ESD Standard for Vehicle ISO 10605 Southeastern Michigan

ESD Standard for Vehicle ISO 10605 Southeastern Michigan IEEE EMC 2011/Nov. /10 Noise Laboratory Co. , LTD Takeshi Ishida 1

My position at IEC & ISO Committees IEC TC 77 ISO TC 22 WG 4 SC 77 A Low frequency SC 77 B High frequency The Japanese national committee WG 10 RF MT 12 ESD・Surge SC 77 C High power 2

　　ESD Standards Object Standard Evaluation Cause Electronic equipment IEC 61000 -4 -2 malfunction human body Vehicle Components ISO 10605 malfunction Break human body Vehicle Components SAE J 1113 -13 malfunction Break human body * Electronic components IEC 61340 -3 -1 IEC 61340 -3 -2 Break human body machine * Semi -conductor IEC 60749 -26 IEC 60749 -27 Break human body machine *Similar to MIL, JEDEC, ANS, ESDA, etc 3

Timeline of ISO 10605 1994　ISO TR 10605 Have some flaws 2001　ISO 10605 Ed 1. 0 2008　ISO 10605 Ed 2. 0 2012? 　ISO 10605 Ed 2. 0 Amendment 1 4

Electrostatic discharge path – Outside • • The discharge may occur by voltage difference between human and vehicle. The discharge path is 1)　Wheel resistance. 2)　Capacitance between vehicle and ground. 5

Electrostatic discharge path – Inside • The discharge path is capacitance between human and back of the seat. 6

ESD effects to electronics equipment ESD Disturbance of RF Surface current Voltage potential enclosure Noise from signal EM coupling by secondary radiation Signal port Noise from power line Digital circuit Power port Stray capacitance 7

Discharge resistor and energy capacitor Capacitor Resistor New Value Purpose IEC ISO 10605 150 p. F Capacitance between human body and ground. ○ ○ outside contact 330 p. F Capacitance between human body and seat. 330Ω Contact by human with metal object 2000Ω Contact by human skin ○ inside contact ○ ○ ○ H. V. PS 8

Tolerance is not all same Discharge current waveform specification Typical C/ R values Peak Current [A/k. V] Tolerance [%] Current at t 1 [A/k. V] Tolerance [%] Current at t 2 [A/k. V] Tolerance [%] 150 p. F / 330Ω 3. 75 ± 10 2 (at t 1 = 30 ns) ± 30 1 (at t 2 = 60 ns) ± 30 330 p. F / 330Ω 3. 75 ± 10 2 (at t 1 = 65 ns) ± 30 1 (at t 2= 130 ns) ± 30 150 p. F / 2000Ω 3. 75 -0/+30 0. 275 (at t 1= 180 ns) ± 30 0. 15 (at t 2= 360 ns) ± 50 330 p. F / 2000Ω 3. 75 -0/+30 0. 275 (at t 1= 400 ns) ± 30 0. 15 (at t 2= 800 ns) ± 50 NOTES: 1. The peak current level shall be taken from the measurement system without any data interpolation. 2. The target used with this measurement system shall fulfil the requirements of clauses A. 1 and A. 2. An example is defined in Annex B. 3. The measurement times (30, 65, 130, 180, 360, 400, and 800 ns) are derived from RC-time constant – 40% (Current t 1) and +20% (Current t 2), to define two values on the falling slope of the current pulse according IEC 61000 -4 -2: 2001 Ed. 1. 2 9

Ideal contact discharge waveform at 5 k. V 150 p. F/330 p. F，330Ω First peak is same Actual waveform 10

Ideal contact discharge waveform at 5 k. V 150 p. F/330 p. F，2000Ω Actual waveform 11

Mathematical formula(150 p. F/330Ω) 1 = 1. 1 ns　　 2 = 2 ns　　 3 = 12 ns　　 4 = 37 ns I 1　= 16. 6 A （ at 4 k. V ）　　I 2 = 9. 3 A （at 4 k. V） n = 1. 8 12

Calibration setup of discharge current waveform Requirement detail is not mentioned 【 Ed. 1】　　　　　　　【 Ed. 2】 13

Detail of discharge current waveform calibration 　 Faraday cage Stray capacitance between gun and faraday cage Faraday cage Target ESD generator Oscilloscope H. V PS Bandwidth of oscilloscope: >1 GHz Ground return cable 14

Target calibration（ Annex A） • No frequency specification on Ed. 1 target • Target frequency response: ～ 1 GHz：<± 0. 5 d. B • Target mechanical structure is described in Annex B Ed 2 Ed 1 15

Comparison of current waveform Ed. 1 Target Ed. 2 Target 16

Frequency response on Ed. 2 target • • • ESD generator 100 k. Hz-4 GHz liner scale 0. 5 d. B/div S 21 Specification ～ 1 GHz： 　<± 0. 5 d. B Frequency 17

　Principle of specific current waveform Simulation waveform Simplified equivalent circuit 18

　　Principle of specific current waveform Simulation waveform Actual waveform Normal gun No capacitor in gun 19

Actual human body discharge current waveform When the target is touched by human with electrode. （air discharge tip） 1 A/div　10 ns/div 1 A/div　500 ps/div 20

Requirement of Ed. 1 current waveform • • Rise time SAE requirement is < 20 ns – Contact ： 0. 7 -1. 0 ns – Air < 5 ns：at 15 k. V(repeatability: 6/10） Impossible RC interval time to measure Rough specification No second peak Not actual shape 21

Air discharge calibration is removed from Ed. 2 • Annex E（informative） Rationale for air discharge generator verification – Due to the complexity of air discharge, no satisfactory verification method has been developed. Therefore it was decided not to require an air discharge verification. • General … – Amenable to humidity – Discharge phenomenon is changed by surface condition of electrode and/or DUT. – Rise time may faster, if discharge voltage is low. – Positive and negative rise time is differed 22

Test setup（Bench test） • Table（non-conductive）height： 0. 7 -1. 0 m • HCP： minimum 1. 6 x 0. 8 m, Plus 0. 1 m greater than DUT/cables. 　 – Material: ：cupper, brass, aluminum 　thickness: >0. 25 mm HCP means vehicle body Needed for outside testing. 23

Test setup（Bench test） • Resistor cable – 470 kΩ resistor on each end – To eliminate HCP charge voltage – To avoid a resonance of cables 24

Test setup（Bench test） IEC : 0. 5 mm • Insulation block height: 50± 5 mm • Insulation support thickness: 2 -3 mm (e. g. polyethylene). No insulation support for direct mount DUT 25

Test setup（Bench test） Ed. 1 50 mm width ground strap？ r tte Ba y ESD gun exerciser • Capacitor: 330 p. F • Interval: >5 s • Each polarity 3 times • Air discharge approach speed: <5 mm/s Ground cable Ground connection point is unclear Insulation block 25 mm 26

Effect of insulation block • Arrangement of DUT Edition DUT Wire harness Direct mount Floating Ed. 1 None 25 mm None Ed. 2 none 2 -3 mm 50 mm 27

Experiment of insulation block Stray capacitance 10 p. F Stray capacitance 259 p. F Current probe insulation 150× 250 mm Metal plate 25 mm 28

Experiment of insulation block 【no insulation block (direct mount)】 Test voltage: 2 k. V 6. 6 A 2 A/div 29

Experiment of insulation block Test voltage: 2 k. V 6. 5 A 5. 5 A 4. 5 A 2. 1 A Ed. 1 Ed. 2 25 mm 2 A/div 30

Experiment of insulation block 【No elimination of charge】 Test voltage: 2 k. V 1 st 2 nd 3 rd Ed. 1 Ed. 2 25 mm 2 A/div 31

Experiment of insulation block 【positive shot after negative 10 times with no elimination of charge 】 Test voltage: 2 k. V 10. 3 A 7. 9 A Ed. 1 Ed. 2 25 mm 2 A/div 32

Discharge test mode Mode Coupling mode Contact Air Direct Contact to DUT metric part Tip：Conical Approach to DUT non conductive part 0. 1 m/s～ 0. 5 m/s Tip：Round※ Indirect Contact to HCP Tip：Conical ※In case of >15 k. V may need large round tip（to avoid charge leak） 33

Comparison of electrode shape Φ 30 mm φ22 mm Standard air tip 34

Comparison of electrode shape 30 k. V　φ30 mm tip Requirement for vehicle 30 k. V　Standard tip 35

Bench test （Direct） Vehicle body potential Ground potential 1 DUT 2 ESD generator 3 ESD generator main 4 Non conductive table 5 HCP 6 Ground point 7 Ground connection 　8 remotely accessible parts of the DUT 9 Periphery 10 Battery 11 Insulation support 12 Insulation block　13 470 kΩresistors 14 GRP （optional）　15 HCP ground connection 36

　　 Bench test （Direct） 37

Bench test （Direct） Ed. 2 • Connect chassis-mounted electronic modules directly to the HCP. • DUT shall be connected to all peripheral units • The supply battery shall be on the test table, with the negative terminal of the battery directly connected to the HCP. • The ESD generator shall be configured with the 330 p. F or 150 p. F capacitor depending on the DUT location in the vehicle. • Apply the ESD at each specified test voltage and polarity (see Annex C). • The test voltages (in accordance with Annex C) shall be increased, using at least two values, • At least 3 discharges shall be applied by not less than 1 s interval. • Charge build-up can be eliminated by briefly connecting a bleeder wire with high resistance ( 1 MΩ) – Wait by natural charge decay. – Air-ionizers may be used to speed up 38

Category of test level： Annex C Component test - Direct – Contact Category １ Category 2 Category 3 L 4 i ± 8 k. V ± 15 k. V L 3 i ± 6 k. V ± 8 k. V L 2 i ± 4 k. V L 1 i ± 2 k. V Component test - Direct - Air Category １ Category 2 Category 3 L 4 i ± 15 k. V ± 25 k. V ± 8 k. V L 3 i ± 8 k. V ± 15 k. V ± 4 k. V ± 6 k. V L 2 i ± 4 k. V ± 6 k. V ± 8 k. V ± 2 k. V ± 4 k. V L 1 i ± 2 k. V ± 4 k. V ± 6 k. V Component test - Indirect - Contact Category １ Category 2 Category 3 L 4 i ± 8 k. V ± 15 k. V ± 20 k. V L 3 i ± 6 k. V ± 8 k. V ± 15 k. V L 2 i ± 4 k. V ± 8 k. V L 1 i ± 2 k. V ± 4 k. V 39

Bench test （Indirect） Ed. 2 New Radiated E-field 1 DUT 2 ESD generator 3 ESD generator main 4 Non conductive table 5 HCP 6 Ground point 7 Ground connection 8 remotely accessible parts of the DUT 9 Periphery 10 Battery 11 Insulation support 12 Insulation block 13 470 kΩresistors 14 GRP （optional） 15 HCP ground connection 16 HCP or ESD ground connection 40

　　 Bench test （Indirect） 41

Bench test （Indirect） Ed. 2 • Connect chassis-mounted electronic modules directly to the HCP. • DUT located distance of 0, 1 m away from the HCP edges. • DUT shall be connected to all peripheral units • The supply battery shall be on the test table, with the negative terminal of the battery directly connected to the HCP. • The ESD generator shall be configured with the 330 p. F or 150 p. F capacitor depending on the DUT location in the vehicle. • Apply the ESD at each specified test voltage and polarity (see Annex C). • The test voltages (in accordance with Annex C) shall be increased, using at least two values, • At least 50 discharges shall be applied by not less than 50 ms interval. • Discharges to coupling planes, the discharge tip is in the same plane as the HCP 42

Radiated E-field by Indirect discharge Opt E-field sensor * ESD generato r Oscilloscope O/E Opt fiber 20 ns/div 0. 55 ns (1. 8 GHz) *Wide band lithium niobate antenna 1 ns/div 43

Component packaging and handling test Ed. 2 New 1 DUT 2 ESD generator 3 ESD generator main 4 Non conductive table 5 HCP 6 Ground point 7 Ground connection 8 dissipative mat 44

Component packaging and handling test No dissipative mat, if the DUT mounted body directly. 45

Component packaging and handling test • DUT is unpowered condition. • DUT locate on dissipative mat, Connect chassis-mounted electronic modules directly to the HCP. • The ESD generator shall be configured with 150 p. F capacitor. • To access recessed connector pins, an insulated solid wire with a cross-section between 0, 5 mm 2 and 2 mm 2 and a maximum length of 25 mm shall be used. • The test voltages (in accordance with Annex C) shall be increased, using at least two values, • At least 3 discharges shall be applied each polarity by not less than 1 s interval. • Charge build-up should be eliminated. • DUT shall pass complete function testing successfully. 46

　Vehicle test - Inside Grounding to door hinge 47

　 Vehicle test - Outside Grounding to wheel with plate Door hinge 48

Vehicle test Ed 2 • • • Conductive surfaces shall be tested using contact mode discharges. Air discharge may also be applied to conductive surfaces. For areas accessible only from the inside of the vehicle, the ESD generator ground connection shall be connected directly to the grounded metallic part of the body (e. g. seat railing, door latch). For outside, the ESD generator ground connection can be connected directly to the nearest metallic part, or directly to a metal plate placed under the wheel. The engine of the vehicle shall be running in drive or idle mode. Choose a generator capacitance of 330 p. F for areas that can easily be accessed only from the inside of the vehicle and resistance of 330 Ω or 2 kΩ. Choose a capacitance of 150 p. F for points that can easily be touched only from the outside of the vehicle and resistance of 330 Ω or 2 kΩ. The test voltages (in accordance with Annex C) shall be increased, using at least two values, At least 3 discharges shall be applied each polarity by not less than 1 s interval. Charge build-up should be eliminated. DUT shall pass complete function testing successfully. 49

Test level of Air discharge ・At least two severity levels must be tested. The IEC 61000 -4 -2 is described only air discharge Reason 1 The air discharge path depend on voltage levels. Reason 2 Rise time depend on the distance of discharge. Discharge path is differed 50

Experiment of air discharge path 51

Experiment of small gap discharge Reference： Mr. Masamitsu Honda Impulse physics laboratory http: //www. impulse-physics. com/index. html 52

Thank you for your attention 53