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discretepower-vs-module-slide15

Based on the power requirements of the example FPGA design on the previous slide, this slide presents a detailed breakdown of the cost. Beginning with the discrete design approach, for the six power rail requirements, the product definition for each power rail must be architected before any design can begin. There are several product definition details to consider. Which PWM controllers to use and will it include the MOSFET driver? What is the switching frequency vs. efficiency requirement? As the switching frequency increases, the filter components become smaller; however, the efficiency is reduced due to the high switching loses in the MOSFETs. What about other features such a PGOOD and sequencing control? Are these requirements in the product definition? What about the physical size of each power rail? Considering the number of external components for each power rail, will there be enough physical board area to handle the component count and still handle the heat dissipation? These are some of the basic requirements a designer will need to consider when doing a discrete design for each individual power rail. The entire process must be repeated for each power rail requirement. Normally, there is also a design review in order to validate the discrete paper designs. Next is inputting all six power rail designs into a schematic capture program. This can easily take 40 hours due to component selection and the physical labor of creating each schematic. Also to be considered is the prototype; time to build, test, validate, and/or debug each power rail. Depending on the equipment and the expertise of the engineer, several tests must be performed. The basic tests include efficiency, output voltage ripple, and load transient response, but there may be other testing required depending on the power supply's feature set that must be factored in to the development time. This can easily take 80 hours or longer depending on the design. If there are any problems, the engineer has to debug and fix the problems himself. Finally, there is the PCB layout for each power rail. Experienced power supply designers know the physical component placement as well as the power and ground for the best heat transfer. This can easily take 80 hours depending on the physical PCB area of the board. The total man hours in this design example are 320 hours.

PTM Published on: 2015-10-16