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Agostino Lanza, on behalf of the APOLLO Collaboration

Agostino Lanza, on behalf of the APOLLO Collaboration

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Agostino Lanza, on behalf of the APOLLO Collaboration

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  1. Agostino Lanza, on behalf of the APOLLO Collaboration M. Alderighi(1,6), M. Citterio(1), M. Riva(1,8), P. Cova (3,10), N. Delmonte(3,10), A. Lanza(3), R. Menozzi(10), A. Paccagnella (2,9), F. Sichirollo(2,9), G. Spiazzi(2,9), M. Stellini(2,9), S. Baccaro(4,5), F. Iannuzzo(4,7), A. Sanseverino(4,7), G. Busatto(7), V. De Luca(7) (1) INFN Milano, (2) INFN Padova, (3) INFN Pavia, (4) INFN Roma, (5) ENEA UTTMAT, (6) INAF, (7) University of Cassino, (8) University of Milano, (9) University of Padova, (10) University of Parma

  2. Features of the PS systems required by the present experiments (mainly at LHC) • Extensive use of the DC/DC technology, which requires a careful design in terms of EMC • Integration with detectors at the design level, to avoid both mechanical and electrical criticalities • Necessity of rad-hard devices, so to place modules in the experimental caverns • Necessity of B-tolerant systems, to be able to place them close to detectors • Implementation of redundancy, because of difficult access of no access at all • Very complex DCS systems, in order to get a fully remote control • Industrial engineering design and industrial scale production The APOLLO Project - Agostino Lanza

  3. Requirements of future LHC upgrades and new experiments • New design, full replacing the present systems whose design dates from early 2000 years • Increased rad-hard performance, because of the increased luminosity of accelerators • Minimization of power loss in cables used for carrying current from PS distributors to the front-end of detectors, moving distributors as close as possible to the front-end • Increased B-tolerance of systems getting closer to detectors and magnets • Better reliability and controls, in order to reduce access time and increase the overall detector efficiency • Avoiding industrial intellectual property, trying to implement the CERN Open Hardware policy The APOLLO Project - Agostino Lanza

  4. Main DC/DC Converter niPOL Converter niPOL Converter niPOL Converter LDO Converter LDO Converter LDO Converter LDO Converter LDO Converter LDO Converter POL POL POL POL POL POL POL POL POL The APOLLO proposal – System architectures Case study: ATLAS LAr calorimeters CRATE • Characteristics: • Main isolated converter with N+1 redundancy • High DC bus • voltage • (12V or more) • Distributed Non-Isolated Point of Load Converters (niPOL) with high step-down ratio Card #1 Card #2 Card #3 POL Converter with high step-down ratio The APOLLO Project - Agostino Lanza 280 Vdc Regulated DC bus

  5. Main DC/DC Converter LDO Converter LDO Converter LDO Converter LDO Converter LDO Converter LDO Converter niPOL Converter The APOLLO proposal – System architectures Parallel study: ATLAS Muon detectors Muon Detectors • Characteristics: • Main isolated converter with N+1 redundancy • High DC bus voltage (12V or more) • Distributed Non-Isolated Point of Load Converters (niPOL) with high step-down ratio, on-chamber installed and high B-tolerant Chamb #1 Chamb#2 Chamb#3 POL Converter with high step-down ratio POL POL POL POL POL POL The APOLLO Project - Agostino Lanza 280 Vdc Regulated DC bus

  6. + T1 C4 Q4 L 1 + + iL 0.9 - T3 Q3 C3 Co Vout Vin 0.8 + T4 C2 Q2 iT2 0.7 + 0.6 C1 Q1 T2 0.5 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 Vout = 12V 13 cm Efficiency (Bext = 0) Transient response Output power kW] Vout Iload The APOLLO proposal - Topologies The Main DC/DC Converter • 3 modules 1.5 kW each • redundancy n+1 • current sharing • interleaved operations • Switch In Line Converter - SILC • phase shift operation • ZVS transitions • high efficiency • reduced switch voltage stress • high frequency capability Output voltage response to a load step change (25 A  37 A) The APOLLO Project - Agostino Lanza 33 cm 7 cm

  7. The APOLLO proposal – Thermal sizing • 3D Finite Element Model (FEM) • FE modeling of the main heating components: • Input power MOSFETs • Output diodes • Inductor • Planar transformer • Thermal measurements 1 • Thermal characterization on single components, to validate models • Thermal design • Designed advanced solutions to improve heat exchange: • Power MOSFETs mounted on IMS board • ISOTOP diode isolated package directly mounted on baseplate • Copper thermal layers for transformer core cooling • Silicone gap filler for transformer windings cooling • Thermal simulation and measurements 2 • Preliminary thermal measurements on the air cooled whole converter • Final requirements • Main converter output power = 3x1 kW • Case dimensions: 150 x 402 x 285 mm3 • Max case temperature = 18°C • Water cooling system • delivery = 1.9 l/min, p = 350 mbar • Tinlet = 18°C, Toutlet ≤ 25°C The APOLLO Project - Agostino Lanza

  8. L1 S1 S2 + + S4 Uin Uo Co R UC1 C1 - - L2 S3 D<50% Uo = UinD/2 Cin S1 C1 S4 S3 L2 L1 Co The APOLLO proposal - Topologies The Point of Loads Specifications: Input voltage: Ug = 12 V Output voltage: Uo = 2.5 V Output current: Io = 3A Op. frequency: fs = 1 MHz 350 nH air core inductors Dim.: L = 6cm, W = 4.2cm Specifications: Input voltage: Ug = 12 V Output voltage: Uo = 2 V Output current: Io = 20A Op. frequency: fs = 280 kHz 2.2 mH ferrite core inductors Dim.: L = 7cm, W = 3.5cm Interleaved Buck with Voltage Divider – IBVD • Characteristics: • Zero voltage switch turn on • High step-down ratio • Reducedswitchvoltage stress (Uin/2) • Interleaved operation with automatic current sharing and ripple cancellation The APOLLO Project - Agostino Lanza

  9. The APOLLO proposal – Rad-hard devices • Seeking for power MOSFETs radiation tolerant up to 10kGy and 1014/(s ∙ cm2) neutrons and protons: • many components, with Vd ranging from 30V to 200V and polarized in various configurations, were tested at the 60Co g ray source in the ENEA center of Casaccia, near Roma • same components were tested with a heavy ion beam, 75Br at 155MeV, at INFN LaboratoriNazionali del Sud in Catania • within the end of the year same components will be tested under neutrons, at the Casaccia nuclear reactor Tapiro, and under protons, at INFN LNS • Seeking for power MOSFETs, controllersand FPGA radiation tolerant: • first irradiation was performed under 216MeV proton beam in Boston, at Massachusetts General Hospital facility, using some of devices irradiated in Italy. Other irradiation campaigns are planned at the same facilities in the next months • Results are still preliminary and under analysis. Other irradiation campaigns are necessary in order to select good devices The APOLLO Project - Agostino Lanza

  10. The APOLLO proposal – Rad-hard devices Some preliminary results of g irradiation up to 9600 Gy of the 200V MOSFET IRF630 The APOLLO Project - Agostino Lanza

  11. L + + VCC VDC C1 DUT vc iDUT Rshunt DRIVER The APOLLO proposal – New technologies GaN test circuit • Study of EPC GaNs: • Work in progress since early 2011 • Two device types under test: 40V and 200V • Difficulties found for soldering devices on PCB • Electrical characterization in progress • Rad-hard tests will come soon UGS [1V/div] UGS [1V/div] UDS [20V/div] -IDS [1A/div] Measured voltage and current during switching periods of a GaN device -IDS [1A/div] Time [10ns/div] -poff(t) Time [10ns/div] The APOLLO Project - Agostino Lanza Rshunt = 85 mW Turn off interval @ Vcc = 100V, IDS = 5A Turn on interval @ Vcc = 100V, IDS = 0A

  12. The APOLLO proposal – New technologies First moulded samples of FES168 • Study of high-B materials: • Collaboration with the private company FN S.p.A. • Base material by Hoganas, FES168 HQ, Fe – Si(6.5-6.9%) • Problems found and solved in the injection moulding phase • Still problems in the sintherization phase • First B tests by end of the year (hopefully) Collaboration with a CERN group (F. Faccio). It aims at studying current sharing of already existing integrated DC/DC converters with low output currents (< 3A), designed by that group The APOLLO Project - Agostino Lanza

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