the apollo project: lv power supplies for the next higggyh ...servel/apollo/low voltage power...

The APOLLO Project: LV PowerSupplies For The Next High Energy pp g gy

Physics ExperimentsMilano, October 19, 2011

Agostino Lanza, on behalf of the APOLLO CollaborationAgostino Lanza, on behalf of the APOLLO CollaborationM. Alderighi(1,6), M. Citterio(1), M. Riva(1,8), P. Cova (3,10), N. Delmonte(3,10), A.

Lanza(3), R. Menozzi(10), A. Paccagnella (2,9), F. Sichirollo(2,9), G. Spiazzi(2 9) M Stellini(2 9) S Baccaro(4 5) F Iannuzzo(4 7) ASpiazzi(2,9), M. Stellini(2,9), S. Baccaro(4,5), F. Iannuzzo(4,7), A.

Sanseverino(4,7), G. Busatto(7), V. De Luca(7)

(1) INFN Milano, (2) INFN Padova, (3) INFN Pavia, (4) INFN Roma, (5) ENEA UTTMAT, (6) INAF, (7) University of Cassino, (8) University of Milano, (9)

University of Padova, (10) University of Parma

Features of the PS systems required by the present experiments (mainly at LHC)present experiments (mainly at LHC)

Extensive use of the DC/DC technology, which requires a f l d i i t f EMCcareful design in terms of EMC

Integration with detectors at the design level, to avoid both mechanical and electrical criticalitiesmechanical and electrical criticalities

Necessity of rad-hard devices, so to place modules in the experimental caverns

Necessity of B-tolerant systems, to be able to place them close to detectors

I l t ti f d d b f diffi lt fImplementation of redundancy, because of difficult access of no access at all

Very complex DCS systems in order to get a fully remoteVery complex DCS systems, in order to get a fully remote control

Industrial engineering design and industrial scale production

Milano, October 19 2011 The APOLLO Project - Agostino Lanza 2

Requirements of future LHC upgrades and new experimentsexperiments

New design, full replacing the present systems whose d i d t f l 2000design dates from early 2000 years

Increased rad-hard performance, because of the increased luminosity of acceleratorsluminosity of accelerators

Minimization of power loss in cables used for carrying current from PS distributors to the front-end of detectors, moving distributors as close as possible to the front-end

Increased B-tolerance of systems getting closer to d t t d tdetectors and magnets

Better reliability and controls, in order to reduce access time and increase the overall detector efficiencytime and increase the overall detector efficiency

Avoiding industrial intellectual property, trying to implement the CERN Open Hardware policy


The APOLLO proposal – System architectures

Case study: ATLAS LAr calorimeters

Characteristics:

CRATE Card #3PO

LDO Convert

Card #2d

• Main isolated converter with N+1 redundancy

280 Vdc

Main DC/DC

Converter

Ler

POL

LDO Convert

er

PO

LDO Convert

POL

LDO Convert

er

POL

LDO Convert

er

Card #1POLniPOL

Converter

POLniPOL

• High DC bus voltage (12V or more) O

LConvert

erLer

POL

LDO Convert

er

POLConverter

POLniPOLConverterRegulated

DC bus

( )

• Distributed Non-Isolated Point of Load Converters DC bus

POL Converter with high step-down ratio

Load Converters (niPOL) with high step-down ratio


The APOLLO proposal – System architectures

Parallel study: ATLAS Muon detectors

Characteristics:MuonDetectors Chamb #3

PO

LDO ConvertChamb #2

Ch b #1

• Main isolated converter with N+1 redundancy

280 Vdc

Main DC/DC

Converter

Ler

POL

LDO Convert

er

PO

LDO Convert

POL

LDO Convert

er

POL

LDO Convert

er

Chamb #1

niPOL

• High DC bus voltage (12V or more)

Di t ib t d N OL

Converter

Ler

POL

LDO Convert

er

niPOLConverter

Regulated DC bus

• Distributed Non-Isolated Point of Load Converters (niPOL) with high step down DC bus

POL Converter with high step-down ratio

with high step-down ratio, on-chamber installed and high B-tolerant


tolerant

The APOLLO proposal - Topologies

The Main DC/DC Converter3 modules 1.5 kW each

Q4T1C4 L

+

+• redundancy n+1• current sharing• interleaved operations

Switch In Line Converter - SILC

Q

Q3 CoVin

Vout

+-C3

C

T3

i

iL

T

+

+

Switch In Line Converter SILC• phase shift operation• ZVS transitions• high efficiency• reduced switch voltage stress

Q1

Q2C2

C1 T2

iT2T4

+

Vout = 12V

• reduced switch voltage stress• high frequency capability

Vout 12V33 cm Efficiency

(Bext = 0)0 8

0.91 Transient response

Output voltage

7 cm

0)

0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.60.50.60.70.8

Vout

Iload

responseto a load step change (25 A 37 A)

Milano, October 19 2011 The APOLLO Project - Agostino Lanza 613 cm

7 cmOutput power kW]

The APOLLO proposal – Thermal sizing3D Finite Element Model (FEM)• FE modeling of the main heating components:

• Input power MOSFETs• Output diodes• Inductor• Planar transformer

Thermal measurements 1• Thermal characterization on single components, to validate models

• Thermal design• Designed advanced solutions to improve heat exchange:

• Power MOSFETs mounted on IMS board• ISOTOP diode isolated package directly mounted on

baseplate

Thermal simulation and measurements 2• Preliminary thermal measurements on the air cooled

baseplate• Copper thermal layers for transformer core cooling • Silicone gap filler for transformer windings cooling

whole converter

Final requirementsM i t t t 3 1 kW• Main converter output power = 3x1 kW

• Case dimensions: 150 x 402 x 285 mm3

• Max case temperature = 18°C• Water cooling system

• delivery = 1 9 l/min Δp = 350 mbar


• delivery = 1.9 l/min, Δp = 350 mbar• Tinlet = 18°C, Toutlet ≤ 25°C

The APOLLO proposal - Topologies

The Point of LoadsSpecifications:Input voltage: U = 12 V

S1 S2

S4

L1

Co RC1

Uin Uo

+UC1

+

Input voltage: Ug 12 VOutput voltage: Uo = 2.5 VOutput current: Io = 3AOp. frequency: fs = 1 MHz

S3

C1 L2 --

D<50% Uo = UinD/2C

350 nH air core inductorsDim.: L = 6cm, W = 4.2cm

50% Uo Uin /

Interleaved Buck with Voltage Divider – IBVD

Characteristics:

Cin

S1

Specifications:Input voltage: Ug = 12 V Characteristics:

• Zero voltage switch turn on• High step-down ratio• Reduced switch voltage stress

C1

1

S3S4

p g gOutput voltage: Uo = 2 VOutput current: Io = 20AOp. frequency: fs = 280 kHz

g(Uin/2)

• Interleaved operation with automatic current sharing and ripple cancellation

L1L2

2.2 μH ferrite core inductorsDim.: L = 7cm, W = 3.5cm


ripple cancellation

Co

The APOLLO proposal – Rad-hard devices

Seeking for power MOSFETs radiation tolerant up to 10kGy and 1014/(s · cm2) neutrons and protons:10 /(s cm ) neutrons and protons:

many components, with Vd ranging from 30V to 200V and polarized in various configurations, were tested at the 60Co γ ray source in the ENEA center of Casaccia, near Roma,

same components were tested with a heavy ion beam, 75Br at 155MeV, at INFN Laboratori Nazionali del Sud in Catania

within the end of the year same components will be tested under neutrons, at the Casaccia nuclear reactor Tapiro, and under protons, at INFN LNS

Seeking for power MOSFETs, controllers and FPGA radiation tolerant:first irradiation was performed under 216MeV proton beam in Boston atfirst irradiation was performed under 216MeV proton beam in Boston, at

Massachusetts General Hospital facility, using some of devices irradiated in Italy. Other irradiation campaigns are planned at the same facilities in the next monthsnext months

Results are still preliminary and under analysis. Other irradiation campaigns are necessary in order to select good devices


The APOLLO proposal – Rad-hard devicesSome preliminary results of γ irradiation up to 9600 Gy of the 200V MOSFET IRF630


The APOLLO proposal – New technologies

LStudy of EPC GaNs: GaN test circuit

VDC

vc

DUT

L

VCC+ C1

iDUT

+Work in progress since early 2011Two device types under test: 40V and 200VDifficulties found for soldering devices on PCB

DRIVER

iDUT

Rshunt

Electrical characterization in progressRad-hard tests will come soon

U [1V/div]Rshunt = 85 mΩ

UGS [1V/div]

Measured voltage and current during switching periods of a GaN device

UGS [1V/div]

-IDS [1A/div]

GS [ ]UDS [20V/div]

-I [1A/div]

Time [10ns/div]

-IDS [1A/div]

-poff(t) Time [10ns/div]


Turn on interval @ Vcc = 100V, IDS = 0A Turn off interval @ Vcc = 100V, IDS = 5A

The APOLLO proposal – New technologies

Study of high-B materials:Collaboration with the private company FN

First moulded samples of FES168

Collaboration with the private company FN S.p.A.

Base material by Hoganas, FES168 HQ, Fe Si(6 5 6 9%)– Si(6.5-6.9%) Problems found and solved in the injection

moulding phaseStill problems in the sintherization phaseStill problems in the sintherization phaseFirst B tests by end of the year (hopefully)

Collaboration with a CERN group (F. Faccio). It aims at studying current sharing of already existing integrated DC/DC converters with low output currents (< 3A), designed by that group


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