Characterization and modeling of ESD events, risk and protection

“The ESD (Electrostatic discharge) failures have been raising critical reliability problems in electronic devices design. However, not all the ESD scenarios have been specified by the IEC standard and the characterizations of the ESD risk for different scenarios are essential to evaluate the ESD robustness of the devices in the real word. The insulation of plastic enclosures provides protection against ESD to the electronic system inside. However, seams between plastic parts are often unavoidable. Different plastic arrangements are constructed to investigate the spark length and current derivatives and to understand the ESD spark behavior for geometries having spark lengths longer than the values predicted by Paschen’s law. For the wearable devices, the core difference between the posture assumed for IEC 61000-4-2 human metal discharge and a discharge to a wearable device is the impedance between the charged body and the grounded structure discharged to. The results show that the current measured in the brush-by scenario can reach values twice as high as the current specified in the IEC standard. A simulation model using the measured impedance and Rompe and Weizel’s law provides predictions on the peak current derivative when the spark length is varied. The increasing peak current derivative with shorter spark length indicates stronger field coupling to the devices. SEED(System-efficient ESD design) modeling helps the designer to predict the ESD risk at the early stage, an accurate TVS model can be used to study the transient response of the external TVS and the on-chip protection when applied in a typical high-speed input/output (I/O) interface”--Abstract, page iv

System efficient ESD design concept for soft failures

This research covers the topic of developing a systematic methodology of studying electrostatic discharge (ESD)-induced soft failures. ESD-induced soft failures (SF) are non-destructive disruptions of the functionality of an electronic system. The soft failure robustness of a USB3 Gen 1 interface is investigated, modeled, and improved. The injection is performed directly using transmission line pulser (TLP) with varying: pulse width, amplitude, polarity. Characterization provides data for failure thresholds and a SPICE circuit model that describes the transient voltage and current at the victim. Using the injected current, the likelihood of a SF is predicted. ESD protection by transient voltage suppressor (TVS) diodes is numerically simulated in several configurations. The results strongly suggest the viability of using well-established hard failure mitigation techniques for improving SF robustness, and the possibility of using numerical simulation for optimization purposes. A concept of soft failure system efficient ESD design (SF-SEED) is proposed and shown to be effective --Abstract, page iv

Characterisation of on-chip electrostatic discharge waveforms with sub-nanosecond resolution: design of a differential high voltage probe with high bandwidth

Bliksem werd tot aan de ontdekking van de bliksemafleider (18e eeuw) gezien als een van de gevaarlijkste bedreigingen voor het stadsleven. Door het gebruik van micro-elektronica werden ingenieurs gewaar dat ditzelfde fysische verschijnsel, elektrostatische ontlading of ESD genoemd, zich ook op microscopische schaal voordoet. In de jaren zeventig was meer dan 30% van al het chipfalen te wijten aan ESD. Om dit tegen te gaan werd met het onderzoek naar ESD-protecties en -meetsystemen aangevangen. Om meer informatie over het gedrag van een ESD-protectie te verkrijgen wordt een ESD-puls op dit systeem losgelaten. Het antwoord van de protectie op deze puls wordt dan bepaald m.b.v. spannings- en stroomgolfvormmetingen. In dit werk wordt een nieuwe nauwkeurige ESD-golfvormmeettechniek voorgesteld die directe metingen op protecties kan uitvoeren. De karakterisering van ESD-golfvormen op chip wordt enorm bemoeilijkt door de grote hoeveelheid elektromagnetische interferentie die de ESD-puls veroorzaakt. Dit wordt omzeild door het gewenste signaal naar een veilige omgeving te transporteren, waar een standaard meettoestel de meting kan uitvoeren. Dit transport wordt gerealiseerd m.b.v. optische communicatie, wat immuun is voor elektromagnetische interferentie. Zo kan nauwkeurige in-situ-informatie worden verkregen waarmee de ESD-protecties in de toekomst verbeterd kunnen worden.Up to the 18th century, lightning was considered one of nature’s most dangerous threats in city life. This all ended with the lightning rod, protecting thousands of homes during lightning storms. The large-scale use of microelectronics has made engineers aware of the same physical phenomenon occuring on a microscopic scale. This phenomenon is called electrostatic discharge or ESD. In the seventies, more than 30% of all chip failure was attributed to static electricity. To counter this effect, the research for on-chip ESD protections was born. Today ESD is a buzzing line of research, as with new and faster chip technologies comes a higher ESD vulnerability. This makes ESD protection and measurement increasingly important. Although ESD is now a major subject in chip design, it copes with a lack of accurate device models. To gain more information on the exact operation of an ESD protection, an ESD pulse is unleashed upon this device. The response of the protection on this pulse is then assessed by performing voltage or current waveform measurements. This work presents a waveform measurement technique able to accurately perform direct measurements on the ESD protection. Due to the high amount of electromagnetic interference caused by the ESD pulse, direct waveform characterisation near the protection is hard. This is solved by transporting the target signal into a clean area, where the measurement is performed by standard lab equipment. The key is that this transportation is realized by means of optical communication, which is immune to electromagnetic interference. This way, accurate in situ information can be used to protect tomorrow’s chips

Characterization of an Integrated Circuit with Respect to Electrostatic Discharge-Induced Soft Failures

This research proposal presents a methodology whereby an integrated circuit (IC) can be characterized with respect to soft-failures induced by Electrostatic Discharge (ESD)-like events. This methodology uses an exclusively black-box approach to determine the response of an IC in a system-level environment, thereby allowing it to be implemented without intimate knowledge of the DUT IC. Results from this methodology can be referenced during system design to raise awareness of specific vulnerabilities of the core system ICs. During work on this methodology, several sub topics have been explored and developed in the field of system-level ESD. Sections 2 and 3 introduce two topics which were developed to facilitate the generation and expression of IC pin models. Papers 1 and 2 introduce injection methods for characterizing complete systems on an interface-by-interface basis and form the foundation for the following works. Papers 2 and 3 mirror Papers 1 and 2 but instead shift focus away from the system as a whole and outline methods for characterizing the integrated circuits directly. Finally, Section 4 outlines a model method which can be used to describe the failures found in Paper 4 in circuit simulation, rounding out the work. Additional measurements which were unable to be included in Paper 4 are included in Appendices A, B, and C --Abstract, page iv

On-die transient event sensors and system-level ESD testing

System level electrostatic discharge (ESD) testing of electronic products is a critical part of product certification. Test methods were investigated to develop system level ESD simulation models to predict soft-failures in a system with multiple sensors. These methods rely completely on measurements. The model developed was valid only for the linear operation range of devices within the system. These methods were applied to a commercial product and used to rapidly determine when a soft failure would occur. Attaching cables and probes to determine stress voltages and currents within a system, as in the previous study, is time-consuming and can alter the test results. On-chip sensors have been developed which allow the user to avoid using cables and probes and can detect an event along with the level, polarity, and location of a transient event seen at the I/O pad. The sensors were implemented with minimum area consumption and can be implemented within the spacer cell of an I/O pad. Some of the proposed sensors were implemented in a commercial test microcontroller and have been tested to successfully record the event occurrence, location, level, and polarity on that test microcontroller. System level tests were then performed on a pseudo-wearable device using the on-chip sensors. The measurements were successful in capturing the peak disturbance and counting the number of ESD events without the addition of any external measurement equipment. A modification of the sensors was also designed to measure the peak voltage on a trace or pin inside a complex electronic product. The peak current can also be found when the sensor is placed across a transient voltage suppressor with a known I-V curve. The peak level is transmitted wirelessly to a receiver outside the system using frequency-modulated magnetic or electric fields, thus allowing multiple measurements to be made without opening the enclosure or otherwise modifying the system. Simulations demonstrate the sensors can accurately detect the peak transient voltage and transmit the level to an external receiver --Abstract, page iv

Hard macrocells for DC/DC converter in automotive embedded mechatronic systems

A novel configurable DC/DC converter architecture, to be integrated as hard macrocell in automotive embedded systems, is proposed in the paper. It aims at realizing an intelligent voltage regulator. With respect to the state of the art, the challenge is the integration into an automotive-qualified chip of several advanced features like dithering of switching frequency, nested control loops with both current and voltage feedback, asynchronous hysteretic control for low power mode, slope control of the power FET gate driver, and diagnostic block against out-of-range current or voltage or temperature conditions. Moreover, the converter macrocell can be connected to the in-vehicle digital network, exchanging with the main vehicle control unit status/diagnostic flags and commands. The proposed design can be configured to work both in step-up and step-down modes, to face a very wide operating input voltage range from 2.5 to 60 V and absolute range from −0.3 to 70 V. The main target is regulating all voltages required in the emerging hybrid/electric vehicles where, besides the conventional 12 V DC bus, also a 48 V DC bus is present. The proposed design supports also digital configurability of the output regulated voltage, through a programmable divider, and of the coefficients of the proportional-integrative controller inside the nested control loops. Fabricated in 0.35 μm CMOS technology, experimental measurements prove that the IC can operate in harsh automotive environments since it meets stringent requirements in terms of electrostatic discharge (ESD) protection, operating temperature range, out-of-range current, or voltage condition

High Temperature Electronics Design for Aero Engine Controls and Health Monitoring

There is a growing desire to install electronic power and control systems in high temperature harsh environments to improve the accuracy of critical measurements, reduce the amount of cabling and to eliminate cooling systems. Typical target applications include electronics for energy exploration, power generation and control systems. Technical topics presented in this book include:• High temperature electronics market• High temperature devices, materials and assembly processes• Design, manufacture and testing of multi-sensor data acquisition system for aero-engine control• Future applications for high temperature electronicsHigh Temperature Electronics Design for Aero Engine Controls and Health Monitoring contains details of state of the art design and manufacture of electronics targeted towards a high temperature aero-engine application. High Temperature Electronics Design for Aero Engine Controls and Health Monitoring is ideal for design, manufacturing and test personnel in the aerospace and other harsh environment industries as well as academic staff and master/research students in electronics engineering, materials science and aerospace engineering

Analysis and modeling methods for predicting functional robustness of integrated circuits during fast transient events

La miniaturisation des circuits intégrés se poursuit de nos jours avec le développement de technologies toujours plus fines et denses. Elle permet une intégration des circuits toujours plus massive, avec des performances plus élevées et une réduction des coûts de production. La réduction de taille des circuits s'accompagne aussi d'une augmentation de leur sensibilité électrique. L'électronique automobile est un acteur majeur dans la nouvelle tendance des véhicules autonomes. Ce type d'application a besoin d'analyser des données et d'appliquer des actions sur le véhicule en temps réel. L'objectif à terme est d'améliorer la sécurité des usagers. Il est donc vital de garantir que ces modules électroniques pourront effectuer leurs tâches correctement malgré toutes les perturbations auxquelles ils seront exposés. Néanmoins, l'environnement automobile est particulièrement sévère pour l'électronique. Parmi tous les stress rencontrés, les décharges électrostatiques (ESD - Electrostatic Discharge) sont une importante source d'agression électrique. Ce type d'évènement très bref est suffisamment violent pour détruire des composants électroniques ou les perturber pendant leur fonctionnement. Les recherches présentées ici se concentrent sur l'analyse des défaillances fonctionnelles. À cause des ESD, des fonctions électroniques peuvent cesser temporairement d'être opérantes. Des méthodes d'analyse et de prédiction sont requises au niveau-circuit intégré afin de détecter des points de faiblesses susceptibles de générer des fautes fonctionnelles pendant l'exposition à un stress électrostatique. Différentes approches ont été proposées dans ce but. Une méthode hiérarchique de modélisation a été mise au point afin d'être capable de reproduire la forme d'onde ESD jusqu'à l'entrée du circuit intégré. Avec cette approche, chaque élément du système est modélisé individuellement puis son modèle ajouté au schéma complet. Un cas d'étude réaliste de défaillance fonctionnelle d'un circuit intégré a été analysé à l'aide d'outils de simulation. Afin d'obtenir plus de données sur cette faute, une puce de test a été développée, contenant des structures de surveillance et de mesure directement intégrées dans la puce. La dernière partie de ce travail de recherche est concentrée sur le développement de méthodes d'analyse dans le but d'identifier efficacement des fautes par simulation. Une des techniques développées consiste à modéliser chaque bloc d'une fonction individuellement puis permet de chaîner ces modèles afin de déterminer la robustesse de la fonction complète. La deuxième méthode tente de construire un modèle équivalent dit boite-noire d'une fonction de haut-niveau d'un circuit intégré. Ces travaux de recherche ont mené à la mise au point de prototypes matériels et logiciels et à la mise en évidence de points bloquants qui pourront constituer une base pour de futurs travaux.Miniaturization of electronic circuits continues nowadays with the more recent technology nodes being applied to diverse fields of application such as automotive. Very dense and small integrated circuits are interesting for economic reasons, because they are cheaper to manufacture in mass and can pack more functionalities with elevated performances. The counterpart of size reduction is integrated circuits becoming more fragile electrically. In the automotive world, the new trend of fully autonomous driving is seeing tremendous progress recently. Autonomous vehicles must take decisions and perform critical actions such as braking or steering the wheel. Those decisions are taken by electronic modules, that have now very high responsibilities with regards of our safety. It is important to ensure that those modules will operate no matter the kind of disturbances they can be exposed to. The automotive world is a quite harsh environment for electronic systems. A major source of electrical stress is called the Electrostatic Discharge (ESD). It is a very sudden flow of electricity of large amplitude capable of destroying electronic components, or disturb them during their normal operation. This research focuses on functional failures where functionality can be temporarily lost after an ESD with various impact on the vehicle. To guarantee before manufacturing that a module and its components will perform their duty correctly, new analysis and prediction methods are required against soft-failures caused by electrostatic discharges. In this research, different approaches have been explored and proposed towards that goal. First, a modelling method for reproducing the ESD waveforms from the test generator up to the integrated circuit input is presented. It is based on a hierarchical approach where each element of the system is modelled individually, then added to the complete setup model. A practical case of functional failure at silicon-level is analyzed using simulation tools. To acquire more data on this fault, a testchip has been designed. It contains on-chip monitoring structures to measure voltage and current, and monitor function behavior directly at silicon-level. The last part of this research details different analysis methods developed for identifying efficiently functional weaknesses. The methods rely heavily on simulation tools, and prototypes have been implemented to prove the initial concepts. The first method models each function inside the chip individually, using behavioral models, then enables to connect the models together to deduce the full function's robustness. It enables hierarchical analysis of complex integrated circuit designs, to identify potential weak spots inside the circuit that could require more shielding or protection. The second method is focused on constructing equivalent electrical black box models of integrated circuit functions. The goal is to model the IC with a behavioral, black-box model capable of reproducing waveforms in powered conditions during the ESD. In summary, this research work has led to the development of several hardware and software prototypes. It has also highlighted important modelling challenges to solve in future works to achieve better functional robustness against electrostatic discharges

High-voltage ESD structures and ESD protection concepts in smart power technologies

Electro-static discharge (ESD) event can cause upset or permanent damage of integrated circuits (IC) and electrical systems. The risk of ESD fails needs to be mitigated or prevented. ESD robustness of IC products and electrical systems is specified, verified and qualified according to respective ESD standards. For high-voltage IC products based on smart power semiconductor technologies for industrial, power and automotive applications, design of effective and cost-efficient ESD protection is a big challenge, demanding wide and deep technical knowledge throughout high-frequency and high-power characterization techniques, semiconductor device physic, circuit design as well as modeling and simulation. The required measurement setups and tester components are developed and introduced. The characterization of ESD protection devices, IC and off-chip circuit elements is enabled and improved. The rise-time filters are important for the study of rise-time dependent ESD robustness. The human metal model (HMM) tester as an alternative to IEC ESD generators provides voltage waveform measurement with good quality in addition to current waveform measurement. It can be used for wafer-level or package-level device characterization. The measurement results of HMM tester and IEC ESD generator are compared. The on-chip ESD protection design relies on proper choice of different types of ESD protection devices and structures, depending on ESD specifications and IC applications. Typical on-chip ESD protection, whether snapback or non-snapback, single device or ESD circuit is introduced. The failure levels studies give a systematic benchmark of the ESD protection devices and structures, concerning device area, clamping voltage and other relevant parameters. The trade-off between those parameters and limitation of different ESD protection is discussed. Moreover, understanding of ESD failure modes is the key to implement effective ESD design. A unique ESD failure mode of smart power semiconductor device is discovered and investigated in detail. In the scope of finding ESD solutions, new active ESD clamps have been further developed in this work. The study of ESD protection is extended to the system-level involving on- and off-chip ESD protection elements. The characteristics of typical off-chip elements as well as the interaction between IC and off-chip protection elements plays essential role on the system robustness. A system-level ESD simulation incorporating IC and off-chip protection elements is desired for system efficient ESD design (SEED). A behavioral ESD model is developed which reproduces pulse-energy-dependent failure levels and self-heating effects. This modeling methodology can be used for assessment of system robustness even beyond ESD time-domain. The validation of the models is given by representative application examples. Several main challenges of high-voltage ESD design in smart power technologies have been addressed in this work, which can serve as guidance for ESD development and product support in future power semiconductor technologies