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8.1. Integration
Typical Design Sequence:
Select process technology.
Select package.
Design system (i.e., architecture).
Determine block-level specifications.
Design die floor plan.
Design transistor-level circuits (i.e., blocks).
Design block layouts according to the floor plan.
Assemble top-level layout.
Extract top-level schematic from layout and simulate.
Submit IC design for fabrication (i.e., "tape-out" design).
Test and evaluate IC in the laboratory.
Iterate another design to fix possible bugs and complications.
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Power IC Design
Substrate MOSFETs:
Body diodes DN can steer dead-time current iDN through the substrate.
vSW transitions and drainbulk capacitors CDBN inject current iCN into the substrate.
Suppression
Reduce Injection:
Minimize dead time tDT and shunt body diode DN with off-chip Schottky diode.
Minimize drainbulk capacitances CDBN and CDBP.
N+ in P+ source and N+ in N well reduce QP's activating voltage vEB.
N+ in N well also recombines QP's base hole carriers to reduce QP current iQP.
Grounded P+ in N well is a QP collector that steers current away from the substrate.
Block and Steer Substrate Current iSUB:
P+ ring collects iSUB and N+N-well ring impedes and steers iSUB into P+ ring.
A shallow P+ ring can suppress substrate noise 10 dB.
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Power IC Design
Page 3
Power IC Design
B. Package
Considerations
Number of pins: Consider application.
Package material: Consider package stress on die, ambient and
junction temperatures TA and TJ, etc. (e.g., ceramic, plastic, etc.).
Type: Consider space requirements (e.g., small-outline IC -SOIC-,
shrink small-outline package -SSOP-, quad-flat no leads -QFN-, etc.).
Size: Consider die area.
Heat transfer: Consider power dissipation and heat flow
(e.g., power-padded package, heat sinks, heat pipes,
fan on the printed-circuit board PCB, etc.).
Page 4
Power IC Design
i. Heat
Power switches and other circuits generate heat when they burn power.
Junction temperature TJ > Ambient temperature TA.
TJ rises with power consumption PIC TJ PIC.
A plastic package melts at roughly 170 C TJ should be less than 150 C.
Convention: TA refers to temperature at the edge of the package.
Typical Specification: TA(MAX) is 85 or 125 C TJ(MAX) is higher.
Simulations: Usually at TA(MAX) Assumption is TJ TA.
Thermogram
Heat Flow:
Page 5
Power IC Design
C. Off-Chip Components
Discrete inductors typically outperform
(with lower RL ESR and higher LO)
on-chip inductors by orders
of magnitude.
One in-package inductor achieves
SiP footprint objectives.
MEMS
Inductors
Page 6
Power IC Design
A. Startup
Problem: vO starts at zero Feedback loop maxes iL to raise vO to target.
Sudden inrush of current can damage components in power path.
Option 1: Limit dL, raise switch resistance RSW, or reduce over-current limit.
Limits iL Limited iL slews CO until vO reaches target.
Peculiarity: vO rises with interruptions.
Option 2: Start the reference vREF at zero and raise slowly to its final state.
vO rises slowly with vREF to target.
Digital: DAC generates vREF and counter and clock raise vREF.
Generates switching noise and occupies substantial silicon area.
Analog: Buffer, ground, and slew vREF' to target.
Noise-free and compact.
Drawback: Requires dedicated or buffered (degraded) vREF.
Option 3:
vSLOW
Page 7
Power IC Design
B. Load-Dump Compensation
Center each worst-case load-dump variation vLD(MAX) about vREF.
Add and tune load-induced shift iOREQ to vREF.
Can cut total variation in half: From 2vLD(MAX) to vLD(MAX).
vREF' = vREF + 0.5vLD(MAX) iOREQ
where
iO(MAX)REQ vLD(MAX)
Implementation
Raise target by 0.5vLD(MAX) to vREF + 0.5vLD(MAX).
Sense iO via iL.
Convert to voltage vI with RS and average with CS.
Subtract vI from target with a summing amplifier or comparator.
Page 8
Power IC Design
C. Comparators: i. Hysteresis
Noise produces uncertainty in transition and jitter at the output.
Comparator
threshold
vin
vout
VOH
Noise
Jitter
VOL
VTRP+
VTRPVOH
VOL
vout
No Jitter
vO is initially low.
MFB is off and iH is 0.
vO rises when i2 overcomes M4's i1.
When vP falls towards vN:
vO is initially high.
MFB is on and iH > 0.
vO falls when M4's i1 overcomes i2 + iH.
Page 9
Power IC Design
Positive
Feedback
i1 + i2 = IT
VTH = v GS1 v GS2 =
2i1
2i 2
K N'S1
K N'S2
At Trip Point
Page 10
iOS v Hg mH12
.
=
g m12
g m12
Power IC Design
D. Ramp Generators
Clock-Synchronized Ramp:
Clock fCLK starts ramp.
Diode DR offsets ramp.
Current source IR slews CR and ramps vR.
vD
vR
tCLK
tCLK t
Relaxation Oscillator
Ramp-Generating Clock:
DR offsets ramp and IR ramps vR.
Comparator CPR ends ramp and resets vR.
CPR restarts ramp after propagation delay tP.
vCLK
vR
tP
E. Gate Drivers
Small inverters cannot drive very large gates quickly.
Build drive with chain of increasingly sized inverters:
S2 S1AX
INV3
vC INV1
INV2
S3 S2AX
vG
Minimum Size
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Power IC Design
F. Dead Time
Risk: Adjacent switches can short inputs/outputs (I/O's) Short supplies.
Fix: Engage power switches only after adjacent switches shut.
Implementation:
Sense adjacent gate signals.
RC or inverter chain delay adjacent gate signals tDEAD.
NOR engages NFETs only when adjacent gate signals are low.
NAND engages PFETs only when adjacent gate signals are high.
Shut-off path and transitions are undelayed.
vG(ADJACENT)
tDEAD
vG
Driver
vG(C)
Page 12
Power IC Design
A. Basic Concepts
Purpose:
Current-mode control.
Over-current protection.
Load-dump compensation.
Power modes: Adjust modes according to load current.
Current-mode capacitor and inductor multipliers.
Ideal Characteristics:
No additional conduction losses PR in the power path.
No additional quiescent power PQ (e.g., to sense small voltages).
Monitors iL continuously.
All on chip.
Linear.
Accurate.
RS dissipates PR.
Page 13
Power IC Design
R
1
<< fSW << L ESR .
2R F C F
2L O
vL
=
sL O + R L ESR
vL
! sL O
$
R L ESR #
+1&
" R L ESR %
vS =
! 1 $
vL
#
&=
1 " sC F % R F C Fs +1
RF +
sC F
vL
LO
and vS iLRL ESR = vESR.
R L ESR
Page 14
Power IC Design
zF =
1
2R L.ESR C F
sL O + R L ESR
LO
Matched time constants.
R L ESR
vL
=
sL O + R L ESR
vL
! sL O
$
R L ESR #
+1&
" R L ESR %
!
1 $ vLG M R F
v S = v L G M # R F ||
&=
sC F % R F C Fs +1
"
LO
and vS (iLRL ESR)GMRF = vESRGMRF.
R L ESR
Page 15
Power IC Design
i L(+)
.
AI
! i L(+) $!
1 $ ! i L(AVG) $
&#
&# R S ||
& RS .
RSCS translates and holds average vS = #
sCS % " A I %
" A I %"
+ No additional PR.
+ On chip.
+ Marginal additional PQ.
+ Senses iL(AVG) with CS or
half of iL without CS.
vSD S vSD I when iS IB, but not precisely otherwise Nonlinear:
vEBS rises (so vSDS falls) when iO rises iS is a nonlinear reflection of iO.
Nonlinear, mirror mismatch, and resistor tolerance 50% Inaccurate.
ii. Regulated
Negative feedback keeps vD at vSW iS is an accurate mirror of iO:
MSSMSO generates an error (vSW vD)gmSO that adjusts vG to keep vD near vSW.
T connection generates an error iS iFB that adjusts vG to keep iFB near iS.
vSGS = vSGI and vSDS vSDI.
iS
i L(+)
AI
i L(+)
AI
Page 16
Power IC Design
D. Comparison
PR
PQ
Monitor
On Chip Accuracy
Cost
Yes
Small RS
1 Pin or
Off-Chip RS
Yes
RDS
No
Yes
iL(AVG)
Yes
RL.ESR
Area
RL.ESR Matched RC No
Yes
iL
Yes
Tuned
Area, Tune
Yes
iL
Yes
Tuned
Area, Tune
Yes
Nonlinear,
Mirror, RS
Yes
Mirror, RS
Delay
RS
Yes Yes
RDS
No
Averaged
Diff.
Matched
G MC
No
iL
Page 17
Power IC Design
A. Hysteretic Buck
Premise: vESR >> vC and vESL vO rises and falls with iL.
Functionality: CPERR keeps vO within hysteresis window vHYS about vREF.
Operation: CPERR compares vO to vREF to generate an error that adjusts dE.
CPERR pulse-width modulates MP according to vO's error.
Features: vO is nearly constant at vHYS and loop responds within one cycle.
zESR recovers phase after pLC2.
RC ESR > RC ESR(MIN) > 0.
pLC2, zESR < f0dB fSW.
f0dB can be high.
! d $! v $
A LG = A ERR A BUCK = ## e &&## o &&
" v o %" d e %
AERR0
ABUCK0, pLC2, zESR
i. Hysteretic Comparator
Hysteretic comparator CPE compares vREF with the rippling vO.
Output vCPO rises until vO reaches upper threshold VTH+ to end tE.
Output vCPO falls until vO reaches lower threshold VTH to end tD.
de
t
D
= e E
v o v o t SW VHYS
t e dt E
D T
T
=
E E SW
v o dv O v O
VHYS
Since vO rises and falls with iL, loop regulates iL current-mode fashion.
Page 18
Power IC Design
ii. Noise
Switching events produce noise.
If vHYS is low, switching noise can trip
comparator and produce glitches.
Reduce Sensitivity:
Filter: RFBCFB filters
high-frequency noise.
AC Hysteresis: CAC overdrives vFB
momentarily to raise noise margin.
If RFB >> ZCFB, overdrive vOD is:
" C AC %
v OD = v HYS(AC) v IN $
'
# C AC + C FB &
1
.
2R FF C FF
Page 19
1
.
2 ( R FF || R FB ) C FB
Power IC Design
Operation:
vFB iL
vO vCO
Rise
di
i FF v IN v O(AVG)
vE
L(+)
C FB
R FF C FB
R FF C FB
dt
dv FB
dt
Fall
di
i FF v O(AVG)
vD
L(-)
C FB R FF C FB R FF C FB
dt
Page 20
Power IC Design
B. Non-inverting BuckBoost
Reduce gate-drive losses PG:
Replace diodes with synchronized FETs.
Open MN when bucking and close MP when boosting.
Operation:
CPBCK and CPBST switches MP and MN in buckboost.
CPBST opens MN and CPBCK switches MP in buck.
CPBCK closes MP and CPBST switches MN in boost.
Switch Control
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Power IC Design
A. Market
Emerging applications are tiny and functionally dense Highly integrated.
Page 22
Power IC Design
Buck SIMO
N
X=1
X=1
Page 23
Power IC Design
v. Charge-Pumped Outputs
How: A switching node vSW initializes a flying capacitor CF.
CF then "flies" with vSW where vSW transitions across vIN + vD.
A rectifier DO(X)CO(X) then detects and holds peak voltage.
Positive Voltage:
When vSW is low, DPDG recharges CFP to vIN.
When vSW rises, DOPCOP holds peak 2vIN.
Negative Voltage:
When vSW is high, SIDN recharges CFN to vIN vD.
When vSW falls, DONCON holds peak vIN + vD.
Replace diodes with MOSFETs to reduce losses.
Charge-pumped outputs are unregulated.
CF's and CO's occupy board or silicon area.
Page 24
Power IC Design
C. Feedback Control
Approach:
Design:
Alternative:
i. Shared Sequence
Shared Energize/Drain Sequence:
One energize/drain sequence for all outputs across operating period tO.
Collective demand sets LO's energizing time tE.
Individual demands set what fraction of LO's iL that reaches each output.
Cross Regulation:
Individual loop reactions to
load dumps offset iL
for other outputs.
No time gaps help
diminish cross regulation.
Switching Events:
tE plus one transition per output 1 + N Low gate-drive power.
Page 25
Power IC Design
Design Notes:
CO(X) establishes dominant pole pC pC << f0dB pI BW < zRHP.
A higher load current iLD(X) pulls vO(X)(PK) lower Load regulation.
vO(X)(AVG) falls with a higher iLD(X) Inherent droop compensation.
Page 26
Power IC Design
Pulse-Width Modulation:
dO(X1)'s fall starts ramp vRAMP.
End of previous output dO(X1) into CPPWM connects LO to vO(X).
AERR compares vO(X) and vR(X) to generate and amplify an error vE(X)
that adjusts LO's connection time dO(X) vO(X)(AVG) vR(X).
Page 27
Power IC Design
Implementation
Use vCLK to
Time-multiplex individual error signals vERR(X) into the current source.
Time-multiplex current source into individual outputs vO(X).
Each error amplifier AERR(X) adjusts each tE(X)tD(X) sequence to regulate vO(X).
Design Notes: Buck stage cannot energize to high output Cannot boost.
Boost stage cannot drain to low output Cannot buck.
tCLK must include margin for iL's response time tI BW.
tO includes margin for NtI BW Refresh vO's less often Lower accuracy.
Page 28
Power IC Design
Too many factors can spoil performance Risk only when necessary.
A bad layout or a poorly packaged die can spoil a good circuit.
Consider all vertical issues, from devices to application.
Good designers balance optimism with pragmatism.
Challenge convention, but subject to worst-case possibilities.
The simplest circuit is usually the fastest and most reliable solution.
The simulator is good for tweaking and validating a design,
not for conceptualizing circuits.
Simulate only when you believe you know what to expect.
Meaningful innovation normally results from
intuition and insight of related technologies.
The END
Thanks for your interest,
and best wishes.
Rincon-Mora.gatech.edu
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