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DRV8256: Inquiries about abnormal operation of DRV8256ERGER and request for circuit review

Part Number: DRV8256

Hi, TI expert.

The customer has applied the DRV8256ERGER and has the following defect during the test.

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1. Designed by applying 5 ICs (DRV8256ERGER) to the PCB of 1 board. (Requires driving 5 motors each) - A total of 5 sets are manufactured

2. Motor load conditions: DC24V, 1.5A or less, respectively

3. The peripheral circuit, time constant, and component arrangement of each of the 5 ICs (DRV8256ERGER) applied to one PCB are the same.

4. During operation, 2 or 3 unspecified ICs (DRV8256ERGER) do not work.

5. IC does not work with the same quantity of all 5 PCBs. (IC points are different for each)
(Example) No.1 PCB: IC3, IC4 do not work,
No.2 PCB: IC1, IC2 do not work.......

6. Phenomenon 1: Most of the non-operating ICs(DRV8256ERGER) generate a lot of heat. If you try to operate again even after cooling down, the heat will increase.
Phenomenon 2: If you put your finger on the non-heating IC among the non-operating ICs(DRV8256ERGER), the motor rotates slowly.

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Q1) Please advise on the cause and advice for the above defects.

Q2) Below is the schematic and Gerber file. Please review whether there are any problems.

   

Please review, and let me know if you need anything.

Thank you.

  • Hi Grady,

    It looks like this is an overtemperature issue. Since you mention placing your finger on top of the IC resumes driver operation. Your finger is acting as a heat sink cooling down the driver below the overtemperature threshold. The best way to confirm is using a thermal camera or any other tool to measure the temperature of the ICs not working.

    Further questions:

    1. Is your board 2 layers or more?
    2. Is there a dedicated GND plane in one of your board layers? There has to be enough GND copper connected to the thermal GND plane of the driver to dissipate the heat
    3. What is the load current for each of the motors?

    Regards,

    Pablo Armet

  • Hi, Pablo

    There is no response to further inquiries from the customer, so I will end it here.
    In the future, if additional questions are asked from the customer, we will reply again.
    thank you