Redundant Power Supply structure and Single Failure Tolerant power connection for Crate applications...
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BI Seminar 22 February 2013 Beam Loss Monitoring Section William Vigano’ PowerPoint PPT Presentation


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Redundant Power Supply structure and Single Failure Tolerant power connection for Crate applications. BI Seminar 22 February 2013 Beam Loss Monitoring Section William Vigano’. Presentation Objectives. 1) Introduction of a “single failure tolerant” power supply structure.

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BI Seminar 22 February 2013 Beam Loss Monitoring Section William Vigano’

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Bi seminar 22 february 2013 beam loss monitoring section william vigano

Redundant Power Supply structure and Single Failure Tolerant power connection for Crate applications.

BI Seminar

22 February 2013

Beam Loss Monitoring Section

William Vigano’

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Presentation objectives

Presentation Objectives

1) Introduction of a “single failure tolerant” power supply structure.

2) Manage the diagnosis for cable connections and Power Supply statuses.

3) Replace Resettable Fuses with Circuit Breakers:

a) To improve the current threshold tolerance.

b) To improve the current cut timing.

4) Maintain the possibility for optional use of the Redundant Power Supply.

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Block diagram

Block Diagram

19’ CRATE

Backplane

Main

Power Supply Unit

Power Interface

Circuit Breaker #1

Card #1

Available Power Supply

Circuit Breaker

Circuit Breaker #2

Card #2

Redundant

Power Supply Unit

Cable Connection Diagnostic

Current Consumption Main PSU

Current Consumption Redundant PSU

Card #n

Circuit Breaker #n

Multiple Cable Connection

Control Unit

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Failure mode analysis concepts

Failure Mode Analysis Concepts

  • Failure mode and effect analysis (FMEA) is the first step of a system reliability study.

  • An FMEA is an inductive failure analysis.

  • An FMEA activity helps to identify potential failure modes based on experience with similar products.

  • A FMEA is also used to structure Mitigation for Risk reduction.

  • Failure probability can be reduced by understanding the failure mechanism and reducing or eliminating the (root) causes.

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Power interface block diagram

Power Interface Block Diagram

Power Interface

Diagnostic Interface

Diagnostic Interface

Connector 1

Connector 2

Main

Power Supply Unit

Fast-On A

Fast-On A

Current Consumption Measurement

Current Consumption Measurement

Available Power Supply

Fast-On B

Fast-On B

Fast-On C

Fast-On C

Jumper

Redundant

Power Supply Unit

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Power interface failure modes

Power Interface Failure Modes

Power Interface

Diagnostic Interface

Diagnostic Interface

Main

Power Supply Unit FAILURE

Connector 1

Connector 2

Fast-On A

Fast-On A

Current Consumption Measurement

Current Consumption Measurement

Available Power Supply

Fast-On B

Fast-On B

Fast-On C

Fast-On C

Jumper

Redundant

Power Supply Unit

The structure above allows to guarantee the availability of the Power Supply, also with a diode in short circuit condition AND a Power Supply in failure.

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Power interface failure modes1

Power Interface Failure Modes

Power Interface

Diagnostic Interface

Diagnostic Interface

Main

Power Supply Unit

Connector 1

Connector 2

Fast-On A

Fast-On A

Current Consumption Measurement

Current Consumption Measurement

Available Power Supply

Fast-On B

Fast-On B

Fast-On C

Fast-On C

Jumper

Redundant

Power Supply Unit

Nothing happen if a diode is broken.

Possible failures are diagnosed.

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Maintenance plan example

Maintenance Plan Example

Power Interface

Diagnostic Interface

Diagnostic Interface

Connector 1

Connector 2

Main

Power Supply Unit

Fast-On A

Fast-On A

Current Consumption Measurement

Current Consumption Measurement

Available Power Supply

Fast-On B

Fast-On B

Fast-On C

Fast-On C

Jumper

Redundant

Power Supply Unit

It is not possible to make automatic diagnostic of these diodes, so their check is part of the Maintenance Plan (otherwise we are in the «Sleeping Failure Case>>).

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48v dc power interface electrical circuits

48VDC Power Interface Electrical Circuits

Input Connectors

Current Monitors

Gnd Connectors

Jumper

MTBF = 2 × 10 7 @ 40°C

(MIL-HDBK-217 Calculation)

MTBF = 4.8 × 10 10@ 40°C

(Supplier Calculation)

Diagnosis Interface

The T5 Collector is connected to a pull-up on the FPGA (or µC) I/O, so if the power line fails, the T5 driving is released and the failure is detected.

Note: 20 years correspond to 1,752 × 10 5

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Circuit breaker block diagram

Circuit Breaker Block Diagram

50mohm (to limit the Drop Out voltage)

Available Power Supply

(e.g.48VDC)

Circuit Breaker

Over Voltage Protection

Shunt

Switch

Output

To the Cards in the Crate

Enable

Auto-Retry

Circuit Breaker

60V max

  • The Current flowing from the Input to the Output creates a Voltage Drop on the Shunt. The Voltage Drop is compared inside the Circuit Breaker against an Interal Voltage Comparator. If the threshold is excedeed, the Circuit Breaker disables the Switch

  • The Circuit Breaker controls the Load In-Rush current, regulating the power-up ramp.

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9v to 60v circuit breaker @ 1amp

+9V to 60V Circuit Breaker @ 1Amp

MTBF = 3.45 × 10 8 @ 55°C

(Supplier Calculation)

MTBF = 2.15 × 10 8 @ 55°C

(MIL-HDBK-217 Calculation)

1

MTBF = 1.55 × 10 7 @ 40°C

(MIL-HDBK-217 Calculation)

TPS2491DGS has Automatic Retry: as soon the over current is removed, the output power supply is available.

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Circuit breaker failure modes

Circuit Breaker Failure Modes

The Shunt short circuit condition is the 3% of the global calculated MTBF, so it is really rare (>1010 working hours). If the Shunt is open, the output voltage is not available.

The N-Mosfet is driven by means of a Charge-Pump, so if the Ciruit Breakers Fails, the Load is Disabled (safe failure).

1

If components dedicated to settings fail, the Circuit Breaker is not anymore compatble with the In-Rush current, but the Trip Current does not change because it depends to the Shunt + Inner Comparator.

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Pcb implementation

PCB Implementation

Diode connections for redundant power supply connections

Circuit Breakers

2,5 cm

5 cm

4 cm

Current Monitors

2 cm

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Crate implementation

Crate Implementation

Circuit Breaker Feedbacks

Power Supplies Connection Feedback

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Additional notes

Additional Notes

1) The schematic has been optimized for 48VDC @ 200Watt.

2) To prevent Common Mode Failures it is better select different types and / or suppliers for the Power Supplies.

3) The current supply measurement resolution with a 12 Bit ADC and VREF = 2,048VDC is => 2,5mA / Bit. (I max = 10,24 Amp)

4) When the Jumper is connected, the current path depends on the Diode’s VF (forward voltage).

5) The Jumper is used to maintain the “single failure tolerance” capability of the circuit when only one Power Supply is connected.

6) The current is always taken from the Power Supply with higher value.

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Thank you for your attention

Thank you for your attention!

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