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Developing concept of electromagnetic filter design by considering new parameters and use of mathematical analysis
Ali Aminalsharie Najafi1, 2, Mehdi Darbandi1*, Mohammad Golmakani3
Department of Electrical Engineering and Computer Science at Iran University of Science and Technology (IUST); Tehran, Iran 2 DCS (Distributed Control System) and Relay section of KREC (Khorasan Regional Electric Company) 3 Department of Industrial Engineering, Payame Noor University, I. R. of Iran
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Keywords:
Printed Circuit Board (PCB), Surface Mount Technology (SMD), Ferrites, Multi Layer Ceramic Capacitor (MLCC), Switch Mode Power Supply (SMPS), Near Field (NF), Electric Field (EF), Radiated Emission (RE), Absorber Lined Shielded Enclosure (ALSE), Electronic Control Unit (ECU), Transverse Electromagnetic (TEM). Introduction: Recent revisions to the US automotive OEM specifications [1] has mandated the radiated emission requirements for the Global Medium Wave (AM) band (0.53 MHz 1.7 MHz) to be reduced to the new miniscule level of 12 dBV/m utilizing average detection method. The previous specifications required a 30 dBV/m using peak measurement for product compliance [2,3,4,5]. This has an enormous impact for the EMC design engineers to employ cost effective mitigation techniques available with the use
JOURNAL OF COMPUTING, VOLUME 4, ISSUE 9, SEPTEMBER 2012, ISSN (Online) 2151-9617 https://sites.google.com/site/journalofcomputing WWW.JOURNALOFCOMPUTING.ORG
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extremely harsh electromagnetic environment. Therefore, the EMC requirements of the automotive sector, is designed to address the vehicle safety and compatibility of control modules critical to the operation of the vehicle. Today, in addition to monitor the internal operation, vehicles are beginning to analyze the external world, sensing events inside the car. Radars are used to detect the presence of external objects. Lasers are utilized to measure distance for cruise control. Video and ultrasonics are used to detect objects behind of the vehicle. The trend will be to extract information external to the vehicle about other vehicles and thus exploit the information to improve safety.
the AM band wavelength (300 meter).EMI filters fail to mitigate the AM band RE non-conformance as measurements indicate later in this article. However, they are effective for conducted emission nonconformance issues. Hence, it is insightful to explore the design mitigation techniques that would fulfill the low level radiated emission requirements. Employing practical EM techniques and tools to locate, and identify the source and find a mitigation solution to alleviate the non-compliance. Thus the use of near field probes, RF current probe, copper tape as shield, and EMI filters are the most popular options available to EMC engineers to investigate the noise source path scenario. This paper will explore the radiated emission non-conformance of SMPS, thus utilizing all the available tools to identify, locate and mitigate the non-conformance. Therefore, it will provide a design guideline to mitigate the SMPS noise and recommend a practical solution to comply with stringent AM band requirements.
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Fig. 3: Switching Node Voltage Waveform (Inductor Terminal) Fig. 1: Radiated Emission AM Band, Monopole Rod Antenna Test Setup In order to investigate the non-conformance observed for the radiated emission, it is insightful to investigate the SMPS related noise at the input power network terminals and the impact of an EMI filter as a mitigation technique. The conducted noise due to 509 kHz switching frequency and its harmonics is illustrated in Figure 4 (without EMI filter). An EMI -filter was designed utilizing two 4.7 F MLCCs (Multi layer Ceramic Capacitor) and 0603 ferrite bead (BLM18PG181SN1) [9]. The EMI filter was integrated at the 12 VDC input terminals of the PCB to investigate the conducted noise suppression impact. The EMI filter dramatically influences the CE noise (Voltage) as shown here (Figure 4). In addition ferrite bead was replaced with a 4.7 H inductor without any further improvements to CE. As observed the mitigation of 509 kHz is not critical here as AM band reception does not include frequency band below 535 kHz.
Fig. 2: SMPS Buck Converter switching Frequency 509 kHz Fig. 3 illustrates a time domain switching waveform at the inductor terminal corresponding with 509 kHz switching frequency.
Fig. 4: Conducted Emissions (Voltage) with and without EMI Filter. In addition, conducted emission (Current) measurement was also performed to examine the noise content as required by automotive OEM. As illustrated in Figure 5, major noise suppression is resulted with the use of the EMI -filter. It is also interesting to note that 509 kHz SMPS fundamental
JOURNAL OF COMPUTING, VOLUME 4, ISSUE 9, SEPTEMBER 2012, ISSN (Online) 2151-9617 https://sites.google.com/site/journalofcomputing WWW.JOURNALOFCOMPUTING.ORG
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frequency is reduced 20 dB compared with CE Voltage mode. As result of this study, one may assume that the application of the EMI filter will result in radiated emission compliance. However, this can be misleading as it is illustrated later.
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Fig. 9: Normalized Electric field distribution (frequency = 1.527 MHz) The location of the strongest electric field corresponds with the coordinates of the inductor L1 and diode (output terminal of the SMPS driver integrated circuit). To reduce or eliminate the E-field, copper tape was employed as an electric field shield. A simple, but effective cavity (Faraday cage) was designed utilizing the copper tape to enclose the inductor diode circuit and was electrically bonded to PCB GND plane. Electric field measurements revealed a dramatic reduction in the E-field intensity and it was decided to explore the concept further in an anechoic radiated emission setup. Figure 10 illustrates the impact of E-field shield as it mitigates 2nd harmonics by 16 dB. It is interesting to note that EMI filter has only shifted the noise to lower frequency and did not reduce the radiated emission. It is important to note that the EMI filter has only reduced the RFI noise by less than 2 dB (insufficient). A slight shift in the frequency measurements (+/- 3 kHz) of SMPS noise is due to the PWM operation of the buck converter. PWM is a non-coherent noise source, thus consecutive measurements would result in slight shift as indicted here. The EMI receiver resolution bandwidth is specified for 9 kHz, hence it is normal to observe an slight frequency shift as shown here and is not erroneous or equipment malfunction. However, for conducted emission it had a major noise reduction impact. This demonstrates the influence of unterminated E-field flux resulting from high dv/dt node, hence the contribution source for the radiated emission non-conformance.
Fig. 10: Prior and after Inductor Electric Shield SMPS 509 kHz Figure 11 illustrates the 3rd harmonic (1.527 MHz) is also reduced by more than 20 dB by utilizing an electric field shield, whereas the EMI filter has only slight effect and 3rd harmonics frequency has shifted as observed in the 2nd harmonic scenario.
Fig. 1: Prior and after Inductor and Integrated Circuit Electric Field Shield
CONCLUSION:
This study is an examination of the recent modifications to the radiated emission requirements for the automotive component level mandates. One major area of the concern is the AM band RE requirements which demands 12 dBV/m compliance levels. The EMC engineers employing PCB EMC robust techniques or EMI filters expect RE compliance. A large number of noise sources exploiting AM band can be mitigated by PCB and EMI filter methods. However, SMPS and its associated inductors and filters need special treatment. As indicated in this paper, unterminated electric field lines originating from high dv/dt traces, or components, must be terminated into PCB ground using an electric field shield. A group of electronic modules which utilize grounded metallic enclosure will not require an E-field shield. However, a large
JOURNAL OF COMPUTING, VOLUME 4, ISSUE 9, SEPTEMBER 2012, ISSN (Online) 2151-9617 https://sites.google.com/site/journalofcomputing WWW.JOURNALOFCOMPUTING.ORG
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number of the automotive electronic modules do not employ metallic enclosure. In order to meet the RE AM band compliance, for the group of modules, employing SMPS operating at switching frequencies of less than 1.7 MHz, as indicated in this paper, a local grounded metallic shield is essential.
REFERENCES:
[1] Ford Motor Company (EMC-CS-2009, September 30, 2009). [2] Ford Motor Company (ES-XW7T-1A278-AC, October 2003). [3] General Motors Corporation (GMW3097 Rev. 5, May 2006). [4] Chrysler Corporation (DC-11224 and DC-11225, May 2007). [5] Chrysler/Fiat, Chrysler Group LLC (CS-11979, April 13, 2010). [6] CISPR 25 Edition 3.0, March 2008, IEC Central Office, Geneva, Switzerland. [7] MIL STD461E, August 20, 1999 Radiated Emission RE102, page 91 101 Electromagnetic Interference Characteristic Requirements for Equipment.
Mehdi Darbandi:
Department of Electrical Engineering and Computer Science at Iran University of Science and Technology (IUST); Tehran, Iran. His e-mail address is:
Mohammad Golmakani:
Department of Industrial Engineering, Payame Noor University, I. R. of Iran. His email address is: