The Power Board of the KM3NeT Digital Optical Module: Design, Upgrade, and Production
<p>Artistic view of the KM3NeT detector. The illustration is not to scale: sunlight does not reach the depths at which the KM3NeT detector is deployed. The total instrumented volume of the KM3NeT detectors, once completed, will be around 1 km<sup>3</sup> for ARCA and 7 × 10<sup>6</sup> m<sup>3</sup> for ORCA.</p> "> Figure 2
<p>(<b>Left</b>) Two-dimensional vertical cross-section of the DOM showing the position of the PB and the main elements of the DOM indicated with arrows. (<b>Right</b>) Three-dimensional representation of the DOM.</p> "> Figure 3
<p>View of the PB of the DOM (upgraded version). The different DC/DC converters to generate the voltages needed by the FPGA and the remaining components of the CLB are marked.</p> "> Figure 4
<p>Architecture of the PB. The rails, which provide the different power supplies needed by the DOM, are managed by the start sequencer, which generates at startup the monotonic power sequence requested by the CLB FPGA. The monitor subsystem surveys the voltages and currents of the different rails, as well as the temperature sensor installed on the board. The 12 V is filtered at the input and the hysteresis system prevents instabilities while powering up and down the PB.</p> "> Figure 5
<p>Diagram of the power supply distribution at the DOM. The BOB of the DOM provides 12 volts to the power board, where the power rails for the Nanobeacon, Piezo, CLB and PMTs are generated. Note that two 3.3 V rails are available, one for the CLB and another for the PMTs.</p> "> Figure 6
<p>Scheme of the Pi filter functioning as input high-frequency filter on the PB.</p> "> Figure 7
<p>Bode diagram of the Pi filter at the PB to filter out high-frequency noise. From 1 MHz up to 1 GHz, the insertion losses are below −35 dB.</p> "> Figure 8
<p>Scheme of the hysteresis subsystem. The configuration of the operational amplifier allows it to start at 11 V and to disconnect when the input voltage drops below 9.5 V. In this way, instabilities are prevented at power up and power down.</p> "> Figure 9
<p>Startup sequence of the PB. The figure shows that the PB indeed generates the various voltages in the sequence needed by the Xilinx FPGA on the CLB.</p> "> Figure 10
<p>Template of the circuit to read out the current. The output line of a power rail passes through a 20 mΩ resistor, where the drop voltage is amplified in a high-precision amplifier. The output of the amplifier is read out in an ADC channel and sent via I<sup>2</sup>C outside of the PB to the CLB.</p> "> Figure 11
<p>Stackup of the PB PCB. It contains four layers, all of them being copper and with a width of 35 <math display="inline"><semantics> <mi mathvariant="sans-serif">μ</mi> </semantics></math>m. The dielectric material is FR4, with a core of 1000 <math display="inline"><semantics> <mi mathvariant="sans-serif">μ</mi> </semantics></math>m and two external frames of 200 <math display="inline"><semantics> <mi mathvariant="sans-serif">μ</mi> </semantics></math>m. For a better representation, the image is not to scale.</p> "> Figure 12
<p>Picture of a CLB with the test points for production functional tests. The different power rail test points are marked on the picture. A CLB running operational firmware is used as load and for measuring the voltages.</p> ">
Abstract
:1. Introduction
2. Design and Architecture of the Power Board
- The filter block at the input voltage of the PB, which removes the high-frequency noise generated by the power converters at the DU base and breakout board;
- The hysteresis block, which prevents the PB from entering into an unstable state during startup and shutdown;
- The startup block, which allows the different voltages to start up monotonically as needed by the FPGA of the CLB;
- The Nanobeacon power supply controller, which controls the power supply of the Nanobeacon and can be configured through I2C;
- The monitoring system, which reads out the voltages and currents of every power rail, in addition to the temperature sensor.
2.1. Input High-Frequency Filter
2.2. Hysteresis
2.3. Power Startup
2.4. DC/DC Rails
2.5. Nanobeacon
2.6. Monitoring System
2.7. Layout
2.8. Firmware
3. Power Board Upgrade
4. Reliability: FIDES and HALT
4.1. FIDES
4.2. HALT
5. Production Control
- The PCB production and assembly process must comply with standard IPC 6011 Class 3 [20].
- Solder paste masks should be generated using the given gerber files, choosing the pad-shrinking factor based on the solder paste and the mask thickness.
- Solder paste must be deposited on the PCB using automatic machines and the aforementioned masks for good uniformity.
- Solder paste deposition must be inspected before the PCB is populated.
- All surface-mounted device components must be placed using automatic pick and place machines.
- A reflow oven must be used for soldering the components.
- The boards must be identifiable. If the PCBs also have an individual identifying code from the producing company, an electronic file with the correspondence between the board label and the PCB label must be provided.
- The production must provide traceability of all procured components in accordance with IPC1782 [21] level 2 (M2), with level 3 (M3) traceability as a second option.
5.1. PCB Test Control
- 100% electrical continuity tests;
- Control of correspondence to IPC Class 3 on a sample of boards performing metallographic micro sections.
5.2. Component Assembly Test Control
- Identification of the board with an appropriate label;
- Automatic optical inspection on the positioning and soldering of components on all boards;
- X-ray inspection and verification of very thin quad flat non-leaded package components.
6. Functional Tests
- Set the input voltage to 12 V and power-on the system;
- Write down the measurements after 1 min and 5 min from power-on, and finally, once the test are finished and the boards are powered off, the results of the tests are stored in an electronic file.
7. Production and Reliability Results
8. Conclusions
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Voltage (V) | Current (A) | Efficiency Original PB (%) | Efficiency Upgraded PB (%) |
---|---|---|---|
1 | 0.13 | 80 | 80 |
1.8 | 0.33 | 80 | 80 |
2.5 | 0.33 | 60 | 78 |
3.3 | 0.81 | 65 | 90 |
3.3 PMT | 0.46 | 90 | 90 |
5 | 0.10 | 60 | 90 |
Process Variable | Ratio | Resistance | Description |
---|---|---|---|
12 V current | 1 | 20 mΩ | 12 V current |
1V0 current | 1 | 20 mΩ | Current at the 1 V rail |
1V8 current | 0.4 | 50 mΩ | Current at the 1.8 V rail |
2V5 current | 0.4 | 50 mΩ | Current at the 2.5 V rail |
3V3 current | 1 | 20 mΩ | Current at the 3.3 V rail |
5V0 current | 0.4 | 50 mΩ | Current at the 5 V rail |
3V3PMT current | 2 | 10 mΩ | Current at the 3.3 V rail for the PMTs |
VLED current | 2 | 10 mΩ | Current at the Nanobeacon rail |
VLED voltage | 10.1 | Voltage at the Nanobeacon rail | |
1V0 voltage | 1 | Voltage at the 1 V rail | |
1V8 voltage | 1 | Voltage at the 1.8 V rail | |
2V5 voltage | 1 | Voltage at the 2.5 V rail | |
3V3 voltage | 2 | Voltage at the 3.3 V rail | |
5V0 voltage | 2 | Voltage at the 5.0 V rail | |
3V3PMT voltage | 2 | Voltage at the 3.3 V rail for the PMTs | |
VLED control voltage | 1 | Voltage at the Nanobeacon rail | |
PB Temp | 100 | Temperature in the PB. Value in °C |
Rail | Voltage (V) | Accuracy (%) |
---|---|---|
1V0 | 1.0 | ±1.5 |
1V8 | 1.8 | ±3.0 |
2V5 | 2.5 | ±3.0 |
3V3 | 3.3 | ±1.5 |
3V3PMT | 3.3 | ±3.0 |
5V0 | 5.0 | ±3.0 |
VLED | 4.0–30.0 | ±1.0 |
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Aiello, S.; Albert, A.; Garre, S.A.; Aly, Z.; Ambrosone, A.; Ameli, F.; Andre, M.; Androutsou, E.; Anguita, M.; Aphecetche, L.; et al. The Power Board of the KM3NeT Digital Optical Module: Design, Upgrade, and Production. Electronics 2024, 13, 2044. https://doi.org/10.3390/electronics13112044
Aiello S, Albert A, Garre SA, Aly Z, Ambrosone A, Ameli F, Andre M, Androutsou E, Anguita M, Aphecetche L, et al. The Power Board of the KM3NeT Digital Optical Module: Design, Upgrade, and Production. Electronics. 2024; 13(11):2044. https://doi.org/10.3390/electronics13112044
Chicago/Turabian StyleAiello, Sebastiano, Arnauld Albert, Sergio Alves Garre, Zineb Aly, Antonio Ambrosone, Fabrizio Ameli, Michel Andre, Eleni Androutsou, Mancia Anguita, Laurent Aphecetche, and et al. 2024. "The Power Board of the KM3NeT Digital Optical Module: Design, Upgrade, and Production" Electronics 13, no. 11: 2044. https://doi.org/10.3390/electronics13112044