TPS54560-Q1: Component explodes

Part Number: TPS54560-Q1
Other Parts Discussed in Thread: MIDAS

Tool/software:

Hi

We have the following issue with the controller of our speed pedelec, after it being used for over a year without any issues, we now start seeing with some bikes  that while people bike the TPS54560-Q1 explodes. We use the TPS54560-Q1 3 times, 2 times to get 12V and once for 5V, but we only ever have this issue with the 5V conversion. Our system works on a 48V battery and controls two motors, the 5V is used to feed some sensors and the RPI controlling the system.

I already did a load test, put shorts on the output and even shorted the diode, trying to recreate this issue, but still no luck.

So I think my main questions are:

  1. Why is it only the 5V system experiencing this issue?
  2. What am I overlooking, is it possible that the motor frequencies that cause the input to fluctuate cause issues? 
  3. Any more tests that I can do to try and recreate the issue in a controlled manner?

Kind regards

Midas

  • Hi Midas,

    Sorry to hear about this issue. 

    Is there any extra inductance or lengthy cable to input of TPS54560-Q1 device(5V output)?. If that is the case, there is a possibility of input voltage crossing the abs. max of the device. I would suggest you to put one electrolytic capacitor (~22uF ) across the input of TPS54560-Q1 device(5V output) and repeat the measurement. 

    Thanks,

    Nitya