DC-DC Power Module Phase 2 –Prototyping and Testing

Rick Fishbune, IBM

Call for ParticipationMay 13, 2015

DC-DC Phase 2 Statement of Work Review

• Introduction of Project Chairs

• Overview of iNEMI/Project Process

• Company participation in Statement of Work

(SOW) development

• SOW Review

• How to Participate

• Q&A

Agenda

Note: All phones will be on mute until the end of the presentation

DC-DC Phase 2

• Rick Fishbune … IBM, Distinguished Engineer, Power Technology Strategy

– Responsible for new technology, architecture, process, materials, reliability for enterprise products.

– Focus upon AC-DC power, DC-DC converters, Power Distribution, Battery Backup Solutions

– Previously responsible for reliability qualifications for power technology solutions introduced within IBM’s

server systems designed for enterprise clients.

• Randy Malik… Lenovo, Senior Technical Staff Member, Distinguished

Inventor, Power Technology

– Responsible for Power Technology, New Power architecture and innovation for Lenovo Servers

– Focus upon High Voltage (380V) DC Distribution and HV DC – DC Power modules

– Previously responsible for reliability qualifications for power technology solutions such as COMMON Form

Factor power supplies using 12V DC Distribution Bus within the server systems.

• David Mohr… Hewlett-Packard, Distinguished Technologist

– Responsible for system power architectures and power technology development for use in Data Center

products.

– Focus upon AC-DC, DC-DC and DC-AC power conversion, power distribution, and battery backup solutions

– Previously responsible for the power architecture used in HP’s Apollo 8000 liquid cooled supercomputer

Project Leaders

iNEMI and Project Process

4

About iNEMI

International Electronics Manufacturing Initiative (iNEMI) is an industry-led consortium

of around 100 global manufacturers, suppliers, industry associations, government

agencies and universities. Working on advancing manufacturing technology since 1994.

Visit us at www.inemi.org

5 Key Deliverables:

• Technology Roadmaps

• Collaborative Deployment

Projects

• Research Priorities Documents

• Proactive Forums

• Position Papers

3 Major Focus Areas:

• Miniaturization

• Environment

• Medical Electronics

Mission: Forecast and Accelerate improvements in the Electronics

Manufacturing Industry for a Sustainable Future.

The Project Process - 5 Steps

SELECTION

DEFINITION

PLANNING

EXECUTION / REVIEW

CLOSURE

1

2

3

4

5Limited to iNEMI Members

Open for Industry input

------------------- iNEMI Technical Committee (TC) Approval Required for Execution

Company Participation in SOW Development

7

8

Phase 2 SOW Participants

Phase 2 Prototyping and Test

SOW Review

9

DC-DC Project Summary

• Problem– Lack of standardized high voltage DC-DC power module for an economical, small

physical size, and high efficiency solution for use in a HVDC power system

• Opportunity– Develop a standardized high voltage DC-DC power module with low cost, small

form factor and higher efficiency for HVDC power system

• Goal– Phase 1: Technical specification of the high voltage DC-DC module (Complete) – Phase 2: Prototyping of a high voltage DC-DC module designed to meet the Phase

1 Technical Specification

Scope of Work

• Development, building, and testing the

prototypes to meet the electrical and mechanical

specifications developed in Phase 1.

• Based on the measured results, decide whether

any changes are required to the phase 1

specification, especially with respect to the

efficiency, power density, mechanical package

size of the module, and input/output pins

configuration.

– This will be done by building modules and testing the

modules, by both suppliers and by the OEMs, to verify

that the modules meet the electrical requirements.

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Overview of DC-DC Module Specification from Phase 1

Item Minimum Nominal Maximum

Input Voltage 360 Vdc 380 Vdc 400 Vdc

Efficiency 92% @ 10% Load 96% @ full load 97% @ 50% load

DC Output Voltage 11.60 Vdc 12.00 Vdc 12.60 Vdc

DC Output Current 0 A 62.5 A

Current Sharing Within 10% when operating ≥20% load

Over Voltage Protection 13.46 Vdc 14.69 Vdc

Under Voltage Protection 9.79 Vdc 10.8 Vdc

Over Current Protection 105% of Max Load 120% of Max Load

Operating Temperature - 5 C 60 C

Packaging DOSA Quarter Brick

Form Factor with Modified

Pinout for HVDC

Reliability 1 MHr MTBF Minimum

IS/IS Not

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Tasks

14

• Task 1: Review of Phase 1 Technical Specification with power

supply manufacturers willing to do prototyping and testing

• Task 2: Develop additional testing criteria beyond what has been

identified in Phase 1 specification

• Task 3: Design and Prototype of Power Modules by Power Supply

Manufacturers

• Task 4: Testing of prototype Power Modules

• Task 5: OEM, Team review of testing results, modify technical

specification as needed

Expected Benefits to Join Phase 2 DC-DC Project

• For Suppliers– Access to the iNEMI HVDC specification developed in Phase 1

– Be aware of the efficiency, power density, reliability and temperature target requirements of HVDC modules for servers in Datacenters, Mobile Switching Centers and Central Offices

– A guaranteed way to obtain OEM feedback on your technical solution– Potential to be first to market with a new HVDC building block– Be a technology leader in HVDC– Understand the implications of Silicon, GaN or SiC based devices as well

as particular preferred topologies in order to fulfill the module target specifications

• For OEMs– A way to influence the technical solutions from suppliers

– Awareness of the details of the HVDC building block

– Improved time to market of future products requiring the DC-DC building

block

– Improved Total Cost of Ownership of HVDC Solution

– Improved Reliability and System Operating Life

Key Participants

• It is the participation and make-up of the

member companies that dictate the success of

the project.

• For this project, it is key that both OEMS and

Power Supply Manufacturers are part of the

project

Phase 2 Prototyping and Test

How to Participate

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How to participate

• Project has been approved by the iNEMI Technical Committee

• Open Enrollment for Project Sign-up will continue until June 26, 2015

• More information can be found at the DC-DC Power Module, Phase 2 (Prototyping and

Testing) page

• Steps for Joining the Project

– Please note: iNEMI membership is required to participate in the iNEMI DC-DC Power

Module, Phase 2 (Prototyping and Testing) Project. The period for becoming a founding

member of this project will close on June 26, 2015. Steps for joining the project are

outlined below.

• For iNEMI members:

– Complete and sign the project statement

– Fax the completed statement to +1 (703) 834-2735 or scan + email to infohelp@inemi.org

• For non-members:

– Discuss annual membership fees with Bill Bader in North America (bill.bader@inemi.org), Haley

Fu in Asia (haley.fu@inemi.org), or Grace O'Malley in Europe (gomalley@inemi.org).

– Complete the iNEMI membership application. (www.inemi.org)

– Fax the completed documents to +1 (703) 834-2735 or scan + email: infohelp@inemi.org.

– Complete and sign the Project Statement

– Fax the completed statement to +1 (703) 834-2735 or scan + email: infohelp@inemi.org.

www.inemi.org

Mark Schaffer

marks@inemi.org

Backup Information

Background/Context

• AC distribution power system for IT equipment – Higher cost for AC UPS

– Lower efficiency and reliability issue for multiple AC/DC conversion

• 48V DC distribution to Telco equipment– Insufficient power delivery due to lower voltage for future Data Centers

• 380V DC distribution (HVDC) on the horizon– Higher efficiency and reliability due to less conversion

– Higher power distribution due to higher voltage

• 380VDC – 12V DC module in existing Data Center AC distribution– Low cost Rack solution by AC – 380V Rectifier and 380VDC – 12V DC module

• 380VDC – 12V DC module in new Data Center DC distribution– Low cost Data Center solution 380V Rectifier and 380VDC – 12V DC module

Scope of Work (Phase 1)

• Documentation and evaluation on the feasibility of a

High Voltage (380V) DC input to a 12V DC output

module.

– Feasibility review of size and power capability

– Research on new devices/materials

– Technical feasibility study and identification of

dependencies for the specification

– Assessment on time to market of the DC-DC module

– Development of a technical specification for a 380V

DC input to 12V DC output module.

DC-DC Power Module Phase 1

This Project Is: This Project IS NOT:

Phase 1 - Spec Development

Development of a technical specification for a DC-

DC device within these tolerances:

•For use in 1 U height box (maximum) 1.75

inches so module is 1.4-1.5 inches height;

Width and Length ---- TBD

•500-750 W range Power Module

•380 +/- 5% VDC Input and 12V DC Output.

•Efficiency Target = 96 – 97% (Target

equivalent to an AC 12V efficiency at a

minimum)

Development of a standard

Ability to work in parallel (modular approach) –

Minimum two suppliers

Repeat of prior or existing work

IT Hardware Optimized and Telecom Hardware

Enabled

Biased towards specific suppliers,

geographies, or market segments

Power Density: 200-250 watts per cubic inch Defining/identifying suppliers

Leverage existing technology Testing or prototyping

Output – Team only use for one year then reverts

to iNEMI (Standard iNEMI agreement); membership

report out is required (level of detail can be very

high)

Sharing of intellectual property

Purpose of Project

• Address most, if not all, the electrical and mechanical

specifications in this project for a DC-DC module.

• Provide the participants with a specification that

includes a complete assessment of the High Voltage DC-

DC module and safety certification requirements.

Expected Benefits of Project

• Cost benefit– Industry standard product– Low cost power solution compared to the company proprietary

expensive solutions

• Improvements in time-to-market– Specification and multiple sources for developing the product

• Define Common Package for HV technology converter

• Size/Efficiency merits– Narrow input voltage range for 380V DC proposed for higher efficiency – Lower DC distribution losses (I2R) due to lower current

• Meet the future power demand (5X more)– 380V DC distribution over 48V DC distribution

Project Phase 1 Tasks

Task 1: Learning/Standards Review

Task 2: Team Discussion/ Specification Development

Task 3: Initial Draft of Specification

Task 4: OEM and Supplier Validation of Spec

Task 5: Specification Update based on Reviews

Beyond Phase 2

• Improvement/enhancement of the prototype (Phase 2+)

– Efficiency, power density, packaging, PMBus control, etc.