EMC-aware Printed Circuit Board Design of DC-DC Converters Raul Blecic Department of electronics, microelectronics, computer and intelligent systems Faculty of Electrical Engineering and Computing University of Zagreb, Unska 3, 10000 Zagreb, Croatia Tel: +385 (0)1 6129547, fax: +385 (0)1 6129653, e-mail: raul.blecic@fer.hr Abstract—In this paper a printed circuit board (PCB) design of DC-DC converters with respect to the electromagnetic compatibility (EMC) is analyzed. The simulation methods for parallel plate waveguides are evaluated and the most appropriate one for the design of DC-DC converters is recognized. The simulation results using the proposed method are compared to the results from the general purpose full-wave electromagnetic (EM) simulators. The influence of the equivalent series resistance (ESR) and equivalent series inductance (ESL) of decoupling capacitors on electromagnetic interference (EMI) is investigated and the concept of reducing the EMI by a careful choice of decoupling capacitors is presented. A new PCB layout scheme is proposed to reduce the EMI of DC-DC converters. Index Terms—PCB layout optimization, circuit-EM cosimulation, EM simulation, cavity mode modeling, integralequation methods, power integrity, power distribution network. I. I NTRODUCTION Switching DC-DC converters are more efficient and smaller in volume and weight when compared to linear converters which makes them an appealing choice for various applications. However, due to the switching mode of operation and high dv/dt and di/dt they are sources of EMI [1]. The ongoing trend of integration of DC-DC converters pushes the switching frequencies to higher values because of the maximum nominal value limitation of integrated reactive components. Higher switching frequencies increase switching losses and degrade the efficiency of DC-DC converters. To decrease switching losses and increase the efficiency, the dv/dt and di/dt are increased [2]. This, in turn, increases EMI even more and makes it the most challenging part of a DC-DC converter design. Products incorporating DC-DC converters must comply with conducted and radiated emission limits according to standards CISPR22, FCC part 15 and EN 55022 as shown in Fig. 1. The EMI of the switching buck DC-DC converter (similar to those in the INVENT project [3]) is studied in [4]. It was found that the resonance formed by the capacitance of the low-side FET in off state Coss and the total inductance of the decoupling loop is the main source of ringing of the phase voltage and for increased EMI. The same authors provided EMC guidelines for buck converter design in [5]. The ringing of the phase voltage and increased EMI were co-simulated in [6]. The same authors suggested six buck converter PCB layout modifications for reducing the EMI in [7], and proposed to (a) Conducted emission levels. (b) Radiated emission levels. Fig. 1. Standards for conducted and radiated emissions levels for products incorporating DC-DC converters [3]. damp the parasitic LC resonance by adding losses in switching loop in a form of RL snubber connected to the drain of the high-side FET. The impact of the PCB layout on the EMI of DC-DC converter was also investigated in [8] and in [9] where, similar to [7], the parasitic LC resonance is damped Fig. 2. required charge to the switching circuits, lowering the power supply noise. However, decoupling capacitors in combination with the parasitic inductances of the capacitor package, trace inductances and IC package inductances form a resonant circuit [15]; below the resonant frequency the capacitor actually shows a capacitive behaviour and reduces the PDN impedance, however, above resonant frequency it shows inductive behavior and is practically useless as a decoupling capacitor. To extend the usable frequency range of decoupling capacitors, several options are available: Basic power delivery system [10]. 1) Multiple capacitors of different values. Multiple capacitors of different values will have an antiresonant peak between each resonant frequency which potentially limits their effectiveness [15], since noise and radiated emission considerably increase at antiresonances [16]. However, if the capacitor values are progressively decreasing, the anti-resonant spike can be shifted to frequencies out of the range of interest [10]. 2) Multiple capacitors all of the same value. For each additional capacitor added, an equivalent capacitance is increased, while an equivalent inductance is decreased. Thus, the PDN impedance is decreased. 3) Embedded PCB Capacitance. Taking the concept of using a large number of equal value capacitors to its limit, the ideal decoupling configuration is an infinite number of infinitesimal capacitors, i.e. distributed capacitor [15]. The parallel-plate waveguide capacitance, if large enough, can be used as a distributed capacitor. However, due to the reflections from the ends of finite parallel plates, the resonances of the embedded PCB capacitance occur which limit its usability [16]. If the boundary of the power-ground plane pair is terminated into parallel-plate characteristic impedance, this resonances are avoided and a resonant-free PDN can be achieved [17], [18]. by choosing capacitors with high ESR. All of the mentioned papers based their work on the fullwave simulations and/or measurements. Full-wave simulations are time consuming which makes them unpractical for the design optimization. Measurements are not only unpractical but are also an expensive way to optimize the design. Therefore, a fast circuit simulation method that enables the optimization of a DC-DC converter PCB design is needed. The fast simulation method for the design, optimization and analysis of DC-DC converters is presented in this paper. This paper is structured as follows: Section II presents basic issues with a power distribution network design and additional requirements imposed by DC-DC converters; Section III presents the analytic solutions and semi-analytic simulation methods for a parallel-plate waveguide, their advantages and disadvantages, and suggest the best simulation method for a DC-DC converter design; Section IV shows the application examples of the suggested method; Section V shows simulation results using the 3D full-wave simulators; and in Section VI the conclusion is given. II. P OWER D ISTRIBUTION N ETWORK A power distribution network (PDN) consists of a power supply, a power load, and interconnect lines connecting the supply to the load (Fig. 2). The power supply is assumed to behave as an ideal voltage source providing nominal power and ground voltage levels, Vdd and Vgnd . The power load is modeled as a variable current source I(t). The interconnect lines connecting the supply and the load are not ideal; the power and ground lines have a finite parasitic resistance Rp and Rg , respectively, and inductance Lp and Lg , respectively. Resistive voltage drops VR = IR and inductive voltage drops VL = LdI/dt develop across the parasitic interconnect impedances, as the load draws current I(t) from the power distribution network. The voltage levels across the load terminals, therefore, change from the nominal level provided by the supply, dropping to Vdd −IRp −Lp dI/dt at the power terminal and rising to Vgnd + IRg + Lg dI/dt at the ground terminal, as shown in Fig. 2 [10]. This change in the supply voltages is referred to as a power supply noise (DC (IR) noise caused by high average currents and an AC (delta-I) noise caused by fast current transients [11], [12], [13], [14]). Decoupling capacitors are often used to reduce the impedance of a power distribution network and provide the Beside EMC, another major issue in the design of DCDC converters are the losses that generate heat which can damage the system if not properly taken care of [19]. This places additional strict requirements on a design of the PDN for DC-DC converters [3] (which, in turn, affects its EMC): 1) The power and ground pins should be connected to power and ground planes that serve as heatsinks. Electrically viewed, power and ground planes form a parallelplate waveguide whose distributed nature needs to be taken into account. 2) Exposed pads can be used to maximize the thermal transfer. Distributed nature of exposed pads should be taken into account. 3) The copper should be as thick as possible to reduce the parasitic resistance. 4) Multiple layers for power and ground planes can be used to decrease parasitic resistance and inductance. Multiple vias should be used for inter-layer connections to minimize parasitic inductance. However, too many vias degrade the quality of the parallel-plate waveguide 2 since perforations in parallel-plate waveguides increase their inductance. Looking at the list of issues from a PDN design and the list of additional requirements from a DC-DC converter design, it is obvious that the design of the PDN is not a straightforward task and that an optimization algorithm is more than welcome. The algorithm would be useful for any system design, and is not limited to the design of DC-DC converters. III. PARALLEL -P LATE WAVEGUIDE M ODELING A. Analytic solutions 1) Cavity-mode model: The impedance between two ports in a parallel-plate waveguide is most often calculated as [20]: Z Z 1 G(r, r0 )dSi dSj , (1) Zij = − Si Sj Si Sj Fig. 3. Rectangular parallel-plate waveguide. 0 where G(r, r ) is the electric field Green function for electric currents in a 2D transmission line structure; the observation point r is element of dSi ; and the source point r0 is element of dSj . Since Green functions are available for rectangular, special triangular and cylindrical cavities only, analytic solutions for impedance matrix in 2D transmission line structures are also available for these geometries only [20]. The cavity mode model is based on the impedance definition (1) so it does not take the perforations from vias into account, and it is available for rectangular and triangular cavities only. Therefore, it is not the appropriate method for a DC-DC converter design. However, it is a very popular modeling method which can be used to verify the validity of semianalytic modeling methods, as well as for the fast analysis of PCB parameters. The influence of the dimensions of the structure and the parameters of the substrate material on antiresonant peaks in impedance profile are investigated in [13]; the influence of decoupling capacitors is investigated in [14], to name a few examples. Cavity-mode modeling method is an analytic solution of the impedance matrix equation of a rectangular parallel-plate waveguide (see Fig. 3) based on the Green function of the 2D Helmholtz equation with the boundary condition of the second kind, i.e. the perfect magnetic walls [11]. The boundary condition corresponds to the requirement that the thickness of the PCB is much smaller than the wavelength which is almost always satisfied in real PCBs. The elements of the impedance matrix are calculated as [12]: Zij = ohmic losses [16]; xi and yi , and xj and yj are the coordinates of the center of the ith and jth ports, respectively; and w is the half-width of rectangular ports and is much smaller than the wavelength of interest. Equation (2) converges extremely slow for the selfimpedance, because of the singularity of the Green function. Using the summation formula of a Fourier series, the double series is reduced to the single series [11]: Zij = ×sinc2 (kyn w) cos(αn x− ) + cos(αn x+ ) , αn sin(αn ) (3) q 2 , x = 1 − (x ± x )/a, and C is where αn = a k 2 − kyn ± i j n a constant equal to Cn = 1 if n = 0 and Cn = 2 if n 6= 0. The ’fast algorithm’ for the input impedance Zii of a rectangular parallel-plate waveguide is also provided in [11], however, when combined with transfer impedances calculated using either double or single summation, it forms an illconditioned impedance matrix and can not be used whenever multiple ports are present. The accuracy of the method greatly depends on the number of modes taken into account, when higher modes are taken into account the solution is more accurate, however, the simulation time is increased [11]. Since resonant frequency for each mode is determined only by the mode itself and is not affected by the number of modes taken into account, for fast evaluation smaller number of modes such as 30-80 (depending on the size of the structure) is sufficient for reasonable accuracy. 2) Cylindrical Wave Definition: Another analytic solution is available for the circular parallel plate as shown in Fig. 4. Solution of the 2D Helmholtz equation for a 2D transmission line structure in cylindrical coordinates is [21]: ∞ X ∞ X jωµh Kmn sinc2 (kxm w)sinc2 (kyn w) 2 + k2 − k ab kxm yn m=0 n=0 × cos(kxm xi ) cos(kyn yi ) cos(kxm xj ) cos(kyn yj ), ∞ X ωµha Cn cos(kyn yi ) cos(kyn yj ) j2b n=0 (2) where ω is the radian frequency; µ is the permeability of vacuum; h is the thickness of the substrate, and is much smaller than the wavelength of interest; a is the length and b is the width of the rectangular cavity; Kmn is a constant equal to Kmn = 1 if m = n = 0, Kmn = 2 if m = 0 ∨ n = 0 and Kmn = 4 if m 6= 0 ∧ n 6= 0; kxm = mπ/a, kyn = nπ/b; k is the complex wavenumber including the dielectric and the (1) (2) Ez = AH0 (kR) + BH0 (kR) j (1) (2) Hφ = [AH1 (kR) + BH1 (kR)], η 3 (4) Fig. 5. Illustration of a real PCB design: irregularly shaped multiply connected boundaries with cut-outs. Fig. 4. Another solution is the segmentation method - an irregular plane pair is divided into smaller and regular shapes, each regular shape is modeled using analytic solution, and then all segments are assembled together [22]. Obviously, the more irregular the structure to be modeled is, the more complex the segmentation is, which limits its usability. 1) Contour integral method (CIM): CIM uses the integral equation solution to calculate the impedance matrix. The problem geometry is shown in Fig. 5. The voltage inside and on the boundary of a source-free region can be expressed by the integral of voltages and current densities on the boundary (multiply connected contour C; see Fig. 5) [23], [24]: I R k (2) [ n̂˙ 0 H1 (kR)V (r0 ) + V (r) = K j C R Cylindrical parallel-plate waveguide. where A and B are arbitrary constants depending on the source and boundary conditions; k is the complex wavenumber; R is the radial distance from the center; η is the wave impedance, (1) (1) η = ωµ/k; H0 and H1 are the zeroth- and the first-order (2) (2) Hankel functions of the first kind; and H0 and H1 are the zeroth- and the first-order Hankel functions of the second kind. With the source condition I = I0 at ri , and the perfect magnetic conductor (PMC) boundary condition (Hφ = 0) at the periphery of the circular parallel plate ρ = R0 , constants A and B are uniquely defined and the input impedance at the center of the circular parallel plate is calculated as [21]: (1) (2) +jηhH0 (kR)Jn (r0 )]dl0 , where K is equal to 1/2 for points on the contour C, and 1/4 for points inside the contour C; R is the vector from the source point r to the observation point r0 , R = r − r0 ; R is the length of R; n̂0 is the normal vector to the contour C at the source (2) (2) point; H0 and H1 are the zeroth- and the first-order Hankel functions of the second kind; k is the complex wavenumber; η is the wave impedance, η = ωµ/k; and h is the thickness of the substrate, and is much smaller than the wavelength of interest. The integration is defined over the source point. To solve the equation (7), the boundary of the power-ground plane pair is divided into many straight segments so that the length of each segment is much smaller than the wavelength (the voltage and current at each segment are approximated to be uniform). Then, V and Jn are expanded using unit pulse functions and the following relation is obtained [23], [24]: (0) Vi −Ez h jωµh H0 (kri ) + ΓR J0 (kri ) , (5) Zii = = = Ii 2πri Hφ 2πkri H (2) (kri ) + Γ(0) J1 (kri ) 1 R where J0 and J1 are the zeroth- and the first-order Bessel (0) functions of the first kind; and ΓR represents the reflection from the outer PMC boundary of the plate pair at ρ = R0 [20]: (2) (0) ΓR = − H1 (kR0 ) . J1 (kR0 ) (7) (6) Note that equation (5) is analytically limited to cylindrical structures and to one center port only and is practically useless in a real PCB analysis. However, it will serve as a basis for the semi-analytic solution presented in the next subsection. [U] · V = [H] · I, B. Semi-analytic solutions (8) where V denotes the unknown voltage vector, I denotes the excitation current vector, and [U] and [H] are (N ×N ) matrices whose elements are calculated as [23], [24]: Z k R ˙ 0 (2) Uij = δij − n̂ H1 (kR)dl0 , (9) 2j w R Z kηh (2) Hij = H (kR)dl0 , (10) 2w w 0 Real PCB design are almost never regularly shaped, are regularly perforated with multiples vias, and often cutouts in power-ground plane pair are present (see Fig. 5). Numerical assessment is necessary when dealing with a real PCB designs. The solution presented in [18] meshes the power-ground plane pair and each element is represented with a transmission line. It is an accurate method, but also an inefficient method, since the generated netlist of a PCB can get quite large. 4 where δij is the Kronecker Delta; and w is the length of the boundary element or the perimeter of the via. The integrals in equations (9) and (10) can be simply evaluated at a distance between the observation point and the center of the source point segment [24]. Finally, the impedance matrix can be calculated as: [Z] = [U]−1 · [H]. (11) Fig. 6. Limitation of this method is the via antipad modeling. Every via antipad can be taken as one additional segment as in [23] or can be divided into several segments as in [24]. If via antipads are modeled using one segment, the evaluation of the contour integral method is faster, but it lacks the accuracy as the perforations from vias are not taken into account; and vice versa. CIM is applied to various types of problems: the return currents is modeled in [25] for SI/PI so-simulation; the decoupling capacitors and air holes are simulated in [26]; emission and susceptibility of parallel-plate waveguide are investigated in [27]; voltage distribution and far-field radiation pattern are simulated in [24], to name a few. 2) Boundary integral equation method (BIE): BIE starts from a different definition of the impedance of a parallel plate waveguide [20]: Z Z 1 G(r, r0 )dli dlj . (12) Zij = − li lj li lj . The line averages, as opposed to area averages, take into account the perforations from vias. It can be shown that the solution of the line average impedance definition is a generalized cylindrical wave defini(0) tion (equation (5)) [20]. There, ΓR represented the reflection from the outer PMC boundary of the plate pair at ρ = R, which can be related to the ratio of the outward and inward zero-order cylindrical waves, the P ×P radial scattering matrix for the plate pair [20]: (f ) where matrix Spp is a P × P matrix denoting direct illuminations among ports [20]: (2) H0 (krij ) i 6= j R Spp (i, j) = (15) 0 i = j; M is the matrix relating ports and boundary elements [20]: jk R ˙ 0 (2) n̂ H1 (kR); (16) Min = − 4 R ZM is the method of moment (boundary element) matrix [20]: jk ˙ 0 (2) −4 R R n̂ H1 (kR) m 6= n (17) ZM (m, n) = 0.5w m = n; and H is the matrix relating boundary elements and ports [20]: (2) Hnj = H0 (kR), n = 1, 2, · · · , N. (18) The impedance is finally calculated using the equation (5). The limitation of this method (and CIM) is the lowfrequency ill-conditioning that originates from the integral equation solution when the whole object becomes small in terms of wavelength. The basic problem is the decoupling of the current into a solenoidal part and a non-solenoidal part [28]. Various methods have been developed to solve this problem [28]. IV. R ESULTS A. Bare-board simulation The parallel-plate waveguide shown in Fig. 6 is simulated using Cavity mode model with single summation and 80 modes taken into account and Boundary integral equation method. The simulated structure is 50 mm long and 50 mm wide. The port coordinates are (5 mm, 5 mm), and the port radius is 1 mm. The frequency range from 1 MHz - 3 GHz, with 201 logarithmically spaced frequency points is simulated. The thickness of the substrate is 0.25 mm, relative permitivity is 4.6, tanδ is 0.02 and the conductivity of the planes is 5.8e7 S/m. The simulation results are shown in Fig. 7. At frequencies at which the structure is comparable to or bigger than the wavelength of interest, both methods show the same results. BIE fails to predict the impedance correctly at frequencies below approximately 100 MHz as a consequence of illconditioning of the electric field integral equation [28]. This can be a great problem since in many applications (including DC-DC converters) most of the signal spectrum falls into frequency range from 1 - 100 MHz. b SR (13) pp = − . a A convenient characteristic of a radial scattering matrix (13) is that it defines the relationship between two ports while all of the source-free ports are matched. This means that the SR pp is calculated from a solid (not perforated) power-ground plane regardless of the number of vias present, which simplifies its evaluation. It can be shown that the SR pp (i, j) is equal to the total electric field at the port i under the condition that the port j is excited and all other ports (except port j and including port i) are matched [20]. Therefore, method for calculating the SR pp matrix is based on the integral equation solution as in the CIM [20]. The boundary is again divided into many small segments, then the integral equation is discretized, and the matrix equation is solved using the method of moments. Final solution for SR pp is [20]: −1 (f ) SR H, pp = Spp + MZM Bare board test case. (14) 5 Impedance, Z [Ohm] 10 10 10 10 10 10 3 BIE Cavity mode 2 1 0 Fig. 9. Test case for evaluation of the influence of ESR and ESL of decoupling capacitors on EMI of DC-DC converter. 1 TABLE I O PTIMIZED PARAMETERS OF THE DECOUPLING CAPACITORS . 2 10 6 10 Fig. 7. 7 8 10 Frequency, f [Hz] 10 9 ESR (Ω) ESL (nH) C2 0.9 0.1 C3 0.4 1 C4 0.1 2 Bare board test case simulation results. in the commercial EM solver to verify the EMI performance. For the reference simulation, the decoupling capacitors are chosen to be the same, with C = 10 uF, ESR = 0.55 Ohm and ESL = 0.1 nH. After a series of simulations it is found that the best set of the parameters with respect to EMI is as shown in Table I. It can be seen that if the ESR of the capacitors close to the chip and the ESL of the capacitors far from the chip are increased, the EMI is decreased. The impedance profiles for reference and optimized cases are shown in Fig. 10. It can be seen that the impedance at low frequencies is sacrificed in order to lower the resonant peak at approximately 300 MHz. Also, the resonant frequency is lowered to approximately 250 MHz. Additional resonant frequency can be seen in optimized impedance profile at approximately 600 MHz. However, since the frequency component of the typical current waveform decreases with a 40 dB per decade (related to the PWM signal that switches the FETs), this resonance is not a real treat. The reduction of the maximum E-field of the optimized case relative to the reference case is 8 dB at resonant frequencies (simulated in the commercial EM solver). Since the far-field analysis is done under the approximation of a broadband signal and a typical current spectrum decreases with a 40 dB per decade, when scaled with respect to frequency of the resonance, the actual reduction in maximum E-field is around 5 dB which still is a great result, especially taking into account that the optimization is done by hand and that only ESR and ESL are varied. It is reasonable to expect that by the automated optimization of the ESR, ESL, position and number of decoupling capacitors additional reduction could be achieved. HS FET Term LS FET Coss 1 nF Fig. 8. C1 0.9 0.1 Z-matrix PCB model The simulation model of the DC-DC converter. B. Influence of the ESR and ESL of the Decoupling Capacitors on EMI of DC-DC converters The resonance formed by the capacitance of the lowside FET in off state Coss and the total inductance of the decoupling loop is the main source of ringing of the phase voltage and for increased EMI [7]. The ESR of the decoupling capacitors can be increased to limit the resonant current and therefore reduce the associated EMI [7]. The test case to assess the influence of the ESR and ESL of the decoupling capacitors is the same as shown in the last two subsections. Additional decoupling capacitors are placed at (15 mm, 5 mm), (15 mm, 15 mm), (15 mm, 25 mm) and (15 mm, 35 mm) (red dots in Fig. 9). The port (observation point) is connected to the phase voltage node (yellow dot in Fig. 9). The high-side FET of the DC-DC converter is modeled as a short circuit, while the low-side FET is modeled as a off state capacitor Coss = 1 nF. The parameters of the decoupling capacitors (ESR and ESL; nominal capacitance and their position are kept the same) are varied in order to lower the impedance looking from the phase voltage node. Lowering the impedance lowers the resonant current which reduces the EMI. The maximum electric far-field is simulated V. 3D EM SIMULATIONS The resonance formed by the capacitance of the lowside FET in off state Coss and the total inductance of the decoupling loop is the main source of ringing of the phase voltage and for increased EMI [7]. If this loop is minimized, the EMI would also be minimized. 6 3 Impedance, Z [Ohm] 2.5 Reference model Optimized model 2 1.5 1 (a) Far-field diagram of the reference design. (b) Far-field diagram of the folded loop design. 0.5 Fig. 12. 0 6 10 10 7 8 10 Frequency, f [Hz] 10 Far-field diagrams of folded loop concept test cases. 9 Boundary integral equation method is recognized to be the appropriate method to simulate DC-DC converters. Boundary integral equation method is implemented in Matlab and the interface to SPICE (SPICE netlister) is written. The influence of ESR and ESL on the EMI of a DC-DC converter design is evaluated. The ESR of the capacitors close to the chip and the ESL of the capacitors far from the chip are increased to reduce the EMI. The far-field analysis is done in the commercial EM solver and the hand-optimized results show the reduction of maximum electric field by 5 dB relative to the reference test case. The final goal of this work is to create the analysis and optimization tool for DC-DC converters with respect to the EMC. Since this is the work in progress, additional 3D EM simulations are done to assess the issues related to the DCDC converter from the INVENT project. The folded loop placement of decoupling capacitors decreased the EMI by 3 dB. Future work includes: Fig. 10. Impedance profile of the reference and optimized parameters of the decoupling capacitors. The idea presented here is to fold the loop and to split one big loop into two smaller ones, in which the current would go in opposite directions therefore canceling the magnetic flux and reducing the EMI. The structures simulated are 20 mm long and 10 mm wide. The thickness of the substrate is 70 um, dielectric constant is 4.6 and tanδ is 0.02. In the reference design, the current flow forms one big loop, while in the folded loop design this one loop is broken into two smaller loops that are folded to minimize the magnetic flux and therefore minimize the EMI. This is achieved by placing decoupling capacitors rotated by 180 degrees when compared to the reference design. The simulations are done in the commercial EM solver. The maximum E-field is decreased by 3.36 dB when the resonance loop is folded. The original and modified PCB layouts are shown in Fig. 11. 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