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Part Number: LMZ10503
in our radar sensor, we are currently experiencing some failures of your integrated DCDC converter, the LMZ10503.
The fact. Each radar has two digital boards; each of them mounts a LMZ10503 to produce a 3.3V rail for the internal peripherals.
The board #1 has a load of 340mA, and the board #2 has a load of 130mA; the boards are identical (I mean they have the same BOM), but the brd#1 provides also the 3.3V for an external module, so this explains the extra load current.
We have produced 384 pieces of digital boards, 192 mounted as brd #1, 192 mounted as brd#2 and we have experienced 15 failures only on the brd #2, due to the damage of LMZ10503.
The LMZ10503 mounted on board #2 (the one with 130mA) works in FCCM (Forced Continous Conduction Mode).
Although the synchronous buck converter allows the FCCM, my idea is the LMZ10503 with a lighter load is more stressed, perhaps due to the inductor current flowing in both directions (assuming as forward the direction of load current): to reinforce the correctness of this hypothesis, the LMZ mounted on board #1 has never failed yet.
Operating conditions. The LMZ10503 derives the 3.3V from a 5V input dc voltage (supplied from an external AC/DC converter); so the buck ripple current, with a duty cycle of 0.66, L=2.2µH, and fsw=1MHz, is:
From the equation above, the board #2 is surely functioning in FCCM, while the board #1 is weakly or not in FCCM.
Simulation. To demontrate the FCCM mode, I also performed a PSPICE simulation using the TI LMZ Pspice model; see the schematics and plot below:
Boards workaround. To limit the reworking intervention on hundreds of boards, I suggested -as praticable workaround- the introduction of a 15Ω resistor (a dummy load) on 3.3V rail, to port the overall load to 342mA, so equalizing the load on each board. Further, on brd#2, I have also increased the output capacitor value to 100µF to improve the filtering.
In the simulation, I implemented the workaround and I introduced a variable load to test the loop stability: see below:
Testing the workaround. As further step, to test the solution described, we applied the workaround on a batch of 10 radar, leaving them powered without interruption; after more of one month of continuous working the results was no LMZ has failed.
Here my questions for you:
Thank you very much for any help
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In reply to Denislav Petkov:
Thank you very much for the prompt response; in general sound strange to look at light load as cause of failure, but consider that the LMZ on board #1, never fail.
From your answer, seems you suspect the instability condition as reason of failure: it is so? Consider the board has also about 8 µF of disseminate ceramic capacitors, on 3.3V rail. In every case, I agree to increment the output capacitor, as was done in the trial of 10 radar.
Regarding the stability, do you consider enough to increment the output capacitor to 100 µF, with 75kHz crossover frequency and 43° of phase margin? From my simulation, with pulsed load, the system seems stable.
Here the answers to your questions:
In reply to Marco Fogli:
Thank you for the details.
Here are a few more comments.
1.The input capacitor value (only 1uF) and placement can definitely be improved. The input capacitor and the internal power MOSFETs form a high di/dt loop. The area of this loop is proportional to the loop inductance. The higher the loop inductance (together with the high di/dt) will result in higher noise. I would suggest placing the input capacitor on the same layer as the LMZ device and right next to the VIN and large GND pad.
Also, I would strongly suggest increasing the input capacitor to 22uF. See page 15 of the DS for suggestions.
2. Increasing the output capacitance to 100uF should help. Please ensure that this ceramic capacitor is sufficiently rated (perhaps 10V cap 1210 case size) so that it does not de-rate its capacitance value under the 3.3V DC bias.
You can also use WEBENCH to improve the component values.
Here is what the tool suggests for your design parameters (5V input, 3.3V output):
And here is the frequency response simulation:
thank you again.
I agree your suggestions.
Increasing the input capacitor and putting it closer to input pin. I think the lack of capacitor near the input pin is, probably, the cause of the LMZ damage, due, perhaps, to a voltage spike, related to di/dt and higher loop inductance.
As you have indicate before, I have performed an AC simulation using Webench; after I repeated the simulation with Pspice on my PC, using the TI LMZ model. The result suggests is convenient to change the feedback and compensation network, with the values you proposed, to obtain more phase margin.
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