Protection devices known as "eFuses (electronic fuses)" are increasingly being adopted in applications that require power system protection. However, when it comes to actual design, many people may have questions such as "Why do we need to use protection devices?" and "What advantages do they offer compared to discrete configurations?"
This article explains the importance of protection in power systems, the design challenges involved, and the features and benefits of eFuse. Finally, we will introduce specific eFuse products for your reference.
The Importance and Challenges of Power System Protection
In applications such as industrial automation, building automation, motion control, and process control, productivity and profitability are critical. Uptime is key, and downtime occurs due to maintenance, human error, and equipment failure. Downtime leads to repair costs and lost productivity, negatively impacting profits. While downtime due to maintenance and human error may or may not be preventable, the majority of equipment failures can be prevented with the right measures.
Power systems are subject to a variety of electrical stresses, such as lightning strikes, overcurrents, and static electricity, which can degrade performance or damage circuits. To prevent these events, it is essential to install appropriate protection mechanisms.
Examples of applications that require protection
Below are some examples of applications where power system protection is important:
- Automotive and transportation: vehicle batteries (12V, 48V), transportation management systems
- Industrial: N+1 redundant power supplies, ±48V distributed power systems, test and measurement equipment, motion control, industrial automation
- Aerospace and defense: avionics equipment, power supply units for various applications
- Communications: Data centers, communications infrastructure equipment, PoE systems
- Medical: Treatment equipment, diagnostic equipment, measuring equipment
Reliable power protection is essential, especially in applications that require constant operation or that involve human body contact.
Where power protection is required
There are three areas in a power supply system that require protection: the input section, the output section, and the inside of the board. Of these, the input and output sections are particularly important.
■ Power supply protection for input section
The input section requires protection against overvoltage (OV) and undervoltage (UV), current limiting, inrush current limiting, and reverse voltage protection. In addition, if the power source does not have sufficient power, power limiting is required to prevent excessive input.
In systems using multiple power supplies, power is switched by ORing or redundancy. In these cases, reverse voltage protection is important to prevent reverse current from a high-voltage power supply to a low-voltage power supply.
■ Power supply protection for output section
At the output, current limiting is required for overloads and short circuits on connectors, and reverse voltage protection for short circuits to the high voltage rail. When feeding multiple power rails, load switches, ORing, and power limiting are required to control the power distribution.
These various protections are essential to improve the safety and reliability of power systems.
Three types of failures in power systems
Faults that occur in power supply systems can be divided into three types: voltage, current, and temperature.
■ Voltage
The input voltage may exceed the normal range due to lightning strikes, blown fuses, static electricity, short circuits caused by external factors, etc.
■ Current
Current-related faults include overloads and short circuits. Overloads occur when a system is asked to perform beyond its capabilities, while short circuits are caused by defective components or incorrect operation. Short circuits can cause permanent damage to the board or even cause a fire.
■ Temperature
A properly designed system will usually not experience thermal failures, but sustained overload, a failed fan, blocked intake or exhaust vents, or a malfunctioning air conditioner can cause temperatures to exceed the expected limits.
These faults occur frequently, so if they are not properly considered during design, the system may not be able to pass test cases during verification. They can also cause downtime during operation. To prevent these problems before they occur, a protection mechanism that can handle a variety of voltage, current, and temperature faults is required.
Design challenges: How to achieve miniaturization, short delivery times, and cost reductions?
Conventionally, power supplies have been protected by combining discrete components and single-function protection ICs. However, this configuration can require dozens of protection components for a single power supply system, resulting in issues such as increased design complexity, larger solution size, and higher costs. It also increases the complexity of component management and procurement risks.
However, in recent years, there has been an increasing demand for smaller solutions, shorter development times, and lower costs, and it has become difficult to meet these demands using conventional design methods that use many components.
This is why eFuse (electronic fuse) is gaining attention as it integrates all protection functions into a single chip. eFuse has a built-in FET and is equipped with a variety of functions, including current detection and limiting, power limiting, thermal protection, and overvoltage (OV) and undervoltage (UV) protection. Some devices comply with UL and IEC standards, ensuring safety without sacrificing reliability. Utilizing eFuse is a promising option for modern power supply designs that must increase reliability within various constraints.
What are the features of eFuse? Various protection functions integrated into one chip
eFuse integrates the protection functions required for power systems into a single chip. Protection functions that previously required many components can now be achieved with a single IC, contributing to simplified design and a reduction in the number of components.
Benefits of using eFuse
Using eFuse offers the following benefits:
■ Increased uptime
It protects power systems from all types of faults, increasing uptime. Unlike traditional fuses that shut off the circuit by blowing, eFuse shuts off the circuit by switching FETs on and off. This eliminates the need for component replacement and allows for repeated use, allowing for quick recovery and reducing downtime. With its auto-recovery function, eFuse can automatically resume application operation once the fault is resolved.
■ Improved design efficiency
The ability to integrate protection functions into a single chip is effective in simplifying the design and reducing the number of components, and also makes it easy to achieve miniaturization and reduce development man-hours.
■ Improved reliability and quality
By selecting eFuses that comply with UL and IEC standards, you can smoothly meet safety requirements and efficiently improve reliability and quality.
By utilizing eFuse, you can meet development requirements such as miniaturization, short delivery times, and cost reduction, while ensuring safety, reliability, and improving uptime.
Analog Devices eFuse MAX17616/A and MAX17617/A
Analog Devices' eFuse introduces the MAX17616/MAX17616A and MAX17617/MAX17617A, which can handle input voltages up to 75V.
Features
The common features are as follows:
● Supports high voltages up to 75V, making it useful in a wide range of applications
Supporting a wide input voltage range from 3V to 75V, it can be used in a wide range of applications, from 12V and 24V to high voltages such as 48V and 54V. It is also used in data centers, where high voltages are becoming increasingly common, as well as in industrial automation and motion control.
● Protection functions integrated into a single chip reduces solution size by more than 65%
The extensive protection features on a single chip reduce solution size by over 65% compared to discrete solutions, including integrated FET, current sensing, thermal foldback, power limiting, current monitoring, ground loss protection, and an integrated gate drive for driving an external FET.
● Output voltage clamp reduces capacitors by over 90%
The built-in programmable output voltage clamp function reduces the number of capacitors required to absorb voltage fluctuations by more than 90 %, significantly reducing the number of components and contributing to a smaller solution size.
● Supports PMBus interface, allowing for flexible design
The PMBus interface allows for flexible settings such as real-time monitoring of voltage and current, selection of current limiting mode, inrush current limiting, and short-term overcurrent protection. Cause analysis in the event of a fault can also be performed using the PMBus interface without the need for an external monitoring device.
Differences in functions depending on model number
The table below summarizes the differences between the four products. The bolded parts are particularly important when making a selection.
|
MAX17616 |
MAX17616A |
MAX17617 |
MAX17617A |
|
|
Input voltage range (without reverse current protection) |
3V-80V |
|||
|
Input voltage range (with reverse current protection) |
3V-75V |
|||
|
Reverse current protection (using external nFET) |
can be |
|||
|
Current Limit |
can be |
|||
|
Thermal Foldback Current Limit |
can be |
|||
|
Input Surge Protection |
OVLO only |
Yes (output voltage clamp) |
OVLO only |
Yes (output voltage clamp) |
|
UL1310 Class-2power limits |
none |
can be |
||
|
PMBus |
can be |
none |
||
|
Telemetry Function |
can be |
none |
||
|
Fault diagnosis function |
can be |
Supported by FLAG Pin |
||
|
Current Monitoring |
can be |
|||
|
Input UVLO |
can be |
|||
|
Output UVLO |
Yes (via PMBus) |
can be |
||
|
Power Good |
can be |
|||
|
Loss of ground protection |
can be |
|||
- Products with an "A" suffix (MAX17616A, MAX17617A) include a programmable output voltage clamp function, which provides input surge protection.
- The MAX17616/MAX17616A supports a PMBus interface and has telemetry (real-time monitoring) and fault diagnosis functions.
- The MAX17617/MAX17617A support UL1310 Class 2 power limiting functionality. Both are equipped with a maximum input voltage of 75V, reverse voltage and current protection, current limiting, and thermal foldback functions. Users can select the optimal product based on their application requirements.
Pin Configuration
The pin configuration diagrams for each of the four products are shown below. The differences in functionality introduced earlier are also reflected in the pin configurations. Please use this as a reference when making your selection.
This time, we introduced the importance and benefits of eFuse (electronic fuse), a protection device that integrates the protection functions required for power systems into a single chip. Analog Devices' eFuse products, the MAX17616/MAX17616A and MAX17617/MAX17617A, are packed with features that help improve the efficiency of power supply design and reduce downtime.
We have evaluation boards available for each product, so please give them a try.
If you are interested, please feel free to contact us.
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