Analysis of improvement for turn on/off performance of the MOSFET gate drive waveform

This thesis shows that the gate waveform of a power MOSFET driven by a specialized driver chip used in industry is imperfect and induces increased power loss in the MOSFET and lowers overall efficiency. The accurate measurements and analysis of the RLC parameters for the transmission line connecting the driver to the MOSFET are presented and a mathematical model for the line is developed based on ABCD parameters. The transmission line is characterized by experimentally measuring the frequency response of the line and extracting the parameters of the line using the mathematical model. Spice simulations and experimental results confirm the results of the extraction process. The simplified Spice model of the power MOSFET driver is developed in conjunction with the transmission line model and simulated with power source circuitry to match the experimental results. Length of the transmission line is changed in Spice simulation to confirm the dependency of length of the line with the performance of the driver. Finally, the slew rate of the gate waveform is shown to improve by inserting a capacitor to split up the transmission line in half. The result is confirmed experimentally

Power Reductions with Energy Recovery Using Resonant Topologies

The problem of power densities in system-on-chips (SoCs) and processors has become more exacerbated recently, resulting in high cooling costs and reliability issues. One of the largest components of power consumption is the low skew clock distribution network (CDN), driving large load capacitance. This can consume as much as 70% of the total dynamic power that is lost as heat, needing elaborate sensing and cooling mechanisms. To mitigate this, resonant clocking has been utilized in several applications over the past decade. An improved energy recovering reconfigurable generalized series resonance (GSR) solution with all the critical support circuitry is developed in this work. This LC resonant clock driver is shown to save about 50% driver power (\u3e40% overall), on a 22nm process node and has 50% less skew than a non-resonant driver at 2GHz. It can operate down to 0.2GHz to support other energy savings techniques like dynamic voltage and frequency scaling (DVFS). As an example, GSR can be configured for the simpler pulse series resonance (PSR) operation to enable further power saving for double data rate (DDR) applications, by using de-skewing latches instead of flip-flop banks. A PSR based subsystem for 40% savings in clocking power with 40% driver active area reduction xii is demonstrated. This new resonant driver generates tracking pulses at each transition of clock for dual edge operation across DVFS. PSR clocking is designed to drive explicit-pulsed latches with negative setup time. Simulations using 45nm IBM/PTM device and interconnect technology models, clocking 1024 flip-flops show the reductions, compared to non-resonant clocking. DVFS range from 2GHz/1.3V to 200MHz/0.5V is obtained. The PSR frequency is set \u3e3× the clock rate, needing only 1/10th the inductance of prior-art LC resonance schemes. The skew reductions are achieved without needing to increase the interconnect widths owing to negative set-up times. Applications in data circuits are shown as well with a 90nm example. Parallel resonant and split-driver non-resonant configurations as well are derived from GSR. Tradeoffs in timing performance versus power, based on theoretical analysis, are compared for the first time and verified. This enables synthesis of an optimal topology for a given application from the GSR

Highly Integrated Dc-dc Converters

A monolithically integrated smart rectifier has been presented first in this work. The smart rectifier, which integrates a power MOSFET, gate driver and control circuitry, operates in a self-synchronized fashion based on its drain-source voltage, and does not need external control input. The analysis, simulation, and design considerations are described in detail. A 5V, 5-µm CMOS process was used to fabricate the prototype. Experimental results show that the proposed rectifier functions as expected in the design. Since no dead-time control needs to be used to switch the sync-FET and ctrl-FET, it is expected that the body diode losses can be reduced substantially, compared to the conventional synchronous rectifier. The proposed self-synchronized rectifier (SSR) can be operated at high frequencies and maintains high efficiency over a wide load range. As an example of the smart rectifier\u27s application in isolated DC-DC converter, a synchronous flyback converter with SSR is analyzed, designed and tested. Experimental results show that the operating frequency could be as high as 4MHz and the efficiency could be improved by more than 10% compared to that when a hyper fast diode rectifier is used. Based on a new current-source gate driver scheme, an integrated gate driver for buck converter is also developed in this work by using a 0.35µm CMOS process with optional high voltage (50V) power MOSFET. The integrated gate driver consists both the current-source driver for high-side power MOSFET and low-power driver for low-side power iv MOSFET. Compared with the conventional gate driver circuit, the current-source gate driver can recovery some gate charging energy and reduce switching loss. So the current-source driver (CSD) can be used to improve the efficiency performance in high frequency power converters. This work also presents a new implementation of a power supply in package (PSiP) 5MHz buck converter, which is different from all the prior-of-art PSiP solutions by using a high-Q bondwire inductor. The high-Q bondwire inductor can be manufactured by applying ferrite epoxy to the common bondwire during standard IC packaging process, so the new implementation of PSiP is expected to be a cost-effective way of power supply integration

Design and Test of a Gate Driver with Variable Drive and Self-Test Capability Implemented in a Silicon Carbide CMOS Process

Discrete silicon carbide (SiC) power devices have long demonstrated abilities that outpace those of standard silicon (Si) parts. The improved physical characteristics allow for faster switching, lower on-resistance, and temperature performance. The capabilities unleashed by these devices allow for higher efficiency switch-mode converters as well as the advance of power electronics into new high-temperature regimes previously unimaginable with silicon devices. While SiC power devices have reached a relative level of maturity, recent work has pushed the temperature boundaries of control electronics further with silicon carbide integrated circuits. The primary requirement to ensure rapid switching of power MOSFETs was a gate drive buffer capable of taking a control signal and driving the MOSFET gate with high current required. In this work, the first integrated SiC CMOS gate driver was developed in a 1.2 μm SiC CMOS process to drive a SiC power MOSFET. The driver was designed for close integration inside a power module and exposure to high temperatures. The drive strength of the gate driver was controllable to allow for managing power MOSFET switching speed and potential drain voltage overshoot. Output transistor layouts were optimized using custom Python software in conjunction with existing design tool resources. A wafer-level test system was developed to identify yield issues in the gate driver output transistors. This method allowed for qualitative and quantitative evaluation of transistor leakage while the system was under probe. Wafer-level testing and results are presented. The gate driver was tested under high temperature operation up to 530 degrees celsius. An integrated module was built and tested to illustrate the capability of the gate driver to control a power MOSFET under load. The adjustable drive strength feature was successfully demonstrated

Hybrid monolithic integration of high-power DC-DC converters in a high-voltage technology

The supply of electrical energy to home, commercial, and industrial users has become ubiquitous, and it is hard to imagine a world without the facilities provided by electrical energy. Despite the ever increasing efficiency of nearly every electrical application, the worldwide demand for electrical power continues to increase, since the number of users and applications more than compensates for these technological improvements. In order to maintain the affordability and feasibility of the total production, it is essential for the distribution of the produced electrical energy to be as efficient as possible. In other words the loss in the power distribution is to be minimized. By transporting electrical energy at the maximum safe voltage, the current in the conductors, and the associated conduction loss can remain as low as possible. In order to optimize the total efficiency, the high transportation voltage needs to be converted to the appropriate lower voltage as close as possible to the end user. Obviously, this conversion also needs to be as efficient, affordable, and compact as possible. Because of the ever increasing integration of electronic systems, where more and more functionality is combined in monolithically integrated circuits, the cost, the power consumption, and the size of these electronic systems can be greatly reduced. This thorough integration is not limited to the electronic systems that are the end users of the electrical energy, but can also be applied to the power conversion itself. In most modern applications, the voltage conversion is implemented as a switching DC-DC converter, in which electrical energy is temporarily stored in reactive elements, i.e. inductors or capacitors. High switching speeds are used to allow for a compact and efficient implementation. For low power levels, typically below 1 Watt, it is possible to monolithically implement the voltage conversion on an integrated circuit. In some cases, this is even done on the same integrated circuit that is the end user of the electrical energy to minimize the system dimensions. For higher power levels, it is no longer feasible to achieve the desired efficiency with monolithically integrated components, and some external components prove indispensable. Usually, the reactive components are the main limiting factor, and are the first components to be moved away from the integrated circuit for increasing power levels. The semiconductor components, including the power transistors, remain part of the integrated circuit. Using this hybrid approach, it is possible in modern converterapplications to process around 60 Watt, albeit limited to voltages of a few Volt. For hybrid integrated converters with an output voltage of tens of Volt, the power is limited to approximately 10 Watt. For even higher power levels, the integrated power transistors also become a limiting factor, and are replaced with discrete power devices. In these discrete converters, greatly increased power levels become possible, although the system size rapidly increases. In this work, the limits of the hybrid approach are explored when using so-called smart-power technologies. Smart-power technologies are standard lowcost submicron CMOS technologies that are complemented with a number of integrated high-voltage devices. By using an appropriate combination of smart-power technologies and circuit topologies, it is possible to improve on the current state-of-the-art converters, by optimizing the size, the cost, and the efficiency. To determine the limits of smart-power DC-DC converters, we first discuss the major contributing factors for an efficient energy distribution, and take a look at the role of voltage conversion in the energy distribution. Considering the limitations of the technologies and the potential application areas, we define two test-cases in the telecommunications sector for which we want to optimize the hybrid monolithic integration in a smart-power technology. Subsequently, we explore the specifications of an ideal converter, and the relevant properties of the affordable smart-power technologies for the implementation of DC-DC converters. Taking into account the limitations of these technologies, we define a cost function that allows to systematically evaluate the different potential converter topologies, without having to perform a full design cycle for each topology. From this cost function, we notice that the de facto default topology selection in discrete converters, which is typically based on output power, is not optimal for converters with integrated power transistors. Based on the cost function and the boundary conditions of our test-cases, we determine the optimal topology for a smart-power implementation of these applications. Then, we take another step towards the real world and evaluate the influence of parasitic elements in a smart-power implementation of switching converters. It is noticed that the voltage overshoot caused by the transformer secondary side leakage inductance is a major roadblock for an efficient implementation. Since the usual approach to this voltage overshoot in discrete converters is not applicable in smart-power converters due to technological limitations, an alternative approach is shown and implemented. The energy from the voltage overshoot is absorbed and transferred to the output of the converter. This allows for a significant reduction in the voltage overshoot, while maintaining a high efficiency, leading to an efficient, compact, and low-cost implementation. The effectiveness of this approach was tested and demonstrated in both a version using a commercially available integrated circuit, and our own implementation in a smart-power integrated circuit. Finally, we also take a look at the optimization of switching converters over the load range by exploiting the capabilities of highly integrated converters. Although the maximum output power remains one of the defining characteristics of converters, it has been shown that most converters spend a majority of their lifetime delivering significantly lower output power. Therefore, it is also desirable to optimize the efficiency of the converter at reduced output current and output power. By splitting the power transistors in multiple independent segments, which are turned on or off in function of the current, the efficiency at low currents can be significantly improved, without introducing undesirable frequency components in the output voltage, and without harming the efficiency at higher currents. These properties allow a near universal application of the optimization technique in hybrid monolithic DC-DC converter applications, without significant impact on the complexity and the cost of the system. This approach for the optimization of switching converters over the load range was demonstrated using a boost converter with discrete power transistors. The demonstration of our smart-power implementation was limited to simulations due to an issue with a digital control block. On a finishing note, we formulate the general conclusions and provide an outlook on potential future work based on this research

Low-voltage, low-power circuits for data communication systems

There are growing industrial demands for low-voltage supply and low-power consumption circuits and systems. This is especially true for very high integration level and very large scale integrated (VLSI) mixed-signal chips and system-on-a-chip. It is mainly due to the limited power dissipation within a small area and the costs related to the packaging and thermal management. In this research work, two low-voltage, low-power integrated circuits used for data communication systems are introduced. The first one is a high performance continuous-time linear phase filter with automatic frequency tuning. The filter can be used in hard disk driver systems and wired communication systems such as 1000Base-T transceivers. A pseudo-differential operational transconductance amplifier (OTA) based on transistors operating in triode region is used to achieve a large linear signal swing with low-voltage supplies. A common-mode (CM) control circuit that combines common-mode feedback (CMFB), common-mode feedforward (CMFF), and adaptive-bias has been proposed. With a 2.3V single supply, the filters total harmonic distortion is less than 44dB for a 2VPP differential input, which is due to the well controlled CM behavior. The ratio of the root mean square value of the ac signal to the power supply voltage is around 31%, which is much better than previous realizations. The second integrated circuit includes two LVDS drivers used for high-speed point-to-point links. By removing the stacked switches used in the conventional structures, both LVDS drivers can operate with ultra low-voltage supplies. Although the Double Current Sources (DCS) LVDS driver draws twice minimum static current as required by the signal swing, it is quite simple and achieves very high speed operation. The Switchable Current Sources (SCS) LVDS driver, by dynamically switching the current sources, draws minimum static current and reduces the power consumption by 60% compared to the previously reported LVDS drivers. Both LVDS drivers are compliant to the standards and operate at data rates up to gigabits-per-second

High-speed low-power modulator driver arrays for medium-reach optical networks

The internet is becoming the ubiquitous tool that is changing the lives of so many citizens across the world. Commerce, government, industry, healthcare and social interactions are all increasingly using internet applications to improve and facilitate communications. This is especially true for videoenabled applications, which currently demand much higher data rates and quality from data networks. High definition TV streaming services are emerging and these again will significantly push the demand for widely deployed, high-bandwidth services. The current access passive optical networks (PONs) use a single wavelength for downstream transmission and a separate one for upstream transmission. Incorporating wavelength-division multiplexing (WDM) in a PON allows for much higher bandwidths in both directions. While WDM technologies have been successfully deployed for many years in metro and core networks, in access networks they are not commonly used yet. This is mainly due to the high costs associated with deploying entire WDM access networks. However, the present optical networks cannot be simply and cost-effectively scaled to provide the capacity for tomorrow’s users. As an effect there is a strong need for new WDM access components which are compact, cost-competitive and mass-manufacturable. Increasing the number of wavelengths for WDM-PON automatically leads to an increase in the number of single pluggable transceivers, which brings substantial design challenges and additional costs. The multitude of TXs and RXs for different wavelength channels increases the total footprint considerably. Photonic integration of transceivers into arrays will significantly reduce the footprint and cost. However, the total power consumption of an array device is an issue. To avoid the use of a thermoelectric cooler, the integration density of components is severely limited by the heat dissipating capabilities offered by their package. As a result the WDM-PON philosophy necessitates the reduction of the transceiver’s power dissipation. From this plea it is apparent that the main technology challenges for realizing future-proof optical (access) networks are reducing active component power consumption, shrinking form factors and lowering assembly costs. In this perspective an over 100 Gb/s throughput component, composed of 10 channels at 11.3 Gb/s per wavelength channel would be a great contribution to the expansion of customer bandwidth. It can provide increased line rates to the end users at speeds of 10 Gb/s per wavelength. As RXs typically consume much less power than externally modulated TXs, they can relatively easily be integrated into an array. Mainly high speed optical transmitters have significant power consumptions and the heat generation caused by power dissipation forms a critical obstacle in the development of a 10-channel transmitter, which again underlines the importance of power reduction. Alongside the introduction of WDM in access networks, also inter-office point-to-point connections in data center environments could benefit from the WDM philosophy. As data center operators often suffer from fiber scarcity or do not own their fiber infrastructure, WDM technologies are essential to deliver reach and capacity extension for these scenarios. Interdata center communication also benefits from cost-, footprint- and energyefficient components operating at high speed to maximize the throughput. As an effect integrated over 100 Gb/s transceivers, such as 4 channels at 28 Gb/s, are highly desirable. The research described in this dissertation was partly funded by the European FP7 ICT project C3PO (Colourless and Coolerless Components for low Power Optical Networks) and the UGent special research fund. The C3PO project aimed to develop a new generation of green Si-photonic compatible components with record low power consumption, that can enable bandwidth growth and constrain the total cost. C3PO envisioned building high-capacity access networks employing reflective photonic components. To achieve this, cost-competitive reflective transmitters based on electroabsorption modulators (EAM) needed to be closely integrated into arrays. A multi-wavelength optical source provides the required wavelength channels for both downstream and upstream signals in the WDM-PON. Chapter 1 gives a short overview of a PON and describes the main implementations of a WDM-PON access network. It introduces integrated low power transmitter arrays for a cost-effective architecture of WDM-PONs and inter-data center communication. Chapter 2 compares different optical transmitters and gives a short overview of their most important characteristics. External modulation through both Mach-Zehnder modulators (MZMs) and EAMs is described. It shows that EAMs are the best choice for low power transmitter array integration, thanks to their lower drive voltage and smaller form factor, compared to MZMs. To achieve a reduced consumption, the electronic modulator driver topology is studied in chapter 3. The challenge in designing modulator drivers is the need to deliver very large currents in combination with high voltage swings. Four distinct output configurations are compared and techniques to reduce the power consumption of the drivers are described. Chapter 5 presents duobinary (DB), a modulation scheme that is gaining interest in today’s optical transmission. As the required bandwidth is about half that of NRZ, it softens the constraints on the transmitter bandwidth. Thanks to its narrow optical spectrum, it has an improved tolerance to dispersion in long haul single mode links and it can improve the spectral efficiency in WDM architectures. For optical DB a precoder is necessary to assure the received signal is equal to the original binary signal. The conducted research that resulted in this dissertation produced 2 low power EAM driver arrays: A 10-channel 113 Gb/s modulator driver array with state-of-the art ultra-low power consumption. A 2-channel 56 Gb/s duobinary driver array with a differential output with low power consumption. Both designs are elaborately analyzed in chapter 4 and 6 respectively. To the best of our knowledge the 10-channel EAM driver array is the first in its kind, while achieving the lowest power consumption for an EAM driver so far reported, 50% below the state of the art in power consumption. The 2-channel EAM driver array is the fastest modulator driver including on-chip duobinary encoding and precoding reported so far. The final chapter provides an overview of the foremost conclusions from the presented research. It is concluded with suggestions for further research

Doctor of Philosophy

dissertationCommunication surpasses computation as the power and performance bottleneck in forthcoming exascale processors. Scaling has made transistors cheap, but on-chip wires have grown more expensive, both in terms of latency as well as energy. Therefore, the need for low energy, high performance interconnects is highly pronounced, especially for long distance communication. In this work, we examine two aspects of the global signaling problem. The first part of the thesis focuses on a high bandwidth asynchronous signaling protocol for long distance communication. Asynchrony among intellectual property (IP) cores on a chip has become necessary in a System on Chip (SoC) environment. Traditional asynchronous handshaking protocol suffers from loss of throughput due to the added latency of sending the acknowledge signal back to the sender. We demonstrate a method that supports end-to-end communication across links with arbitrarily large latency, without limiting the bandwidth, so long as line variation can be reliably controlled. We also evaluate the energy and latency improvements as a result of the design choices made available by this protocol. The use of transmission lines as a physical interconnect medium shows promise for deep submicron technologies. In our evaluations, we notice a lower energy footprint, as well as vastly reduced wire latency for transmission line interconnects. We approach this problem from two sides. Using field solvers, we investigate the physical design choices to determine the optimal way to implement these lines for a given back-end-of-line (BEOL) stack. We also approach the problem from a system designer's viewpoint, looking at ways to optimize the lines for different performance targets. This work analyzes the advantages and pitfalls of implementing asynchronous channel protocols for communication over long distances. Finally, the innovations resulting from this work are applied to a network-on-chip design example and the resulting power-performance benefits are reported