Problem of the day

Problem of the Day

MPS Solutions

A Wi-Fi solution company came to MPS asking for a high-efficiency, synchronous, buck converter that can operate continuously at a 5A output current. Efficiency and a compact solution was their top priority, and over-current protection was also required for safety.

MPS had the solution with our MP2225. With a low RDS(ON) (MOSFET turn-on resistance), our MP2225 can reach up to 97% efficiency.  Pulse-skip mode can improve efficiency during light-load condition. Hiccup OCP rules out the need for power recycling of the converter once a protection is triggered. The MP2225 is available in a space-saving, 8-pin, TSOT23 package.

Here’s how you achieve EMI reduction with minimal size in automotives. Say you need a small 1A constant-current LED driver to operate from a 12V battery with up to 40V with load dump. This leaves very little room for filtering. The AEC-Q100 MPM6010 power module is a unique solution to this problem. This tiny 3x5mm QFN module has an integrated inductor and small input cap, reducing the switching loop and EMI. This allows the EMI filter to be minimized, reducing size and cost.
It IS possible to add a quadrature encoder to the front shaft of a motor, yes! An industrial motor drive customer approached MPS with this problem, and MPS had the solution: the MagAlpha line of magnetic sensors. Using the MA702, a ring magnet can be placed on the motor front shaft and the angle can be sensed from the side of the magnet. The MA702 is programmable, allowing the number of pulses per revolution to be set to match the previous optical encoder.
Let’s learn how to achieve a precise output with a fast transient time and tight tolerance. Think traditional voltage or current mode controls can help you? Guess again! MPS’s Constant on Time (COT) control is the way to go. A hard disk drive customer needed a buck converter to regulate a 1V output to ±1.5% when spinning up a disk drive that required a fast transient load step from 0-6A @ 10A/us. Our MPQ8633A COT control solution met the transient spec with only three 22uF caps to achieve >90% peak efficiency.

Recently, a network interface adapter company asked MPS for a compact solution with 10A of sustained output current. Solution size, efficiency, and fast transient performance were critical in their design.

The MPM3682 meets this requirement in every aspect. The 12x12mm module includes internal inductor, and only a minimal number of standard, external components are needed. The compact module provides ease-of-use features and saves room for the customer’s board. Adaptive constant-on-time (COT) control provides ultra-fast transient response and efficiency that can reach up to around 96%.

One networking hardware company was looking for a 20A synchronous step-down converter power solution with an adjustable current limit. The step-down converter needed to operate within an 8 - 12V input voltage range. Efficiency and transient performance were a key concern.

Our MPQ8633B met the requirement. Constant-on-time (COT) control mode provides extremely fast transient response. With MPS’s propriety switching loss reduction technique, the MPQ8633B’s efficiency can approach 95%.  Pulse-skip mode and forced continuous conduction mode (FCCM) can optimize the efficiency and ripple in light-load condition.

Cost is an important advantage of sensorless motor control. MPS has leveraged this advantage by developing 10-14 bit angular feedback using the MA702, MA704, and MA730 series of magnetic motor position feedback sensors. For an unprecedented low cost, control advantages such as full efficiency at low speed, high torque upon start-up, and elimination of complex sensorless algorithms can be introduced into controller designs without adding major BOM cost.

Are potentiometer reliability issues limiting the life of your product?  With the MA800 series of magnetic angle sensors, you can replace the potentiometer with a contactless solution with push-button detection built in. Including the target magnet, the cost is comparable to that of a standard potentiometer.

The MA800 series is a solid-state monolithic IC with eight bits of resolution and a choice between digital, PWM, and ABZ outputs. There is no physical contact between the knob and IC, so reliability issues are relegated to the past.

Many IoT devices require a small, non-isolated supply with two output voltages. The MP163 family was developed in response to this common need, and many customers have found it to be a great fit in space-challenged designs, such as smart bulbs and occupancy sensors.  The MP163 combines an offline buck converter with an integrated 700V MOSFET and a second-stage LDO and is available in a compact SOIC-8 package.

Optical module vendors are constantly looking for the smallest voltage regulators in the industry to power EML drivers, so MPS created the MP1400. The MP1400 is a negative voltage buck-boost in an ultra-small 0.8mmX1.6mm CSP package that has helped save space in many QSFP designs. Despite its small size, the MP1400 can provide 0.6A peak current with an adjustable output voltage from -0.9V to -6V.

Wireless charging designs must evolve quickly to keep up with mobile devices charging on the go.  One supplier found that their wireless charging design dissipated too much heat at the highest charge rate and drew too much standby power. For the main logic power rail, the MP2263 covered both of these requirements with excellent efficiency at the 1A max load and also ran ultra-cool in standby mode with just 12µA of quiescent current. The 30V max input specification worked with a wall adapter, and the small 2x3mm QFN package fit easily on the board.

A customer came to MPS looking for a BLDC motor control solution without an MCU. MPS had the solution with the MP6532.  The MP6532 is a solution for BLDC motors with MCU in high-feature applications or without MCU in low-feature applications. The MP6532 is capable of driving three half bridges consisting of six N-channel power MOSFETs up to 60V. This provided the customer with a platform design approach for different-size motors.

A hardware engineer was designing an asset-tracking device powered from a small Li-ion coin cell. He needed a very low Iq buck converter with a load switch to power the multi-band radio transceiver. There are two rails required: 2.8V/100mA for the core and 2.8V/80mA for the RF transceiver that is switchable.

MPS’s MP28310 was a perfect fit for this customer’s application. The 500nA Iq of this buck converter was especially appealing. The buck output of the MP28310 powered the core rail, and the LDO was used as a load switch by connecting its input from the buck output and using its CTRL4/5 pins to turn its output on and off.

A customer came to MPS looking for a small solution with a low output voltage ripple for a 5V bias supply to operate from 12V bus voltage. We recommended our low output voltage ripple MPM3606 module solution. The MPM3606 comes in a 3x5 package, including the inductor, and can deliver up to 600mA of output current from an input voltage of up to 21V. The MPM3606 allowed the user to either set or disable light-load operation. By disabling light-load operation, the customer achieved very low output voltage ripple throughout the operating range with the use of just one 22µF ceramic output capacitor.

How do you achieve automotive EMI compliance in a small area? LED indicators/markers typically require up to 1A of constant-current drive from the 12V battery (load dump ≥40V), yet have limited area and plastic enclosures. This leaves little room for EMI filtering.

The MPM6010 module uniquely solves this problem. This tiny 3x5mm QFN module has an integrated inductor and small input cap, reducing the switching loop and EMI. This allows the EMI filter to be minimized, reducing size and cost. The MPM6010 is also AEC-Q100 qualified.

MPS was recently challenged to design a 30W USB-C-PD adapter with power density greater than 17W per cubic inch and efficiency higher than 91%. This adapter also had to have 30mW of no-load power consumption without an optocoupler. The MPX2001 was a perfect fit. This part integrates a flyback controller, synchronous rectifier controller, reference, error amplifier, and high-voltage isolator in a SOICW-20 package. The high level of integration in the MPX2001 allows the design to be built with a minimal number of parts.

A leading supplier of automotive USB modules contacted MPS for a step-down converter with good efficiency when the load current was below 100mA. They needed a low quiescent current when the USB ports were open. The MPQ4431 was an ideal solution. It employs advanced asynchronous mode (AAM), which helps achieve high efficiency in light-load condition by scaling down the switching frequency to reduce switching and gate driving losses. The MPQ443x family of devices covers load current ranges from 1.0A to 3.5A.

An automotive Tier1 supplier contacted MPS looking for a part for their multi-USB charger projects.  The projects consisted of different combinations of ports and types. The size of the PCB was a major concern. The MPQ4487 and MPQ4488 integrated circuits were ideal solutions for this project. Both devices consist of an efficient 6A buck converter and two current-limit switches in a 5mm x 5mm QFN-26 package. The MPQ4487 has enable and status pins for each switch. The MPQ4488 includes automatic detection of several charging schemes, and both devices are AEC-Q100 qualified.

A large HVAC system manufacturer contacted MPS looking for a cost-effective, step-down converter with high efficiency and a wide input voltage range.  Their product had a high feature content and a small form factor and required a small PCB area and low power loss.

The solution was our MPQ4559. The MPQ4559 is guaranteed over the industrial temperature range and operates over an input voltage range of 3.8 - 55V.  The external compensation components can be calculated easily using the MPS DC/DC Designer tool.  The MPQ4559 is available in a 3mm x 3mm QFN-10 package.

Two customers recently needed a QC 3.0 controller supporting a Type-A interface. The parts also needed to be feature-rich in a small footprint. We had the solution in our MP5032 and MP5034 devices. The MP5032 was used in an AC/DC charger, and the MP5034 was used in a power bank.  Each part supports DCP schemes and more, and the MP5032 also has an adjustable current limit. Both parts are available in TSOT23-8 packages.

A geologic science supplier had to cope with the problem of tracking the rotation of a shaft over extraordinary spans of time (months!), peculiar form factors, and uncertainty of the orientation of their magnet.  Typical motor control sensors wouldn’t cut it for this application.

The MA704 Contactless Angle Sensor was a perfect fit, with a small 3x3 footprint and support for a wide range of spatial configurations (both on-shaft and off-axis).  The on-axis support allowed the company to get away with a magnet shape that suited their needs exactly.  Here’s to keeping the world (slowly) turning.

MP5505A has found its home in many storage applications that require power loss protection. Its energy back up storage and release feature has helped solid state drives and hard drives to complete writing when power failure is detected. Its high storage voltage enables designer to use higher voltage capacitor to store more energy and further reduce the quantity of capacitors.

A manufacturer of electronic locks was given a challenge to make a secure lock that operated for 10 years from a primary cell power source rated at 30mA/life. To complete this project they needed to manage every bit of available energy very carefully. The MP28200 enabled them to accomplish this by consuming only 200nA of quiescent current while powered and 70nA while in shutdown. By pulsing the power converter on when needed the ultralow power dc/dc converter squeezed the minimum amount of energy from the battery when required to power the electronics for the expected service life of the lock.

A common challenge for industrial applications is adding features in the same space as a previous design. Many industrial circuits are designed to operate on 24VDC (19V to 29V) and the voltage regulator for these projects can take up considerable space. The MPM3515 is a 1.5A rated voltage converter module that supports an input voltage of 4V to 36V. The package for the MPM3515 is only 3mm x 5mm x 1.6mm. The whole converter circuit takes just 6mm x 6.5mm--thus making room for additional circuits that implement new function. 

A Telecom OEM who designs and makes their own Optical module, needs to generate a negative 7V/1A rail off of +5V input. The -7V rail is used to bias the heaters of their Optical-to-Optical Switch ASIC. Since their PCB is tight, the design engineer asked if he can use a buck power module for an inverting buck-boost topology.

The MPM3630 18V, 3A, Buck power module can be used for an inverting buck-boost topology. Its 18V and 3A ratings met the 12V switch node voltage rating and 2.9A peak inductor current requirement, respectively for this application. Its 3x5x1.6mm size occupies very little space on small PCB.

An automotive lighting supplier was faced with the challenge of fitting all the electronics needed for their LED bulbs in smaller and smaller form factors.  All of this while surviving input surges around 36V, and passing stringent CISPR EMI tests (darn AM radios…).

The MPM6010 LED Driver Module saved the day, with a tiny 3x5 footprint and quiet as a mouse in the EMI tests due to a minimized power loop.  Combine this with the fact that the MPM6010 is AEC-Q100 qualified and you’ve got an automotive success story.

Optical Modules are a large industry that requires highly efficient converters in an extremely small form factor, all of which provide the power needed in high-bandwidth communications apps. System efficiency must be above or equal to 90% with an input voltage of 3.3V; most of the time the core rail – 0.6V to 3.0V @ max of 5A – is most influential in the efficiency calculation.

 A customer needed such a converter and MPQ8626 was a perfect fit. It is a 6A part capable of achieving this requirement with its low RDSon integrated power MOSFETs, adaptive COT control structure, small 2x3mm package.

A startup in the LED Lighting Industry needed to design a 7W Dual Output AC/DC PSU for their Lighting controller. The major challenge was to keep the height below ½ inch and power density at 11W per cubic inch. The MP020-5 uniquely satisfies this need. This part integrates the primary side flyback controller and a high voltage primary Mosfet in one single SOIC8 package. Primary side regulation eliminates the need for an opto-coupler and allows for a simpler transformer design The MPS team worked hard to meet all the specs and delivered a very cost effective solution to a delighted customer.

A leading charger manufacturer recently approached MPS with the need for a 71W Multi-port USB C–PD charger to fit within an unusual teardrop type enclosure. The All in one flyback controller, MPX2001 was the key to success. This part integrates the primary side controller, the secondary synchronous rectifier controller, precision reference, error amplifier and the High voltage isolator in a SOICW-20 package. The high level of integration created space for thermal management in a sealed plastic enclosure and also enabled to reduce design cycle time to 4 weeks.