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High Efficient Power Conversion from Car Batteries to Next Generation Microcontroller Systems (PwrSwipe) Gerhard Maderbacher 1 , Karlheinz Kogler 1 , Joachim Pichler 1 , Federico Capponi 1 , Herbert Gruber 1 , Sylvia Michaelis 1 , Dietrich Michaelis 1 , Andreas Einwanger 2 , Christoph Sandner 1 , Anamaria Anca 1 , Gottfried Beer 2 1 Infineon Technologies Austria AG - Villach, 2 Infineon Technologies AG - Regensburg Abstract Project Partners Goal was to design a PMU with reduced footprint at competitive costs and performance The target application is an automotive microcontroller system in 40nm CMOS technology with multiple power domains This work is a pre-study for next generation fully integrated power management systems for automotive applications Automotive Applications Body Applications Board Supply in a Car Demonstrator HV-Chip: 130nm BCD CMOS LV-Chip: 40nm (Flash) CMOS High Voltage Pre-Regulator: Vin: 16V…6V Vout: 5V/3.3V Iload max : 500mA Peak efficiency: 80% Low Voltage Regulators Vin: 5V/3.3V Vout: 1.2V/1.3V Iload max : 500mA/200mA Peak efficiency: 90% IFAT: Chip Design Lyon: Chip Design IFAG: Packaging Tyndall: Power Inductor, Consortium Lead IPDiA: Capacitors & Interposer UPM: Concept Bosch: Application & Requirements Funded by EU FP7-ICT-2011-8 PowerSWIPE Project no.: 318529

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Page 1: High Efficient Power Conversion from Car Batteries …pwrsocevents.com/wp-content/uploads/2014-presentations/ep...High Efficient Power Conversion from Car Batteries to Next Generation

High Efficient Power Conversion from Car Batteries to Next Generation Microcontroller Systems (PwrSwipe)

Gerhard Maderbacher1, Karlheinz Kogler1, Joachim Pichler1, Federico Capponi1, Herbert Gruber1, Sylvia Michaelis1, Dietrich Michaelis1, Andreas Einwanger2, Christoph Sandner1, Anamaria Anca1, Gottfried Beer2

1Infineon Technologies Austria AG - Villach, 2Infineon Technologies AG - Regensburg

Abstract Project Partners

•Goal was to design a PMU with reduced footprint at competitive costs and performance •The target application is an automotive microcontroller system in 40nm CMOS technology with multiple power domains •This work is a pre-study for next generation fully integrated power management systems for automotive applications

Automotive Applications

Body Applications

Board Supply in a Car

Demonstrator

HV-Chip:

130nm BCD CMOS

LV-Chip:

40nm (Flash) CMOS

•High Voltage Pre-Regulator: •Vin: 16V…6V •Vout: 5V/3.3V •Iloadmax: 500mA •Peak efficiency: 80%

•Low Voltage Regulators •Vin: 5V/3.3V •Vout: 1.2V/1.3V •Iloadmax: 500mA/200mA •Peak efficiency: 90%

•IFAT: Chip Design •Lyon: Chip Design •IFAG: Packaging •Tyndall: Power Inductor, Consortium Lead •IPDiA: Capacitors & Interposer •UPM: Concept •Bosch: Application & Requirements •Funded by EU FP7-ICT-2011-8 – PowerSWIPE – Project no.: 318529

Page 2: High Efficient Power Conversion from Car Batteries …pwrsocevents.com/wp-content/uploads/2014-presentations/ep...High Efficient Power Conversion from Car Batteries to Next Generation

High Efficient Power Conversion from Car Batteries to Next Generation Microcontroller Systems (PwrSwipe)

Gerhard Maderbacher1, Karlheinz Kogler1, Joachim Pichler1, Federico Capponi1, Herbert Gruber1, Sylvia Michaelis1, Dietrich Michaelis1, Andreas Einwanger2, Christoph Sandner1, Anamaria Anca1, Gottfried Beer2

1Infineon Technologies Austria AG - Villach, 2Infineon Technologies AG - Regensburg

SC DC-DC

•Simulated Converter Efficiency for Different Input Voltages •Peak Efficiency at Iload=100mA: 84% •Switching Activity: 20MHz

•SC DC-DC Converter: 40nm CMOS Technology Series-Parallel Cfly: 8x30nF Cout: 260nF Vout: 1.2V/1.3V

•Gain modes: 1/2 ( Vdd=3.3V ) 1/3 ( Vdd=5V )

•4 Interleaved Stages: 2 Cfly/stage 9 Switches/stage fsw = 2.5 MHz

•Controller: Pulse Frequency Modulation

•Multi-phase limits output voltage ripple limits chip noise (lower current peaks at

the input)

• Driving Capability under Worst Case Conditions (PVT)

Multi Phase Topology

Simulation Results

Efficiency Simulations

Layout SC DC-DC

LC DC-DC

•LC DC-DC Buck Converter: 40nm CMOS Technology Vin: 5V/3.3V Vout: 1.2V/1.3V Iloadmax: 500mA fsw: 10MHz Peak efficiency: 90% •Lout/Cout: 250nH/350nF •High Side and Low Side Current Sensing

Peak Current Control DCM Mode Over Current Protection •Automatic Dead Time Optimization in the Power Stage •Operating Modes:

PWM-CCM, PWM-DCM, PFM

BDCS

Power

Stage

Control

reference voltaget

Controller

current sense (comp_p)t

pm

os_d

ign

mo

s_

dig

TD1 TD2

FSM

current sense (comp_n)t

body diode conduction sensor outputt

sw

itch

co

ntr

ol

TD

1, T

D2t

Co

ut

LVout

VDD_PWR

feedbackt

Level-

Shifter

Level-

Shifter

I_

reft

VSS_PWR

sw

n1

VDD_PWR

VSS_PWR

current

sense

m

1 current

sense

SPI

Programmable

Chip Interface

actuating

variable

PFM

Reference

Voltage /

Reference

Current

PWM-CCM/DCM

Page 3: High Efficient Power Conversion from Car Batteries …pwrsocevents.com/wp-content/uploads/2014-presentations/ep...High Efficient Power Conversion from Car Batteries to Next Generation

High Efficient Power Conversion from Car Batteries to Next Generation Microcontroller Systems (PwrSwipe)

Gerhard Maderbacher1, Karlheinz Kogler1, Joachim Pichler1, Federico Capponi1, Herbert Gruber1, Sylvia Michaelis1, Dietrich Michaelis1, Andreas Einwanger2, Christoph Sandner1, Anamaria Anca1, Gottfried Beer2

1Infineon Technologies Austria AG - Villach, 2Infineon Technologies AG - Regensburg

Power Stage Optimization Simulation Results

Layout LV DC-DC

•Device Properties Extracted from Spice Simulations, Optimization is Done in Matlab •Device Properties: Ron, Turn on Losses, Turn off

Losses, Reverse Recovery Losses, Gate Drive Losses, Body Diode Conduction Forward Voltage

•Example Ron:

VGS

VSS

VDD

ILoad

DUT

Ron = f(w,VGS) [Ω]

•Optimization Tool

HV DC-DC

•HV DC-DC Buck Converter: 130nm BCD Technology Vin: 6V up to 16V Vout: 5V/3.3V Iloadmax: 500mA fsw: 10MHz Peak efficiency: 90% •Lout/Cout: 1uH/1uF •Cls = 40nF (capacitor for low-side driver supply)

•Chs = 20nF (bootstrap capacitor for high-side driver)

•Dead Time Optimization •Operating Modes:

PWM-CCM

Simulation Results

Layout HV DC-DC