Abedinpour 2007
Abedinpour 2007
Abedinpour 2007
AbstractThe design and analysis of a fully integrated multistage interleaved synchronous buck dcdc converter with on-chip
filter inductor and capacitor is presented. The dcdc converter
is designed and fabricated in 0.18 m SiGe RFBiCMOS process
technology and generates 1.5 V2.0 V programmable output
voltage supporting a maximum output current of 200 mA. High
switching frequency of 45 MHz, multiphase interleaved operation,
and fast hysteretic controller reduce the filter inductor and capacitor sizes by two orders of magnitude compared to state-of-the-art
converters and enable a fully integrated converter. The fully integrated interleaved converter does not require off-chip decoupling
and filtering and enables direct battery connection for integrated
applications. This design is the first reported fully integrated
multistage interleaved, zero voltage switching synchronous buck
converter with monolithic output filters. The fully integrated
buck regulator achieves 64% efficiency while providing an output
current of 200 mA.
Index TermsFully integrated switched-mode (SM) dcdc
converter, interleaved synchronous buck converter, zero voltage
switching (ZVS).
I. INTRODUCTION
Manuscript received July 15, 2006; revised January 29, 2007. This paper
was presented in part at the IEEE International Solid-State Circuits Conference
(ISSCC), San Francisco, CA, Feb. 59, 2006 and at the IEEE International Symposium on Circuits and Systems (ISCAS), Island of Kos, Greece, May 2124,
2006. Recommended for publication by Associate Editor P. Luk.
S. Abedinpour is with Freescale Semiconductor, Inc., Tempe, AZ 85284 USA
(e-mail: siamak.abedinpour@freescale.com).
B. Bakkaloglu and S. Kiaei are with the Ira A. Fulton School of Engineering, Arizona State University, Tempe, AZ 85287-08406 USA (e-mail:
bertan.bakkaloglu@asu.edu; sayfe.kiaei@asu.edu).
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TPEL.2007.909288
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Fig. 3. Power management architecture (a) centralized off-chip, (b) monolithic with off-chip passive components, and (c) fully integrated on-chip.
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Fig. 5. ZVS synchronous buck dcdc converter (a) circuit and (b) waveforms.
zero current switching (ZCS). For a power MOSFET, ZVS operation also eliminates the switching loss associated with reverse
recovery of the non-optimum body diode and improves the reliability of the converter. Fig. 5(a) shows a zero voltage switching
(ZVS) synchronous buck converter where the voltage across the
power device terminal is zero during the switching transient,
ideally eliminating switching losses. For ZVS operation it is
desirable to achieve a peak-to-peak current ripple equivalent to
twice the full load current. This ensures that the inductor current
reaches a negative value under all load conditions, as shown in
Fig. 5(b). The inductor value that guarantees this peak-to-peak
current ripple is given by
(1)
is the steady state duty cycle,
is the switching
where
frequency, and is the nominal output current. By introducing
between conduction of
and
a dead-time
the energy stored in the inductor can discharge their output
capacitances and cause their body diode to conduct prior to
and
can turn on
their channel conduction. Therefore,
under ZVS conditions [13], [14]. As a result, the Miller effect
in both switches is eliminated and the gate drive and the turn-on
switching loss are significantly reduced. The output capacitance
and
keeps the voltage across them close to zero
of
while they turn off, keeping the turn-off switching loss small.
Although a smaller filter inductor value results in a faster transient response and provides suitable conditions for ZVS operation, the resulting larger current ripple causes higher conduction
loss in the switches, inductor, and parasitic resistances. The resulting larger current ripple requires a larger filter capacitor to
decrease the output voltage ripple. In order to maintain a low,
steady-state output voltage ripple and fast transient response, ,
similar stages of synchronous buck converters can be operated
in parallel with a common output filter capacitance, as shown in
phase difference between the
Fig. 6(a). By applying a 360
triggering pulses of the adjacent power stages, the output current
ripple can be cancelled out while maintaining the fast transient
response characteristics of a single stage [15]. Fig. 6(a) shows
the timing diagram of the triggering pulses associated with the
interleaved power stages. As a result, the effective output frequency is increased and a smaller capacitance is required at the
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(4)
Fig. 7(a) shows the circuit of the two-stage interleaved ZVS
synchronous buck converter topology that has been fabricated.
and
The waveforms in Fig. 7(b) show the gate pulses of
, the current through the filter inductors
and
, the
output current , the filter capacitor current , and the output
load current .
III. CIRCUIT DESIGN
This section presents the circuit design of the fully integrated
SM dcdc converters implemented in a distributed power management architecture. Fully integrated dcdc converters are adjacent to the digital and analog blocks of a mixed-signal IC.
Fig. 2 shows the monolithic distributed power management architecture fabricated in 0.18 m SiGe RFBiCMOS process technology [9]. With high speed, low noise figure, high linearity,
and less dependence of speed on high field strength and supply
voltage SiGe RFBiCMOS process technology is well suited to
portable wireless applications. Table I summarizes the characteristics of this process. A modular platform-based approach is
utilized to develop this process. It is based upon a low power
0.18 m CMOS technology that provides both 35 A standard
devices for 1.8 V operation as well as 50 A (or 70 A) devices for 2.7 V (3.3 V) I/O circuits. Up to five layers of Cu metallization are available. The RFBiCMOS technology adds the
CMOS,
following elements to the CMOS technology: low
isolated NMOS, Analog NPN BJT, SiGe NPN HBT, MIM Cap,
and a high inductor. A high resistivity -substrate is utilized
for optimal passive element and signal isolation characteristics.
High quality passive components and the above mentioned features make the 0.18 m SiGe RFBiCMOS process technology
the best choice for fabricating fully integrated SM dcdc converters for portable wireless applications.
The IC consists of four monolithic dc-dc converters connected to the battery. Implemented topologies are synchronous
buck, two-stage interleaved synchronous buck, ZVS synchronous buck, and a two-stage interleaved ZVS synchronous
buck converter. Fig. 7(a) can be used to describe the structure
of both the monolithic synchronous buck converter and the
ZVS synchronous buck converter portion of the distributed
power supply architecture. The only difference between the
two converters is in their controller block. The converter shown
enclosed in the box is self contained and only requires
Fig. 7. Two-stage interleaved ZVS synchronous buck dcdc converter (a) circuit and (b) waveforms.
TABLE I
0.18 m SiGe RFBiCMOS PROCESS TECHNOLOGY
and
inputs for operation. The following circuits are implemented in the fully integrated converters.
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A. Comparator
The comparator compares the converter output voltage,
,
and generates the
signal at
with the reference signal
its output. Current-mode comparators have higher speed, larger
bandwidth, and lower supply voltage requirements compared to
their conventional voltage-mode counterparts [17]. Fig. 8 shows
the circuit schematic of the designed current comparator block.
The circuit consists of a -to- converter, a current subtractor,
three cascaded current source inverting amplifiers, and an inand
verter at the output stage. The difference between
inputs of the comparator is converted into
,
is then applied to
at the output of the subtractor stage.
the first current source inverting amplifier, which uses a resistive feedback to reduce its input and output resistance
1 gm . These small resistances reduce the voltage
swing at nodes and , which causes faster transient response
time in the following inverting amplifiers.
In the single stage converters, the resulting PWM waveform
at the output of the comparator is applied directly to the controller block. In the two-stage interleaved converters, the PWM
signal is first applied to a phase-shift block to generate the required PWM signals for each stage of the converter. Fig. 9 shows
the circuit diagram of the phase shift block and its various waveforms. The phase shift block generates the PWM and PWM
signals, which have a 180 phase difference. The PWM and
PWM signals are then applied to the controller blocks to gento control the switching of the
erate the gate pulses
MOSFETs
and generate the required output voltage
.
specified by
B. Controller
The controller block of the synchronous buck converter circuits consists of the gate drive circuits for transistors
,
. The CMOS gate drive circuit is a cascade of
and
inverters, which generates gate pulses
and
to drive the large input capacitance of
and
. Fig. 10
. The width of
shows the gate drive circuit for transistors
each MOSFET in the inverter chain is larger than the previous
one by a scaling factor of , determined by (5), where
is the input capacitance of
and
is the input capacitance of the minimum size inverter
(5)
Fig. 9. Phase shift block (a) circuit diagram and (b) waveforms.
(6)
Since the delay is not very sensitive to changes in the scaling
5 is chosen as a compromise between delay and the
factor,
transisadditional complexity of extra inverter stages. For
tors
5, and for
transistors
4.
Fig. 11(a) shows the block diagram of the controller block
for the ZVS converter, which consists of two separate gate drive
circuits for the PMOS and NMOS power switches and a logic
circuit to ensure precise non-overlap time between two pulses.
Fig. 11(b) shows various simulated waveforms of the ZVS controller. The PWM signal is applied to the logic circuit, which
and
pulses from the output of the gate drive ciruses the
cuits as feedback signals to introduce a dead-time between the
PWM and PWM pulses. These signals are then applied to the
and
pulses to be applied
gate drive blocks and generate
to the converter power train. This ensures ZVS operation over
the entire load range. The body diode conduction of both power
MOSFETs prior to their channel conduction is evident from the
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Fig. 11. ZVS controller (a) block diagram and (b) simulation results.
(a)
(b)
Fig. 12. Variation of MOSFET power losses as a function of device width for (a) NMOS and (b) PMOS.
Power MOSFETs
are formed by parallel connection of an array of unit size cells. The unit size cells have a width
20 m and multiple gate fingers with a minimum gate
of
0.5 m. Equation (8) is used to choose the required
length
width of the unit size cells, , in order to reduce the RC delay
contributed by the gate structures, which affects the switch transitions
(8)
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Fig. 13. Cross section of synchronous buck converter power train: (a) nonisolated and (b) hybrid isolation.
In this equation
is the resistance of a poly-silicon gate,
m , width of
m , and sheet resistance
with a length of
of
.
is the total capacitance of the
is the gate oxide capoly-silicon gate, where
. Gate finpacitance per unit area with an oxide thickness of
gers are contacted at both ends, which reduce the resistance of
the poly-silicon gate fingers that are connected in parallel with
metal interconnect. The number of fingers in each unit cell determines the size of the cell and is chosen to ensure optimum
isolation.
D. Substrate Noise Isolation
Fig. 13(a) shows the cross section of the power MOSFETs
of the single-stage monolithic synchronous buck converter of
, has
Fig. 5(a). As shown in Fig. 11(b), the switching node
large switching voltage transients. Switching noise is coupled
to the substrate through the drain-substrate capacitance of the
power MOSFETs. The resulting current passes through the
impedance in the path to ground and generates a voltage. As a
result, the noise floor of the substrate common to other circuit
blocks on the chip is increased, which reduces their performance. The noise level depends on the converter load current,
switching frequency, drain-substrate capacitance, and the parasitic impedance of the substrate to ground. For a significant
portion of each switching cycle, large transient currents flow
through the channel of the synchronous rectifier and degrade
the performance of the adjacent circuit blocks. Furthermore,
for a small portion of each switching cycle the body diode of
each power MOSFET conducts prior to its channel conduction
to ensure ZVS turn-on
Fig. 14(a) shows the simplified schematic used to model the
switching noise. A heavily doped substrate behaving as a single
(9)
Fig. 14(b) shows the magnitude of the frequency response of
for five different values of
. The results show that
the amplitude of the substrate noise is minimized by reducing
.
the inductance
In order to increase the level of isolation in the design of the
monolithic power converters, a hybrid isolation strategy is implemented, as shown in Fig. 13(b). An -buried layer is added
together with an -well ring to create an isolated p-well and
completely isolate the body of the NMOS device from the substrate. In order to further minimize the substrate injection, a
guard ring is also placed, completely enclosing the -well
ring. The width of the guard ring is chosen to maximize the
amount of isolation provided by this double ring configuration.
The number of gate fingers, which determines the size of the
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Fig. 15. (a) Power loss contribution of single-stage synchronous buck dcdc
converter and (b) variation of inductance ACR/DCR versus frequency.
Fig. 14. (a) Simplified schematic used to model the switching noise and (b)
magnitude of the frequency response of v (S ).
power MOSFET unit cell, is chosen such that effective isolation is achieved by reducing the resistance of the substrate and
-well ring contacts.
E. Integrated Filters
6 nF is an array of parThe integrated filter capacitor
allel connection of 1 pF unit size cells. The gate capacitor in
this process provides a specific capacitance of 8 fF m . Five
layers of Cu metallization are available in this process. In order
to obtain high performance inductors, a patterned electroplated
copper layer is utilized. This optional mask layer is located after
the fifth layer of Cu metallization and lies above the passivation
layer. Formed with an extra 10 m thick electroplated copper
11 nH, provides
layer, the high performance inductor,
20 at 2 GHz [9]. But the inductor conduction loss still
dominates the other power loss components of the converter.
Fig. 15(a) shows the power loss contribution of various components of the single-stage synchronous buck converter. Fig. 15(b)
shows the variation of the inductor ac resistance normalized to
its DCR as a function of frequency. The plot shows that for
switching frequencies up to 200 MHz, the use of inductor DCR
is accurate for calculating the inductor conduction losses.
IV. MEASUREMENT RESULTS
Fully integrated dcdc converters are fabricated in 0.18 m
SiGe RFBiCMOS process technology. Each single-stage
2.2 mm, and
converter occupies a silicon area of 1.5 mm
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Fig 18. (a) Measured output waveform of the two-stage interleaved ZVS synchronous buck converter for V = 2.8 V, V
= 1.8 V, with a resistive load of
22
. and (b) Efficiency versus load current for single-stage synchronous buck
and ZVS synchronous buck converters, for V = 2.8 V and V
= 1.8 V.
(a)
(b)
Fig. 17. Photograph of the (a) packaged prototype and (b) evaluation PCB.
TABLE II
PERFORMANCE AND ARCHITECTURE COMPARISON
OF THIS DESIGN WITH REPORTED WORK
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Fig. 19. (a) Efficiency vs. load current for two-stage interleaved and two-stage
interleaved ZVS synchronous buck converters, for V
2.8 V and V
1.8 V and (b) transient response of the two-stage interleaved ZVS synchronous
2.8 V and V
1.9 V.
buck converter to a step load of 50 mA at V
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