Coupled inductors on silicon for PwrSoC in the frame of PowerSwipe project
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1 Coupled inductors on silicon for PwrSoC in the frame of PowerSwipe project Santosh Kulkarni*, Bruno Allard** *Microsystems Centre, Tyndall National Institute, University College Cork, Ireland **Ampere lab, INSA Lyon, France PAGE 1
2 PowerSwipe Concept PAGE 2 2
3 PowerSwipe Consortium Partners First EU Funded programme on PwrSoC/PwrSiP PAGE 3 3
4 Powerswipe-Demonstrators SOC + LV-PMIC Passive Interposer PCB Motherboard Demo 1- Low Frequency dc-dc for Automotive Passive LC Demo 2- High Frequency dc-dc for multi-phase IVR applications PAGE 4
5 Powerswipe integrated coupled inductors Summary of presentation Design, Fabrication & Small Signal testing of Loosely coupled inductor device Large Signal characterization of integrated coupled inductors Large signal Inductance, resistance, BH loop Impact of dc bias on magnetic material under test Summary PAGE 5
6 Achieve miniaturisation of power passives: Increased switching frequency of switched-mode DC-DC converter ( MHz) Power passives footprint comparable to DC-DC converter IC (1 to 2 mm 2 ) HF DC-DC converter-specs Inductor design Freq. (MHz) L (nh) Coupling factor PowerSwipe Motivation/Objectives Efficiency (magnetics) Efficiency (IC) Total efficiency Coupled ~0.4 90% 90,4% 81% Design 1: Coupled inductor PAGE 6
7 PowerSwipe coupled inductor Design & Fabrication L (nh) Core Length Core Thickness Copper width Copper Thickness DCR (Ohm) Device Footprint 45 Coupled 0.95 mm 2 μm 40 μm 15 μm mm2 45nH Coupled Coupled inductor prototype Device Schematic Device Cross-section PAGE 7
8 Powerswipe coupled inductor Small signal Characterization Small signal testing: LCR meter & 4-probe Kelvin setup- INSA Lyon ü Good frequency & current response 20% drop Small signal testing: L vs DC bias- Tyndall I sat =650mA PAGE 8
9 Powerswipe coupled inductor Coupling Measurement Two port VNA test for coupling k measured = 0.38; k design = 0.4 PAGE 9
10 Large Signal Characterization Set-up Signal generator- Agilent E8257D Power amplifier- Applied Research 25A250A Current probe- Pearson current 2877 Voltage probe- Tap 1500 PAGE 10
11 Test circuit for coupled inductor measurement Key issues with large signal testing set-up - Noise - Use 4 wire measurement for the DUT - Error in amplitude & phase measurement - Attenuation & time delay from current & voltage probes - Accurate compensation system to correct this skew - Compensation is done through a measurement on a capacitor of known impedance PAGE 11
12 Voltage & Current waveforms for Capacitor- Compensation Time 40MHz ns Current attenuation PAGE 12
13 Inductance & DC resistance measurements Inductance (Self/Mutual) stays constant upto 60MHz Resistance measurement shows a dramatic increase after 60MHz This behaviour not consistent with small signal test data Possible explanation- Voltage probes damaged PAGE 13
14 DC bias measurements Voltage & Current waveforms including compensated current loops Iac- 20mA; Ferquency- 60MHz DC saturation current- 700 ma (consistent with small signal measurement) PAGE 14
15 Large signal testing to plot BH different bias currents 10 Hz - B value estimated using Faraday s law - H value estimated using Ampere s law PAGE 15
16 Final circuit testing of Powerswipe coupled inductors Inductor Passive Interposer Switch Initial test on single phase discrete inductor with Interposer completed Circuit testing of coupled inductor with VR ongoing at INSA, Lyon- Result will be presented at future conferences PAGE 16
17 Benchmarking Powerswipe VR performance 110MHz, board MHz, interposer Load current (A) Interposer V Load current (A) V Active die 20 State of the art 100 MHz cascode 100 MHz standard V 11 nf VOUT/VIN Ä Efficiency Globally better on interposer Slightly increased on-board for low load current 11 nf 33 nf 60 nh 16 nf PAGE Frequency (MHz) nf Efficiency (%) Efficiency (V)
18 Summary First EU funded project on PwrSoC/PwrSiP Target applications- Automotive & IVR Developed multiphase coupled inductors for IVR Racetrack coupled inductors designed using CAD tool Fabricated using Tyndall s Double Metal Layer process Small signal measurement in good agreement with design data Developed large signal characterization system for measuring coupled inductor performance Circuit level testing of VR s ongoing PAGE 18
19 Acknowledgements Tyndall National Institute- Prof. Cian O Mathuna, Dr. Paul McCloskey, Dr. Ningning Wang, Dr. Zoran Pavolvic, Ricky Anthony, Nicolas Cordero, Margaret Hegarty, Joe O Brien, Declan Casey, James Rohan, Anne-Marie Kelleher, Graeme Maxwell Lab Ampere, INSA, Lyon- Florian Neveu, Dr. Christian Martin Universidad Carlos III de Madrid- Dr. Cristina Fernandez Herrero Funding- European Union for funding the work through FP7 (Project: PowerSwipe) under Grant PAGE 19
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72 Resonant Frequency of the LRC Circuit (Power Output, Voltage Sensor) Equipment List Qty Items Part Numbers 1 PASCO 750 Interface 1 Voltage Sensor CI-6503 1 AC/DC Electronics Laboratory EM-8656 2 Banana