DRV8825: Driver Borad IC failure. Over heat, Motor not running and display collapsed due to this DRV8825 Driver board failure

VETRIVEL,

1. What is the normal current and what is abnormal current? Can you show the current difference on a scope?

2. Could you swap few DRV8825 between the good boards and bad boards to see if this issue goes with the DRV8825 or the board.

3. If possible, would you share the DRV8825 schematic?

Dear Wang Li,

1. Normal working DRV board taking 6mA. Not working Board is taking 18mA wihtout Running condition.

2. When Swapping good board IC to Bad Board it is working good. Bad board IC not working in Good Borad

3. Attached DRV8825 driver board schematicDRV8825 Driver Board schematic.docx

VETRIVEL,

DRV8825 is a 2.5A driver. I won't think 6mA and 18mA difference can cause the controller disturbed and LCD Display collapsed. Please Compare AOUTx; BOUTx current and input voltage scope waveform between good sample and bad sample when you have the issue.  

Dear wang li,

This 6mA is taking in OFF state. that is the motor not initiated and not running.

The same failure board is taking 18 mA in this OFF state.

If the current taking 2A in run state is also OK but the failure Boards are taking more current in OFF state.

please read the attachment and suggest more.

DRV8825 failure Details.docx

VETRIVEL,

I still don't know what issue that board have except a high "OFF" state current.

Please measure each pin voltage between bad board and good board. Are they same or different? 

Dear Wang Li,

In our Boards mostly SLEEP & RESET pins are geting failed. For this pin We have given 3.3 V directly.

What is the possiblity of failure in this pins How to solve this.

Vetrivel,

"In our Boards mostly SLEEP & RESET pins are geting failed."

SLEEP pin and nRESET pins are input pin and have 7V maximum voltage rating. Since the failure rate is very high. Can you try to add 100k series resistor in front of SLEEP pin and nRESET pin?

Dear Wang Li,

I will try and reply you

Dear Wang Li,

we are waiting for new Driver board assembly. All the boards in hand were spoiled by analysis. I will share details ASAP.

wait for me and I still need your support

dear wanli,

your solution as worked some.

we ave modified our circuit as you said new circuit board will arrive shortly. once arrived I will share you the details of the report with actual product combined testing

Dear Wangli,

I have received my new driver board updated with 100K resistance.

This type is resolved in manual soldering in existing boards. Trial in existing PCB.

But the new design updated with 100K resistance in Driver board is not solved completely.

Out of 100 15 nos failed. In this failed cases current consumed is OK. Working PCB current & this failure board current is OK. But motor is not Running.

When I am trying to change the resistance value fro 100K to 10K 2 nos worked OK. other boards not working. even tried 2.2K, 100E, 22K all are failed motor alone not running.

Dear Wangli,

I have received my new driver board updated with 100K resistance.

This type is resolved in manual soldering in existing boards. Trial in existing PCB.

But the new design updated with 100K resistance in Driver board is not solved completely.

Out of 100 ,15 nos failed. In this failed cases current consumed is OK. In the 15 No's we tried When I am trying to change the resistance value from 100K to 10K 2 nos worked OK.But Balance 13No's of DRV8825 IC Getting continuity with Ground (Pin number 22 (STEP) was getting short with Ground).Working PCB current & this failure board current is OK. But motor is not Running.

Vetrivel,

Last time, "Over 300 nos 96 failures are found."; "In our Boards mostly SLEEP & RESET pins are geting failed." and "SLEEP & RESET pins are getting failed. For this pin We have given 3.3 V directly."

The layout solution is: "add 100k series resistor in front of SLEEP pin and nRESET pin".

Now, what we have is: "Out of 100 ,15 nos failed."; "change the resistance value from 100K to 10K 2 nos worked OK" and " Balance 13No's of DRV8825 IC Getting continuity with Ground (Pin number 22 (STEP) was getting short with Ground)."

This indicates the step pin also need a series resistor to protect it from the same driving source. Similar principle, if the STEP was driven by the same source as SLEEP pin and nRESET pin's. We have to add a resistor or voltage clamp to protect it. Now, I am curious, why the SLEEP pin; nRESET pin and Step pin's source has such strong overvoltage behave. I would think that source is not stable. Would you increase the source's output capacitance to make it stable?

BTW, we may need to change the pull-up resistor to 10kohm pull-up for SLEEP pin and nRESET pin. Can you try it to see if any failure happens? That can prove 10kohm safe or not.

Hello Vetrivel,

I didn't see an update for couple days. If you have further question about the STEP pin damage or the driving source spike, let us start a new thread to discuss it.