Multi-Phase Voltage Regulator Phase Identification via Rotating Single-Phase Testing
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Solution Overview
Problem
Current conventional ICT test equipment and procedures cannot effectively identify defective power phases in multi-phase voltage regulators, as they rely on electrical testing and have limited access to nodes, making it difficult to detect issues like solder joint problems and phase validation under normal operating conditions.
Innovation Solution
Implementing a digital VR controller-based testing method that uses a rotating single phase operation mode to individually calibrate and test each phase of a multi-phase voltage regulator, allowing for more accurate current sense monitoring and identification of bad phases through phase current sense calibration and reconfiguration via communication buses like PMBus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ICT test equipment is used to test multi-phase voltage regulators, then the test equipment can perform electrical testing and verify output voltage, but it cannot identify defective power phases due to limited node access and inability to isolate individual phase performance
Solution Approach 1:
The patent applies segmentation by dividing the multi-phase VR testing into individual phase evaluations. The test equipment sequentially enables and tests each phase independently through control signals, allowing defective phases to be identified by comparing individual phase performance against expected characteristics, thereby overcoming the inability to isolate phase failures in conventional simultaneous testing
Solution Approach 2:
The patent employs dynamics by implementing a rotating single-phase operation mode where the enabled phase changes over time. The test equipment dynamically switches which phase is enabled for testing, allowing each phase to be evaluated under identical test conditions while maintaining system operation, thus enabling precise phase-level defect detection without permanent system shutdown
2Reliability
If a multi-phase voltage regulator has one defective phase, then the VR may still appear to function normally during manufacturing testing with phase1 operating, but the defective phase will cause system malfunction when additional power load is added
Solution Approach 1:
The patent applies preliminary action by performing comprehensive phase validation during manufacturing testing before the product reaches the customer. The test equipment evaluates each phase's ability to handle load independently, identifying defective phases early in the manufacturing process, so that unreliable products are filtered out before deployment where they could cause system failures under increased load
Solution Approach 2:
The patent implements feedback by using the test equipment to monitor and measure the performance of each phase during rotating single-phase operation. The system compares measured parameters (current, voltage, power) against expected values and provides feedback to identify phases that do not meet specifications, ensuring only reliable phases are confirmed as functional before product completion
3Measurement precision
If conventional ICT testing is performed with no substantial load applied, then phase1 may operate normally and output voltage may be within tolerances, but other phases cannot be validated for their ability to contribute to output under load
Solution Approach 1:
The patent employs dynamics by implementing a rotating single-phase operation mode where the enabled phase changes over time. The test equipment dynamically switches which phase is enabled for testing, allowing each phase to be evaluated under identical test conditions while maintaining system operation, thus enabling precise phase-level defect detection without permanent system shutdown
Solution Approach 2:
The patent applies parameter changes by modifying the operational state of each phase during testing. The test equipment changes the enable/disable state of individual phases through control signals, allowing systematic evaluation of each phase's contribution to output under controlled conditions, thereby achieving complete phase validation that conventional static testing cannot provide
Data Source
AI summary
Methods and systems are disclosed that may be implemented to complete individual phase current sense calibration of a multi-phase voltage regulator (VR) and/or to detect any and all individual bad phases of such a VR by utilizing the reconfiguration capability of a digital VR controller-based VR in conjunction with an improved test process. The disclosed systems and methods may be employed in one example to identify that all individual phases of the multi-phase VR are operational to contribute to the output of the multi-phase VR using a rotating single phase operation testing mode. Individual phase current sense calibration may also be additionally or alternatively completed while the VR is operating under the rotating single phase operation mode.