers are often unfamiliar with battery regulatory requirements, which can lead to complications during the design of plastic enclosures. Understanding some of the design and management elements will help avoid production process complications. With any enclosure, the most important aspect is that it must be able to support the battery itself. It must also pass rigorous tests—especially when associated with transportation safety certifications.
Plastic Enclosures
Designing and Managing
TECH REPORT
21
Custom Battery Pack
By Anton Beck, Battery Product Manager Epec Engineered Technologies
Customers are often unfamiliar with battery regulatory requirements, which can lead to complications during the design of plastic enclosures. Understanding some of the design and management elements will help avoid production process complications. With any enclosure, the most important aspect is that it must be able to support the battery itself. It must also pass rigorous tests—especially when associated with transportation safety certifications.
Plastic Enclosures
Designing and Managing
22
Power Developer
One of the first steps a customer must take when approaching a manufacturer is to determine the level of design—either full or partial. A full design would allow the manufacturer to begin with a complete working knowledge of the project. The creation of CAD files, progressive meeting schedules, approval stages, and the production volume will be established based on the depth of the full or partial design. The production volume will determine the level of tooling required, which can raise costs and extend the time of a project’s completion. Tooling can raise costs and/or extend the time of a project’s completion. The ultimate goal is to get the design completed the first time through because of the cost, time involved, and tooling, but meeting the transportation certification requirements is paramount.
Branding Your EnclosureBranding the enclosure is not as complex, but just as important. Any customer looking to add their company’s branding to the application can and should do so. Product branding is available by means of labels, digital printing, or etching specific to the application requirements.
Sealing the Plastic EnclosureAfter the internal components have been secured, the enclosure has to be sealed. Take note that sealing the enclosure is part of the final assembly. Ultrasonic wielding is a method that uses high-frequency acoustic vibrations to generate heat, which melts the material and voids any need for screws or bolts.
Ultrasonic wielding is a robust and economically sound solution. Using screws or bolts are still a viable option; however, having access to surface screws or bolts may be good for repair but also easy access for end users to alter the application. Glue is another adequate sealing solution, which is typically used in lower quantities.
Figure 1. Custom battery pack enclosure with custom plastic connector components.
Figure 2. Custom branded enclosure with company logo.
Figure 3. Battery pack plastic enclosure with internal components.
Complete Battery Pack Enclosure CustomizationThe complete customization of a battery pack plastic enclosures is available right down to the plastic grade itself. It is important to understand what type of environment the application will be primarily used in, whether it be extreme or mild conditions. ABS plastic, for example, is less expensive, however it becomes very brittle when exposed to certain cold temperatures. There are a lot of plastic grades available and in some cases it is possible to create a hybrid grade.
The focus on determining the best plastic grade for any given application starts with the environmental conditions, but drop tests and transportation certification requirements should be kept in consideration.
IT IS IMPORTANT TO UNDERSTAND WHAT
TYPE OF ENVIRONMENT THE APPLICATION WILL BE PRIMARILY USED IN,
WHETHER IT BE EXTREME OR MILD CONDITIONS.
ONCE THERE IS AN UNDERSTANDING OF THE ACTUAL PRODUCT
DETAILS, SUCH AS HOW IT WILL BE USED, HANDLED AND STORED,
THE ENCLOSURE SHOULD BE DESIGNED INTERNALLY.
Securing Internal ComponentsInternal components must be secured to ensure the parts stay in place during use. Once there is an understanding of the actual product details, such as how it will be used, handled and stored, the enclosure should be designed internally.Procedures for securing internal parts include RTVs, designing ribs, combination of glues, and in most cases foam spacing—all of which help hold parts in place and minimize any shifting.
TECH REPORT
23
One of the first steps a customer must take when approaching a manufacturer is to determine the level of design—either full or partial. A full design would allow the manufacturer to begin with a complete working knowledge of the project. The creation of CAD files, progressive meeting schedules, approval stages, and the production volume will be established based on the depth of the full or partial design. The production volume will determine the level of tooling required, which can raise costs and extend the time of a project’s completion. Tooling can raise costs and/or extend the time of a project’s completion. The ultimate goal is to get the design completed the first time through because of the cost, time involved, and tooling, but meeting the transportation certification requirements is paramount.
Branding Your EnclosureBranding the enclosure is not as complex, but just as important. Any customer looking to add their company’s branding to the application can and should do so. Product branding is available by means of labels, digital printing, or etching specific to the application requirements.
Sealing the Plastic EnclosureAfter the internal components have been secured, the enclosure has to be sealed. Take note that sealing the enclosure is part of the final assembly. Ultrasonic wielding is a method that uses high-frequency acoustic vibrations to generate heat, which melts the material and voids any need for screws or bolts.
Ultrasonic wielding is a robust and economically sound solution. Using screws or bolts are still a viable option; however, having access to surface screws or bolts may be good for repair but also easy access for end users to alter the application. Glue is another adequate sealing solution, which is typically used in lower quantities.
Figure 1. Custom battery pack enclosure with custom plastic connector components.
Figure 2. Custom branded enclosure with company logo.
Figure 3. Battery pack plastic enclosure with internal components.
Complete Battery Pack Enclosure CustomizationThe complete customization of a battery pack plastic enclosures is available right down to the plastic grade itself. It is important to understand what type of environment the application will be primarily used in, whether it be extreme or mild conditions. ABS plastic, for example, is less expensive, however it becomes very brittle when exposed to certain cold temperatures. There are a lot of plastic grades available and in some cases it is possible to create a hybrid grade.
The focus on determining the best plastic grade for any given application starts with the environmental conditions, but drop tests and transportation certification requirements should be kept in consideration.
IT IS IMPORTANT TO UNDERSTAND WHAT
TYPE OF ENVIRONMENT THE APPLICATION WILL BE PRIMARILY USED IN,
WHETHER IT BE EXTREME OR MILD CONDITIONS.
ONCE THERE IS AN UNDERSTANDING OF THE ACTUAL PRODUCT
DETAILS, SUCH AS HOW IT WILL BE USED, HANDLED AND STORED,
THE ENCLOSURE SHOULD BE DESIGNED INTERNALLY.
Securing Internal ComponentsInternal components must be secured to ensure the parts stay in place during use. Once there is an understanding of the actual product details, such as how it will be used, handled and stored, the enclosure should be designed internally.Procedures for securing internal parts include RTVs, designing ribs, combination of glues, and in most cases foam spacing—all of which help hold parts in place and minimize any shifting.
24
Power Developer
Safety Circuits Required for Lithium BatteriesLithium batteries installed in a battery enclosure are required to have a safety PCB connected due to the transportation certification. In some cases a nickel hydride battery will have a safety circuit installed. The basic functionality of having a safety circuit in place is to protect the battery from overcharging, short-circuiting, over-discharging, and cell balancing.
If there are multiple battery cells within a battery pack, they need to operate in sequence. If the cells don’t function in sequence they will continue to drift out of balance—ultimately causing expediential reduced battery cycle life.
Upgrading a Battery Pack’s Existing DesignIf a customer needs to replace an outdated battery or improve the battery enclosure altogether that is a possibility. To achieve this, a customer’s data files would be ideal so we can copy the external dimensions. A customer’s sample of the preexisting design would also prove to be beneficial. Going from an outdated battery to a lithium battery will lead to changing battery chemistries. This result will alter the design of the battery, and will also change the internal design of the enclosure.
Change the battery and chemistry will alter space availability, but there is also the ability to reverse-engineer the entire battery design to meet the customer’s current enclosure to minimize cost. If the customer has a new enclosure in the budget it would be the best available decision. Ultimately we would be creating an entirely new upgraded solution for the customer.
Changing Cell TypesThere are common battery cell types available and typically customers tend to go that route. The more common types of battery cells are more economically favorable. A customer may even choose to go from a cylindrical battery to a prismatic battery but more often than not customers usually want to stay with the common form factor.
There may need to be alterations made to the enclosure such as cutting, standoffs, or adding additional foam padding if the solution is smaller. There are ways around the design to customize it using either an existing enclosure or modifying it to meet the new battery.
ITAR-sensitive Battery Pack ApplicationsITAR-sensitive battery pack projects must be completely managed domestically in the United States. “For epec, the design and development would be conducted in our Denver, Colorado technical center, and all assembly would be managed at Epec’s headquarters in New Bedford, Massachusetts. There are secure IT resources in place and all necessary actions have been taken to work within compliance with the Department of State.
Figure 4. Lithium battery pack with safety circuitry.
ConclusionIt is best that you understand the process of how your manufacturer will manage and design your project’s battery pack’s plastic enclosure. Knowledge of the elements of the overall design benefits the customer. Having this Knowledge of the overall design and its elements will benefit the customer’s solution.
IF THE SOLUTION IS SMALLER, THERE MAY NEED TO BE ALTERATIONS MADE
TO THE ENCLOSURE SUCH AS CUTTING, STANDOFFS, OR ADDING FOAM PADDING.
TECH REPORT
25
Safety Circuits Required for Lithium BatteriesLithium batteries installed in a battery enclosure are required to have a safety PCB connected due to the transportation certification. In some cases a nickel hydride battery will have a safety circuit installed. The basic functionality of having a safety circuit in place is to protect the battery from overcharging, short-circuiting, over-discharging, and cell balancing.
If there are multiple battery cells within a battery pack, they need to operate in sequence. If the cells don’t function in sequence they will continue to drift out of balance—ultimately causing expediential reduced battery cycle life.
Upgrading a Battery Pack’s Existing DesignIf a customer needs to replace an outdated battery or improve the battery enclosure altogether that is a possibility. To achieve this, a customer’s data files would be ideal so we can copy the external dimensions. A customer’s sample of the preexisting design would also prove to be beneficial. Going from an outdated battery to a lithium battery will lead to changing battery chemistries. This result will alter the design of the battery, and will also change the internal design of the enclosure.
Change the battery and chemistry will alter space availability, but there is also the ability to reverse-engineer the entire battery design to meet the customer’s current enclosure to minimize cost. If the customer has a new enclosure in the budget it would be the best available decision. Ultimately we would be creating an entirely new upgraded solution for the customer.
Changing Cell TypesThere are common battery cell types available and typically customers tend to go that route. The more common types of battery cells are more economically favorable. A customer may even choose to go from a cylindrical battery to a prismatic battery but more often than not customers usually want to stay with the common form factor.
There may need to be alterations made to the enclosure such as cutting, standoffs, or adding additional foam padding if the solution is smaller. There are ways around the design to customize it using either an existing enclosure or modifying it to meet the new battery.
ITAR-sensitive Battery Pack ApplicationsITAR-sensitive battery pack projects must be completely managed domestically in the United States. “For epec, the design and development would be conducted in our Denver, Colorado technical center, and all assembly would be managed at Epec’s headquarters in New Bedford, Massachusetts. There are secure IT resources in place and all necessary actions have been taken to work within compliance with the Department of State.
Figure 4. Lithium battery pack with safety circuitry.
ConclusionIt is best that you understand the process of how your manufacturer will manage and design your project’s battery pack’s plastic enclosure. Knowledge of the elements of the overall design benefits the customer. Having this Knowledge of the overall design and its elements will benefit the customer’s solution.
IF THE SOLUTION IS SMALLER, THERE MAY NEED TO BE ALTERATIONS MADE
TO THE ENCLOSURE SUCH AS CUTTING, STANDOFFS, OR ADDING FOAM PADDING.
26
Power Developer
CUI Ushers in the New Age of Digital Power
Interview with Mark Adams – CUI
The power landscape is always changing. As the demand for efficiency and robustness rises due to data center and IoT applications, engineers are looking for more enhanced power products to meet these new requirements. Evolving from digital power foundations, CUI has placed significant development efforts on a software-defined power infrastructure that moves away from module-based solutions on towards a complete power ecosystem. EEWeb spoke with CUI’s Mark Adams about the unique benefits of a software-defined power ecosystem, the new industry power requirements for IoT and data storage applications, and how power is coming to the forefront of product design.
The Move Towards Software-defined
POWER
INDUSTRY INTERVIEW
27
CUI Ushers in the New Age of Digital Power
Interview with Mark Adams – CUI
The power landscape is always changing. As the demand for efficiency and robustness rises due to data center and IoT applications, engineers are looking for more enhanced power products to meet these new requirements. Evolving from digital power foundations, CUI has placed significant development efforts on a software-defined power infrastructure that moves away from module-based solutions on towards a complete power ecosystem. EEWeb spoke with CUI’s Mark Adams about the unique benefits of a software-defined power ecosystem, the new industry power requirements for IoT and data storage applications, and how power is coming to the forefront of product design.
The Move Towards Software-defined
POWER
28
Power Developer
Could you explain what you consider to be software-defined power?
Software-defined power is the new industry buzzword that has evolved from the digital age of power. The concept of digital power means taking the analog functionality of power and giving it a brain. To achieve a software-defined infrastructure, intelligence is needed from a control aspect as well as monitoring of the information gathered, so that algorithms can be created in order to achieve greater efficiencies and overall performance. The next logical step is for the complete power architecture to become software-defined, taking advantage of digital power adaptability and introducing software control to manage the entire power system continuously as operating conditions change. Power is no longer viewed simply as a series of modules, or “power islands.” With the advent of software-defined power, it has transformed into an ecosystem where the whole has the potential to be greater than the sum of the parts. The connections between the power modules are now driving the real gains in performance. As power quickly moves from the analog to the digital world, many possibilities at the infrastructure-level are beginning to arise.
What are some real-life examples of software-defined power applications?
I recently rented a car when I was on a business trip in Europe, where there is a proliferation of stop-start technology to improve fuel consumption. When you are sitting at a light, the car shuts off, disconnecting the gas. When the light turns green and you press on the gas, the engine starts again and off you go. This approach leverages the idea that when power is not needed, the system goes into a reduced or idle state, thus saving energy. This simple approach has proven to save 10% on fuel consumption in cars with this technology. The electronics industry has also looked at this idea to save power when it is not needed—or at a minimum, reduce consumption as the need changes. As power quickly moves from the analog to the digital world, many possibilities at the infrastructure level are beginning to arise.
The concept of digital power means taking
the analog functionality
of power and giving it a brain.
The additional power required to support IoT represents the biggest challenge facing power developers in the coming years.
INDUSTRY INTERVIEW
29
Could you explain what you consider to be software-defined power?
Software-defined power is the new industry buzzword that has evolved from the digital age of power. The concept of digital power means taking the analog functionality of power and giving it a brain. To achieve a software-defined infrastructure, intelligence is needed from a control aspect as well as monitoring of the information gathered, so that algorithms can be created in order to achieve greater efficiencies and overall performance. The next logical step is for the complete power architecture to become software-defined, taking advantage of digital power adaptability and introducing software control to manage the entire power system continuously as operating conditions change. Power is no longer viewed simply as a series of modules, or “power islands.” With the advent of software-defined power, it has transformed into an ecosystem where the whole has the potential to be greater than the sum of the parts. The connections between the power modules are now driving the real gains in performance. As power quickly moves from the analog to the digital world, many possibilities at the infrastructure-level are beginning to arise.
What are some real-life examples of software-defined power applications?
I recently rented a car when I was on a business trip in Europe, where there is a proliferation of stop-start technology to improve fuel consumption. When you are sitting at a light, the car shuts off, disconnecting the gas. When the light turns green and you press on the gas, the engine starts again and off you go. This approach leverages the idea that when power is not needed, the system goes into a reduced or idle state, thus saving energy. This simple approach has proven to save 10% on fuel consumption in cars with this technology. The electronics industry has also looked at this idea to save power when it is not needed—or at a minimum, reduce consumption as the need changes. As power quickly moves from the analog to the digital world, many possibilities at the infrastructure level are beginning to arise.
The concept of digital power means taking
the analog functionality
of power and giving it a brain.
The additional power required to support IoT represents the biggest challenge facing power developers in the coming years.
30
Power Developer
It usually takes 12 kW to power a server rack and another 6 kW just to keep it cool. With plenty of room to improve, software can help to remove these massive losses by limiting the amount of time that the equipment operates. A data center is designed to support a maximum level of traffic, but in reality
runs at 30-50% utilization most of the time. It must always be prepared for the next event that will spike usage. Looking again at the car I rented, it was designed with different transmission settings, from Eco all the way to Performance. Each step gave me a higher level of performance for driving, but lower fuel optimization.
Software-defined power can do the same thing for the data center, running the equipment on “Eco Mode” most of the time, then quickly transitioning the system to “Performance Mode” when there is a spike in traffic.
Power consumption is becoming an even greater problem because of the Internet of Things (IoT), which is quickly moving to the Internet of Everything (IoE). IoT devices are proliferating across every industry, from retail, transportation, infrastructure management, and manufacturing, to mining, food production, and security. All of these devices are producing information that must be communicated, stored, and backed-up at data centers. In a few years, we will be approaching almost a trillion deployed sensors,
adding strain to the infrastructure. The additional power required to support IoT represents the biggest challenge facing power developers in the coming years. Software-defined power is providing engineers and data center managers the ability to actively manage power delivery in real time as load requirements change.
A recent report stated that by 2020, data centers will consume 140-billion kilowatt-hours, which is probably underestimated. With numbers that high, what kinds of power savings are possible?
Data center usage represents over 10% of the world’s electricity consumption, which is why CUI believes this area presents the best opportunity to leverage the concept of software-defined power to deliver energy savings. In fact, CUI has recently signed an agreement with a software company in San Jose, California to collaborate on development in this space. There is data available that shows we can go from $1-million per megawatt/year to $850-thousand per megawatt/year with a more optimized system and with significantly reduced capital expenditure. By employing techniques such as intelligent power allocation across server racks, reducing peak power loads by leveraging real-time power caching, and using historical patterns to intelligently allocate power to individual nodes, CUI believes it is possible to save ten to fifteen-percent in power consumption compared to existing infrastructure technologies.
How does the Architects of Modern Power™ (AMP Group) fit into all of this?
The Architects of Modern Power is a group founded by CUI, Ericsson Power Modules, and Murata to focus on advanced power products, most of which incorporate digital control. We are collaborating to provide the customers with the most complete solutions available today, and tomorrow. With the growing move toward software-defined power systems, the ongoing requirement for true multi-sourcing options requires a much deeper look into the structure of the power supply. Not only do power supplies need to be mechanically compatible, but the controllers and configuration files need to be 100% compatible as well. If any of this is not present, then disruptions to
The AMP Group is working to develop
standards that are not only mechanically compatible, but software compatible
as well.
production flow could occur—or even worse, incompatibility on the board could cause failures. The AMP Group is working to develop standards that are not only mechanically compatible, but software compatible as well.
The other important point is that the AMP Group will drive future innovations through collaboration on technology roadmaps. Because this is much more than a mechanical group, we are working closely with leading semiconductor companies and customers to define the features and performance metrics that will be needed by the systems one, three, and even five years down the road. It is truly a collaborative commitment that will make this consortium successful and allow the customer base to rely on AMP Group products for their designs.
Technology Collaboration From Design to Production
Collaboration ensures consistent product performance between partners and accelerates innovation to meet customer design challenges.
Developing a Product Roadmap for Tomorrow’s Power Needs
Our industry’s greatest challenge is to create and deliver a technology roadmap for an intelligent power ecosystem in line with the needs of the future.
True Multi-Source Compatibility
• Common Footprints • Common Feature Sets • Common Configuration Sets
INDUSTRY INTERVIEW
31
It usually takes 12 kW to power a server rack and another 6 kW just to keep it cool. With plenty of room to improve, software can help to remove these massive losses by limiting the amount of time that the equipment operates. A data center is designed to support a maximum level of traffic, but in reality
runs at 30-50% utilization most of the time. It must always be prepared for the next event that will spike usage. Looking again at the car I rented, it was designed with different transmission settings, from Eco all the way to Performance. Each step gave me a higher level of performance for driving, but lower fuel optimization.
Software-defined power can do the same thing for the data center, running the equipment on “Eco Mode” most of the time, then quickly transitioning the system to “Performance Mode” when there is a spike in traffic.
Power consumption is becoming an even greater problem because of the Internet of Things (IoT), which is quickly moving to the Internet of Everything (IoE). IoT devices are proliferating across every industry, from retail, transportation, infrastructure management, and manufacturing, to mining, food production, and security. All of these devices are producing information that must be communicated, stored, and backed-up at data centers. In a few years, we will be approaching almost a trillion deployed sensors,
adding strain to the infrastructure. The additional power required to support IoT represents the biggest challenge facing power developers in the coming years. Software-defined power is providing engineers and data center managers the ability to actively manage power delivery in real time as load requirements change.
A recent report stated that by 2020, data centers will consume 140-billion kilowatt-hours, which is probably underestimated. With numbers that high, what kinds of power savings are possible?
Data center usage represents over 10% of the world’s electricity consumption, which is why CUI believes this area presents the best opportunity to leverage the concept of software-defined power to deliver energy savings. In fact, CUI has recently signed an agreement with a software company in San Jose, California to collaborate on development in this space. There is data available that shows we can go from $1-million per megawatt/year to $850-thousand per megawatt/year with a more optimized system and with significantly reduced capital expenditure. By employing techniques such as intelligent power allocation across server racks, reducing peak power loads by leveraging real-time power caching, and using historical patterns to intelligently allocate power to individual nodes, CUI believes it is possible to save ten to fifteen-percent in power consumption compared to existing infrastructure technologies.
How does the Architects of Modern Power™ (AMP Group) fit into all of this?
The Architects of Modern Power is a group founded by CUI, Ericsson Power Modules, and Murata to focus on advanced power products, most of which incorporate digital control. We are collaborating to provide the customers with the most complete solutions available today, and tomorrow. With the growing move toward software-defined power systems, the ongoing requirement for true multi-sourcing options requires a much deeper look into the structure of the power supply. Not only do power supplies need to be mechanically compatible, but the controllers and configuration files need to be 100% compatible as well. If any of this is not present, then disruptions to
The AMP Group is working to develop
standards that are not only mechanically compatible, but software compatible
as well.
production flow could occur—or even worse, incompatibility on the board could cause failures. The AMP Group is working to develop standards that are not only mechanically compatible, but software compatible as well.
The other important point is that the AMP Group will drive future innovations through collaboration on technology roadmaps. Because this is much more than a mechanical group, we are working closely with leading semiconductor companies and customers to define the features and performance metrics that will be needed by the systems one, three, and even five years down the road. It is truly a collaborative commitment that will make this consortium successful and allow the customer base to rely on AMP Group products for their designs.
Technology Collaboration From Design to Production
Collaboration ensures consistent product performance between partners and accelerates innovation to meet customer design challenges.
Developing a Product Roadmap for Tomorrow’s Power Needs
Our industry’s greatest challenge is to create and deliver a technology roadmap for an intelligent power ecosystem in line with the needs of the future.
True Multi-Source Compatibility
• Common Footprints • Common Feature Sets • Common Configuration Sets
32
Power Developer
How does CUI’s recent acquisition of Canadian Power Supply Manufacturer Tectrol play into the grand scheme of things?
CUI has been designing products at the point-of-load and the bus converter level for some time, so Tectrol represented a logical addition in order to strengthen our position in the power market. The acquisition provides us with a talented AC-DC design team as well as a manufacturing arm here in North America, allowing CUI to bring products to market faster. We are now able to address all aspects of a software-defined power system, from the front-end power supply to the point-of-load.
In what ways is power coming to the forefront in product design?
Significant innovations in semiconductor technology have taken place over the past few years to address the growth in cloud computing and IoT, which has had a tremendous impact on board-level power infrastructure. These innovations have driven-up the power demands relating to performance, complexity, and flexibility. In the last decade alone, the supply voltage for high-density logic and processor devices has fallen from an average of 3V, to as low as a 0.6V threshold level in some cases. Similarly, power demands for server-class equipment, which are generally
Over a typical lifetime of three years, the cost to power a server actually exceeds the equipment purchase price.
thermally limited, are still up to and beyond 100W. The result is a current demand approaching a 150A threshold at the point of load (POL) with increasingly tight voltage tolerances. This drive for perfect power conversion is stressing conventional power architectures and circuit design. Furthermore, this level of performance is expected to be designed into the same, if not smaller physical space in each successive generation of product. It is demanding a revolution in the way system suppliers and component manufacturers deal with the emerging compromises forced into the design mix.
At the infrastructure-level, energy is the most significant resource consumed by the data centers at the heart of today’s cloud and IoT services. Over a typical lifetime of three years, the cost to power a server actually exceeds the equipment purchase price. The cost of running the cooling systems vital to maintain a safe equipment-operating temperature must also be considered. The desire to minimize these costs is a serious concern for data center operators, bringing power to the forefront of the conversation.
34
Power Developer
Offer Benefits in Every Detail
When talking about the rise of new technologies, it’s
definitely no question that the automotive market is of major interest in the industry. With a revolution of alternative energy and power efficiency progressing at lightning speed through the automotive world, the possibilities for new power management technologies seem boundless. Cypress Semiconductor, a leading solution provider in everything from leading-edge SoC technology to memory, has recently launched a line of power management ICs (PMICs) for automotive applications that address the industry trends of efficiency and reliability. EEWeb spoke with Sven Natus of Cypress Semiconductor, about the benefits of the new line of PMICs and the new horizon of automotive power technology applications.
Automotive PMICs
from Cypress
35
EEWeb FEATURE
Offer Benefits in Every Detail
When talking about the rise of new technologies, it’s
definitely no question that the automotive market is of major interest in the industry. With a revolution of alternative energy and power efficiency progressing at lightning speed through the automotive world, the possibilities for new power management technologies seem boundless. Cypress Semiconductor, a leading solution provider in everything from leading-edge SoC technology to memory, has recently launched a line of power management ICs (PMICs) for automotive applications that address the industry trends of efficiency and reliability. EEWeb spoke with Sven Natus of Cypress Semiconductor, about the benefits of the new line of PMICs and the new horizon of automotive power technology applications.
Automotive PMICs
from Cypress
36
Power Developer
Formed in 1982, Cypress has grown from what Natus calls a basic ‘microcontroller bending’ company into an industry leader with a full portfolio of products. Providing a wide variety of memory, microcontrollers, and analog products like power management ICs, Cypress, via its recent merger with Spansion, has certainly transformed itself into a serious player in the world of progressive automotive technologies. Today, Natus says, “the idea at Cypress is to leverage our broad range products in our portfolio to offer truly comprehensive and custom solutions to our customers.” For example, the company recently made a significant design win for the U.S. auto market that combines memories, microcontrollers, one of Cypress’ pioneering PSoC (programmable system-on-chip) devices, and a power management IC into one powerful engine control unit (ECU). In terms of variety and integration, Natus remarks that “what we are really aiming for is how we can combine Cypress’s products to bring best possible value to our customers.”
The company also offers a succinct summary of the critical role that ECUs play in today’s vehicles, saying that “ECUs are now used for critical systems. They must be protected against harsh thermal and electrical conditions to ensure proper operation.” Cypress automotive PMICs support system safety functions by providing input voltage supervisors, output voltage/current supervisors, thermal management, and watch-dog timers to protect ECUs from damage and erroneous operation. As implied, a lot of energy in the automotive department
at Cypress is being oriented toward the company’s portfolio of automotive PMICs. Currently, three different distinct types of automotive PMICs provide the company’s customers with a multifaceted and scalable approach to custom solutions. “We want to keep our solutions as widely accessible as possible,” Natus points out.
Scalable Power Management Solutions for Automotive
Cypress bases its series of designs on a single-voltage rail PMIC called the S6BP20x, which is available in a variety of voltage configurations. These primary PMICs, which are attached to the battery as first-stage managers of current, demonstrate particular value in providing a very wide input voltage. Natus explains that common voltage fluctuations, as when starting the car, can expose the electrical system to risks of both cold-crank (low voltage) and load-dump (high voltage) scenarios. Providing efficient protection, however, the company’s primary PMICs are designed to operate within a range of 2.5V to 42V and can handle an unusually wide amount of possible fluctuation.
Also in the company’s tier of primary PMICs, the S6BP50x provides three additional output voltage rails and work seamlessly with Cypress’s Traveo microcontrollers that bring sharp graphics to driver information applications such as instrument clusters.
“For advanced driver assistance systems (ADAS) applications,” he explains, “Cypress provides a secondary PMIC oriented toward providing multiple output voltage rails and allowing customers to create a whole cluster or HUD.” To achieve that goal, the company’s S6BP40x design provides customers with up to six additional output voltages, including low-power regulation modes.
Customer Benefits in Every Detail
Compared to their most direct competition, Cypress products not only offer a very wide range of input voltages, but also provide the advantage of small footprints. “Cypress optimizes its PMIC products to run very efficiently in terms of conversion, with a switching frequency of up to 2MHz. This allows us to work with very small peripheral components,” Natus describes. “The higher the
Cypress automotive PMICs support system safety functions by providing input voltage supervisors, output voltage/current supervisors, thermal management, and watch-dog timers to protect ECUs from damage and erroneous operation.
“Common voltage fluctuations, as when starting the car, can expose the electrical system to risks of both cold-crank (low voltage) and load-dump (high voltage) scenarios.”
37
EEWeb FEATURE
Formed in 1982, Cypress has grown from what Natus calls a basic ‘microcontroller bending’ company into an industry leader with a full portfolio of products. Providing a wide variety of memory, microcontrollers, and analog products like power management ICs, Cypress, via its recent merger with Spansion, has certainly transformed itself into a serious player in the world of progressive automotive technologies. Today, Natus says, “the idea at Cypress is to leverage our broad range products in our portfolio to offer truly comprehensive and custom solutions to our customers.” For example, the company recently made a significant design win for the U.S. auto market that combines memories, microcontrollers, one of Cypress’ pioneering PSoC (programmable system-on-chip) devices, and a power management IC into one powerful engine control unit (ECU). In terms of variety and integration, Natus remarks that “what we are really aiming for is how we can combine Cypress’s products to bring best possible value to our customers.”
The company also offers a succinct summary of the critical role that ECUs play in today’s vehicles, saying that “ECUs are now used for critical systems. They must be protected against harsh thermal and electrical conditions to ensure proper operation.” Cypress automotive PMICs support system safety functions by providing input voltage supervisors, output voltage/current supervisors, thermal management, and watch-dog timers to protect ECUs from damage and erroneous operation. As implied, a lot of energy in the automotive department
at Cypress is being oriented toward the company’s portfolio of automotive PMICs. Currently, three different distinct types of automotive PMICs provide the company’s customers with a multifaceted and scalable approach to custom solutions. “We want to keep our solutions as widely accessible as possible,” Natus points out.
Scalable Power Management Solutions for Automotive
Cypress bases its series of designs on a single-voltage rail PMIC called the S6BP20x, which is available in a variety of voltage configurations. These primary PMICs, which are attached to the battery as first-stage managers of current, demonstrate particular value in providing a very wide input voltage. Natus explains that common voltage fluctuations, as when starting the car, can expose the electrical system to risks of both cold-crank (low voltage) and load-dump (high voltage) scenarios. Providing efficient protection, however, the company’s primary PMICs are designed to operate within a range of 2.5V to 42V and can handle an unusually wide amount of possible fluctuation.
Also in the company’s tier of primary PMICs, the S6BP50x provides three additional output voltage rails and work seamlessly with Cypress’s Traveo microcontrollers that bring sharp graphics to driver information applications such as instrument clusters.
“For advanced driver assistance systems (ADAS) applications,” he explains, “Cypress provides a secondary PMIC oriented toward providing multiple output voltage rails and allowing customers to create a whole cluster or HUD.” To achieve that goal, the company’s S6BP40x design provides customers with up to six additional output voltages, including low-power regulation modes.
Customer Benefits in Every Detail
Compared to their most direct competition, Cypress products not only offer a very wide range of input voltages, but also provide the advantage of small footprints. “Cypress optimizes its PMIC products to run very efficiently in terms of conversion, with a switching frequency of up to 2MHz. This allows us to work with very small peripheral components,” Natus describes. “The higher the
Cypress automotive PMICs support system safety functions by providing input voltage supervisors, output voltage/current supervisors, thermal management, and watch-dog timers to protect ECUs from damage and erroneous operation.
“Common voltage fluctuations, as when starting the car, can expose the electrical system to risks of both cold-crank (low voltage) and load-dump (high voltage) scenarios.”
38
Power Developer
“There’s a big focus on attention to detail,” Natus concludes. “Some of our PMICs are even equipped with a spread-spectrum clock generator, which distributes noise over a wide bandwidth to avoid the possibility of radio interference,” he says. In keeping with the growing industry standard of providing workshop software for designers and engineers to virtually design and test products, Cypress also continues working on providing their web-based Easy DesignSim™ software. For the time being, it only provides service relative to one of the company’s automotive PMIC designs, but, as Natus points out, the teams at Cypress are working as hard as possible to get everything that the company has available into the system architecture as soon as possible. Considering the speed of innovation in the market thanks to the work of companies like Cypress, it’s not hard to expect plenty of the company’s plans coming together in the increasingly tangible future.
switching frequency, the smaller peripheral components like inductors and capacitors can be used,” and this earns a very small comparative footprint, which also naturally translates into lower total costs. “The idea is to make the whole PMIC scheme entirely scalable to any custom solutions,” Natus says, “not only microcontrollers, but controllers combined with any possible array of other devices to maximize the customer’s approach to the automotive market.”
Further, he explains, Cypress products also do a very good job meeting the standards of OEMs—in this case, car manufacturers—in terms of EMC compliance and how much current is being consumed when a vehicle is switched off. “Generally, an ECU is required to stay below 100µA to keep from draining the battery unnecessarily,” Natus details, adding that “it’s important for us that our products are in a very low range of consumption that helps to optimize a truly modern power-optimized design. As an example, our S6BP50x is designed to meet a typical quiescent current of 15µA.” The completely separate switching scheme for low-power operation in the company’s designs serve to increase that capability even further.
“...Cypress also continues working on providing their web-based Easy DesignSim™ software.”
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