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JOURNAL OF COMPUTING, VOLUME 4, ISSUE 9, SEPTEMBER 2012, ISSN (Online) 2151-9617 https://sites.google.com/site/journalofcomputing WWW.JOURNALOFCOMPUTING.

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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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(*Corresponding author: Mehdi Darbandi) Abstract: Radiated emission (RE) compliance


requirements of automotive sector demands one of the most difficult design challenges for EMC engineers as compared with those of FCC and military standard mandates. Recent revisions to EMC requirements has exasperated the RE compliance levels considerably. Automotive industry radiated emission requirements span over a wide frequency range (150 kHz 1.583 GHz). The European Long Wave (150 kHz 280 kHz) and global Medium Wave AM band (0.53 MHz 1.7 MHz) is the subject of this article. Onboard receivers in modern vehicle intended for the reception of the RF services, indicated as low frequency LW and MW audio broadcast, can be susceptible to unintended noise source(s). The modern vehicle is abundantly rich in noise source with a large number of electrical and electronics components. As a result of integration of electronics in modern vehicle, it hence creates the most demanding electromagnetic environment. of EMI filters and robust PCB design practices. This paper is a practical approach to assist the engineers in the auto industry to locate and identify the noise source, thus applying rigorous fundamental techniques to resolve the RE non-conformity issues. The TEM radiation concept is a misnomer when measurements are conducted in the near field region as defined in the automotive RE test methods [1,2,3,4,5]. Every EMI problem comprises of three elements: source, victim and coupling mechanism. The source refers to a noise generator with high dv/dt or di/dt, and the victim here refers to RE antenna. Coupling mechanism can be categorized into conducted and non-conducted coupling. Nonconducted coupling comprises of electric field coupling, magnetic field coupling and a combination of both which results into radiation at far field (TEM wave). Automotive AM band antenna is placed at 1 meter distance from DUT harness, thus victim (RE antenna) at AM band (wavelength ~ 300 m) is located at the near-field region of the DUT noise source Automotive AM band RE measurement method should be classified as electromagnetic field (E and H) coupling mechanism to the rod antenna, which requires a new mind-set approach and mitigation mechanisms. It is important to note that, regardless of the severity of the recent RE requirements mandated in the new specifications, or measurement methodologies, it is reported to be realistic requirements and supported with the vehicle level correlation data. Automotive OEM vehiclelevel measurements demonstrate that offending sources, which fail the 12 dBV/m component level requirement RE levels, are audible on onboard AM band receivers. In fact, US OEM will not grant conditional compliance or deviations, and it mandates RFI mitigation(s) to fulfil the 12 dBV/m level. As we witness, the electronics content in modern premium automobile increased dramatically in recent years, and it accounts for approximately 45% of the total vehicle cost. As a result, it brings safety, complexity and reliability challenges in an

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

2012 Journal of Computing Press, NY, USA, ISSN 2151-9617

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.

AM - BAND AUTOMOTIVE NOISE SOURCE:


It is important to emphasize that in automotive environment a large number of critical activities operate at frequencies which can impair the product compliance at AM band with new mandates. As an example, LIN (Local Interconnect Network) bus as a low cost serial communication system intended to be used for distributed electronic systems in vehicles, which complements the existing portfolio of automotive multiplex networks. LIN is a low-cost single-wire implementation based on ISO9141 for an automotive VBAT-based (12 VDC) application with speed up to 20 kBits/s. In addition, Low speed CAN bus and High speed CAN bus for smart communication, PWM controlled motors, or PWM controlled lamps, switch mode power supplies (SMPS) are few of the essential components of the vehicle electronics. They all contribute to the MW band noise source, influencing AM band onboard reception. Hence, a complex set of mitigation techniques are required to resolve each problem separately. In this paper a critical aspect to all automotive modules, which utilize SMPS as power management stage, is explored with respect to 12 dBV/m AM band requirements. Switch mode power supplies (SMPS) are integral part of modern automotive control module power distribution networks. Conducted and radiated emission noise mitigation and reduction techniques for various SMPS topologies and networks can be found in many text books in power electronics and EMC publications. Most of the literature is dedicated for compliance requirements mandated by FCC part 15/J and Military Standard MIL-461E specifications [6,7]. SMPSs concepts operating at switching frequencies of 100s kHz create a formidable challenge for the newly adopted 12 dBV/m AM band requirements. Conventional EMI filters cannot address the radiated electromagnetic waves as vehicle wires/harness length is only a very small fraction of

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.

AM BAND RADIATED EMISSION TEST SETUP:


As outlined in previous sections, automotive OEM specifications [1,2,3,4,5] Radiated Emission (RE) requirements are based on CISPR 25 Edition 3 [6] ALSE method. RE requirements cover the frequency range from 150 kHz to 1.583 GHz. Low frequency RE covers European (EU1) Long Wave band (0.15 MHz 0.28 MHz) and Global Medium Wave (AM) band (0.53 MHz 1.7 MHz). AM band compliance limit (12 dBV/m) is based on average detection (9 kHz Resolution Bandwidth, RBW) measurement method [1]. CISPR 25 3rd Edition 2008 [6], page 43 adopted by US automotive OEM utilizes rod antenna for RE measurement. Figure 1 illustrates the test setup on a table with height (h = 900 +/- 100 mm) and rod antenna (h + 10/-20 mm above ALSE floor). ECU to load box harness length measures as 1500 +/- 75 mm. The distance between the rod antenna and ECU harness measures as 1000 mm +/- 10 mm. Rod antenna, with counterpoise (typical 600 mm X 600 mm) is electrically connected alongside its full length to CISPR-25 ground plane as shown. The details of RE test setup can be found in CISPR 25, 3rd Edition 2008 - page 43 [6] or in US OEM EMC specifications [1,2,3,4,5].

2012 Journal of Computing Press, NY, USA, ISSN 2151-9617

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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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.

CONDUCTED EMISSION EMI FILTER:


A PWM DC/DC Buck converter with a wide input voltage range from 4.5VDC-42VDC (switching frequency of 509 kHz) and regulated output voltage of 3.3 V suitable for automotive applications was selected for conducted and radiated emission investigation. The components were placed on a 2layer PCB (FR4 substrate) with EMC robust PCB best practices applicable to the automotive world. Fig. 2 is an image of the SMPS PCB. Fig. 3 illustrates a time domain switching waveform at the inductor terminal corresponding with 509 kHz switching frequency.

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

2012 Journal of Computing Press, NY, USA, ISSN 2151-9617

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.

Fig. 6: Hand held Electric Field Mapping

Fig. 5: Conducted Emission (Current) - with and without EMI Filter.

NEAR FIELD INVESTIGATION:


Electric and magnetic field probes were utilized to scan (map) the 2nd and 3rd harmonics of SMPS switching frequency (SW freq. = 509 kHz) on the surface of SMPS PCB. H-field probe did not reveal a significant difference in field measurements as probe was moved back-and forth across the entire surface of the PCB. The measurement was within a +/- 2 dB variation. Therefore, H-field analysis was discarded. However, E-field mapping of the PCB surface resulted in a significant (+/- 60 dB) variation and thus was explored further. An E-field probe was utilized to map the DUT spatial field distribution at 1.018 MHz and 1.527 MHz (AM band reception frequency). Figure 6 and Figure 7 demonstrate the E-field hand-held mapping technique investigation and setup. Figure 8 and Figure 9 indicate the location and distribution of E-field at 2nd and 3rd harmonics respectively utilizing automated E-field scanner with E-field probe located at 1 cm above the PCB components. The small dimensions of the E-field probe enabled high spatial resolution setup. The measured data was normalized for relative field intensity investigation, hence source location identification. The coordinates of the inductor and diode is identified and corresponds well with the peak intensity of the E-field map. Hence, indicating a component, or PCB layout noise source.

Fig. 7: Electric field investigation setup.

Fig. 8: Normalized Electric field distribution (frequency = 1.018 MHz)

2012 Journal of Computing Press, NY, USA, ISSN 2151-9617

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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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

2012 Journal of Computing Press, NY, USA, ISSN 2151-9617

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.

Ali Aminalsharie Najafi:


Department of Electrical Engineering and Computer Science at Iran University of Science and Technology (IUST); Tehran, Iran. His e-mail address is:

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:

2012 Journal of Computing Press, NY, USA, ISSN 2151-9617

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