438 lines
23 KiB
TeX
438 lines
23 KiB
TeX
%! TEX root = ../thesis.tex
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\chapter{Experiments}
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Now that the theoretical model is complete, experiments can be done to start checking that model.
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The results of these experiments are usable for either voltage or current measurements.
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\section{Experimental Setup}
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The first setup was used during the calibration phase, while the second setup was used for creating the regulation model.
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\subsection{Calibration Setup}
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To now calibrate a PowerIt a setup is required that can sweep the input voltage, as well as draw different currents from the PowerIt (see \autoref{fig:expsetup1}).
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For that a setup with a bench power supply an electronic load and an external voltmeter are used.
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Additionally a STM32-Discovery board and a RaspberryPi microcomputer were connected to flash new firmware onto the PowerIt.
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\begin{figure}[H]
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\centering
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\includegraphics[width=.35\columnwidth]{./pics/setup_ps_el_mm.jpg}
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\includegraphics[width=.45\columnwidth]{./pics/poweritv1_test_setup_corr.jpg}
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\caption{%
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Photographs of the first experimental setup.
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On the left side visible are a Keithley K2100 voltmeter (top), a Elektro-Automatik PS8080 bench power supply (middle) and EL9080 electronic load (bottom).
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On the right side visible are a PowerIt with connected STM32-Discovery board (left), and Raspberry PI (top).
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Also in the picture is the power supply connection (cables at top of PowerIt).%
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}%
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\label{fig:expsetup1}
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\end{figure}
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To now calibrate the board the bench supply could be controlled, to sweep through a voltage range, or in a similar fashion the electronic load could sweep through different current draw scenarios.
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\subsection{Power Wafer Setup}
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To obtain the required measurements for creating a regulation model the second setup was used (\autoref{fig:expsetup2}).
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These required measurements are the calculation of I\(_\text{ret}\), R\(_0\) and R\(_1\) of \autoref{eq:vout2}.
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\begin{figure}[H]
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\centering
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\includegraphics[height=.55\columnwidth]{tikz/setup2.pdf}
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\hspace{1.5cm}
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\includegraphics[height=.53\columnwidth]{pics/setup_pw_back_2.png}
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\caption{%
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Photographs of the second experimental setup.
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In this setup the Wafer system assembly was used.
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This module has a height and length of 50cm and a width of 15cm.
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The left side shows the back side of the assembly.
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Here are the PowerIt (1), CURE (3) and AnaB (2) boards mounted, as well as a RaspberryPi (4) and a STM32-Discovery (5).
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The right side shows the empty front side of the MainPCB and the wafer heat sink.%
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}%
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\label{fig:expsetup2}
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\end{figure}
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This setup is similar to a BrainScaleS wafer module as it exists inside the system.
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But in contrast to these systems there are no FPGAs, AuxPwr or FCP boards (reference~\cite{waferembedding},fig 2.2).
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The MainPCB has the PowerWafer attached and is also connected to 8 CURE boards, 2 AnaBs and a PowerIt.
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\section{Characterization}
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The first experiments to run are the characterization of hardware behavior.
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These will then result in a PowerIt calibration, which later then can be used as basis for creating a regulation method.
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For the complete calibration process the calibration setup was used.
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\subsection{Sampling Time}
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First up was selecting an optimal sample tick number.
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The sample ticks are the cycles for which an adc will probe a pin.
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In this case the uncalibrated measurement of input voltage was taken as example, and repeated with each of the possible 8 settings.
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In addition a voltage measurement was taken with an external voltmeter\footnote{Keithley 2100}. The voltameter was connected to the \SI{48}{\volt} input voltage terminal.
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The difference from the supplied Voltage, set with the external power supply\footnote{} was then calculated.
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In \autoref{sampleticks1} these calculated values are plotted.
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\begin{figure}
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\centering
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\hspace*{-.175\columnwidth}
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\includegraphics[width=1.3\columnwidth]{./data/m04_cycledepends/cycledepends_20180529.pdf}
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\caption{Top: input difference from set voltage vs set voltage for different possible scaler values.
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Bottom: gain error of the linear fitted curves vs set scaler value (May 29th 2018, $\approx$32\si\degree C)}%
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\label{sampleticks1}
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\end{figure}
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The in \autoref{sampleticks1} contained absolute error of the voltmeter is not 0 but signifficantly different from the power supply voltage.
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Therefore from here on the reference voltages were taken with the external voltmeter, if possible.
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This avoids added uncertainty introduced by the power supply.
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Also shown are the calculated gain errors, in case of all 8 settings.
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Important to note is the relative error in only one case not usable.
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Here the \verb|cycleTime|-Setting was set to 0 and therefore the smallest available sampling time of 3 Ticks was chosen.
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This result excludes 0 as a possible value to use.
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All other measurements are within error margin of each other, and because a smaller time frame is preferred, the best value to use is 1.
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This results in a sample time of 15 Ticks or \SI{77}{\nano\second} per pin.
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% TODO: move to appendix
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%\begin{figure}[H]
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% \centering
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% \hspace*{-.175\columnwidth}
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% \includegraphics[width=1.3\columnwidth]{./data/m04_cycledepends/cycledepends_20180530.pdf}
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% \caption{plotted difference from set input voltage, and fitted linearly, May 30th 2018, $\approx$25\si\degree C}
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% \label{sampleticks2}
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%\end{figure}
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\subsection{Voltages}
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Now that a sample time is chosen, it is possible to proceed with the voltage calibration measurements.
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Note, that measurements can be less accurate, the more components are contained in their respective measurement circuit.
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The reason for that is, that small errors can accumulate and in e.g. the case of 48V's be amplified by a factor of 8.
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\subsubsection{48V Input}
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In this setup the voltmeter is connected to positive and negative input voltage terminal.
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When looking at calibrating the input voltage (\autoref{v48_precalib}), we can clearly see a relatively constant offset of $\approx$1V.
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This is most likely the result of a offset voltage introduced behind the secondary amplifier.
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In \autoref{v48_precalib} a polynomial fit of 2nd degree\footnote{A Fit of second degree will be used in the complete calibration process} is done and its coefficients extracted (\autoref{pitdb}, line 9).
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These coefficients not only show an offset, but also some deviation in the incline and curve from the default values.
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\begin{figure}[H]
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\centering
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\vspace{-1cm}
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\hspace*{-.16\columnwidth}
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\includegraphics[width=1.3\columnwidth]{../pitstop/20180824/calib_v48.pdf}
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\vspace{-1cm}
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\caption{
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Calibration of \SI{48}{\volt} input voltage.
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Plotted are measured and reference vs the calculated vin voltage.
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The Calibration sweeps from \SIrange{43.2}{52.8}{\volt}.
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The fit is of second degree and its inverse are the to use calibration coefficients.
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(fit:{\(
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\pyval{poly48v2}V_\text{IN}^2+\pyval{poly48v1}V_\text{IN}+\pyval{poly48v0}=V_\text{MONITOR\_48V}
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\)})}%
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\label{v48_precalib}
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\end{figure}
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\subsubsection{9.6V Output}
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For this setup the voltmeter was connected to a PowerIt \verb|GND| and \verb|10V| pad.
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The 9.6V Calibration, shows a slight difference between internal values and the reference measurement.
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This results in a list of coefficients (\autoref{pitdb}, line 7), very similar to those set in the theoretical defaults (\autoref{pitdb-example}).
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\begin{figure}[H]
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\centering
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\vspace{-1cm}
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\hspace*{-.16\columnwidth}
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\includegraphics[width=1.3\columnwidth]{../pitstop/20180824/calib_v10.pdf}
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\vspace{-1cm}
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\caption{%
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Calibration of \SI{9.6}{\volt} input voltage.
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Plotted are measured and reference vs the calculated vin voltage.
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The Calibration sweeps from \SIrange{43.2}{52.8}{\volt}, and the supply modules divide that into \SIrange{8.64}{10.56}{\volt}.
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The fit is of second degree and its inverse are the to use calibration coefficients.
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(fit:{\(
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\pyval{poly10v2}V_\text{10V}^2+\pyval{poly10v1}V_\text{10V}+\pyval{poly1v0}=V_\text{MONITOR\_10V}
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\)})}%
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\label{v10_precalib}
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\end{figure}
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This small difference is explained by the simple voltage division used as our circuitry, and no amplification, as for the input voltage circuit.
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\subsubsection{1.8V Output}
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The last voltage to calibrate is divided into two domains, one for supplying the analog, and one for the digital side of the wafer circuitry.
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Each deliver between \SI{1.549}{\volt} and \SI{2.022}{\volt} and both are settable by their respective circuit (both as in \autoref{fig:gen18v}).
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And for each measurement the voltmeter was either connected to POwerIt \verb|GND| and \verb|1.8V analog| or \verb|1.8V digital| pins.
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\begin{figure}[H]
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\centering
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\vspace{-1cm}
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\hspace*{-.15\columnwidth}
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\includegraphics[width=1.3\columnwidth]{./data/m03_poticalib/adccalib_02.pdf}
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\caption{Calibration: analog 1.8V Output voltage, plotted are external measurement and internal values vs set resistance R\(_S\)at the voltage module.}%
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\label{fig:v18_precalib}
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\end{figure}
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Visualized in \autoref{fig:v18_precalib} is the analog domains calibration, showing nearly no difference in board and reference measurements. Mostly due to direct connection between created voltage and the STM-Chips pin.
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\subsection{Currents}
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With now calibrated Voltages, the next step is to measure the behavior of the current measuring circuits.
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Note that the 9.6V Output does in fact not have a include circuit for measuring its current draw, and that this number will be obtainable from all other (calibrated) measurements.
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\subsubsection{48V Input}
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This experiment will calibrate the 48V input current.
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The setup consists of connecting the electric load to \verb|GND| and \verb|10V| pins.
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In it the current drawn by the PowerIt sweeps over a range from \SIrange{0}{20}{\ampere}.
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In \autoref{fig:calib48i} quite a gap between observed and measured values can be seen.
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This is most likely a gain error, which would result in a error in \(m_2\), as observed.
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And the fitted curve has the following parameters:
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\begin{align}
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V_\text{MONITOR\_48I} =&~m_0 + m_1\cdot I_\text{IN} + m_2\cdot I_\text{IN}^2\\
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m_0 =&~\pyval{poly48i0}\nonumber\\
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m_1 =&~\pyval{poly48i1}\nonumber\\
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m_2 =&~\pyval{poly48i2}\nonumber
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\end{align}
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from which the inverse will used for calibration inside the PowerIt.
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\begin{figure}[H]
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\centering
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\vspace{-1cm}
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\hspace*{-.16\columnwidth}
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\includegraphics[width=1.3\columnwidth]{../pitstop/20180824/calib_i48.pdf}
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\vspace{-1cm}
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\caption{%
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Calibration of \SI{48}{\volt} input current.
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Plotted are measured and reference current vs the calculated pin voltage.
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The Calibration sweeps over \SIrange{0}{20}{\ampere}.
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The fit is of second degree and its inverse are the to use calibration coefficients.
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}%
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\label{fig:calib48i}
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\end{figure}
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\subsubsection{1.8V Output}
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For the calibration experiment of both 1.8V output currents, the current draw ranged from \SIrange{0}{90}{\ampere}.
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The electric load was connected to a \verb|GND| and \verb|1.8V analog| or \verb|1.8V digital|pin depending on the measurement.
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Observed were the values in \autoref{precalib18i}.
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Visible is a different incline of internal measurement and reference.
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\begin{figure}[H]
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\centering
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\vspace{-1cm}
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\hspace*{-.165\columnwidth}
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\includegraphics[width=1.3\columnwidth]{../pitstop/20180824/calib_i18.pdf}
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\vspace{-1cm}
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\caption{%
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Calibration of \SI{1.8}{\volt} output current for both digital and analog.
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Plotted are measured and reference current vs the calculated pin voltage.
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The Calibration sweeps over \SIrange{0}{90}{\ampere}.
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The fits are of second degree and their inverse are the to use calibration coefficients.
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}%
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\label{precalib18i}
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\end{figure}
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The fitted curve for the analog side were:
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\begin{align}
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V_\text{MONITOR\_1I8\_ANA} =&~m_0 + m_1 \cdot I_\text{1.8V, ana} + m_2 \cdot I_\text{1.8V, ana}^2\\
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m_0 =&~\pyval{poly18iana0}\nonumber\\
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m_1 =&~\pyval{poly18iana1}\nonumber\\
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m_2 =&~\pyval{poly18iana2}\nonumber
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\end{align}
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, while the digital side had quite similar values of:
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\begin{align}
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V_\text{MONITOR\_1I8\_DIGI} =&~m_0 + m_1 \cdot I_\text{1.8V, digi} + m_2 \cdot I_\text{1.8V, digi}^2\\
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m_0 =&~\pyval{poly18idigi0}\nonumber\\
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m_1 =&~\pyval{poly18idigi1}\nonumber\\
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m_2 =&~\pyval{poly18idigi2}\nonumber
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\end{align}
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This also show, that both parts are so similar in behavior, that a single sides observations would have sufficed.
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\section{1.8V Regulation}
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As Described beforehand the Output Voltages for both analog and digital can be adjusted to some degree and therefore we can compensate for the dropoff occurring between PowerIt Output Terminals and Reticles.
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The following experiments were run unsing the Power Wafer setup.
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To run any test with the PowerWafer, the patterns in \autoref{fig:wpattern} were used.
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There are two reasons for that, firstly these patterns distribute the current draw in a regular fashion as to distribute the load between the connectors.
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Secondly, when powering Reticles all of the energy is converted into heat, via the ohmic resistors.
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\begin{figure}[H]
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\centering
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\includegraphics[width=\columnwidth]{./data/theory/wpattern.pdf}
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\caption{Used regular patterns for current tests on PowerWafer}%
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\label{fig:wpattern}
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\end{figure}
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And although the copper heat sink and fans (see \autoref{fig:expsetup2}), should be able to handle this heat in a HICAN wafer system, when grouping together reticles and powering them, the dissipation does not suffice.
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This is the case, because the Power Wafer is drawing more current per reticle than a HICANN wafer would during an experiment.
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The internal temperature probes (between heat sink and wafer) register well above \SI{50}{\celsius}, when grouping 3 or more reticles.
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\subsection{Characterization of Dropoff}
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Wanting to observe and characterize the voltage drop, first the connections between PowerIt and Reticles can be measured with the in \autoref{fig:retmodel} described connections, which in actuality are the PowerIT Terminal and corresponding analog readout pin on a Analog readout board.
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To use the PowerWafer for testing one of the patterns in \autoref{fig:wpattern} will be used, each pattern has a approximate current draw of 120A and will distribute heat and draw per terminal evenly.
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In \autoref{1v8dip} a single reticles (\#40) voltage drop for different Current Draws is visualized.
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A relatively linear trend and residuals of a trigonometric behavior can be observed (most likely the result of the inaccurately measurable current draw, which here is done inside the PowerIt).
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\begin{figure}[H]
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\centering
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\vspace*{-1.5cm}
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\hspace*{-.16\columnwidth}
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\includegraphics[width=1.3\columnwidth]{../pitstop/20180824/ret_vdip.pdf}
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\vspace{-1cm}
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\caption{Voltage drop observed between PowerIt and HICANN, each point represents a state after enabling additional Reticles on the PowerWafer (right upper wafer in \autoref{fig:wpattern})}
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\label{1v8dip}
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\end{figure}
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Here a Voltage Drop vs. Current draw of the wafer shows a linear behavior and therefore can be regulated on basis of the current measurement done by on board Measurement circuit.
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\subsection{Numerical-Correction (Regulation)}
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The initial idea, to approach the correction of this dropoff is a Numerical: the SWRM (\autoref{sec:swrm}) and its corresponding Equations can be applied here.
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\autoref{eq:fullreg}, which maps the measured output current to a corresponding potentiometer setting, requires the Dropoff to be linear, which was observed.
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To apply this approach, two assumptions need to be made:
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\begin{itemize}
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\item all reticles have the same current draw (already not accurate, see \autoref{1v8dip})
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\item all reticles experience the same voltage drop (as observed for reticle 40)
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\end{itemize}
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and the following four values are required, before a regulation can be attempted:
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\begin{itemize}
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\item \(I_{ret}\), the current draw of a single reticle,
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\item \(R_0\), the resistance between PowerIt and FET,
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\item \(R_1\), the resistance of a single Reticle
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\item \(V_{off}\), the wanted Voltage at a Reticle
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\end{itemize}
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To get a representative value of \(I_{ret}\) for use in the SWRM, the mean current draw per reticle was taken (\autoref{fig:ihist}):
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\begin{align}
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\pyval{iretmeancorr}\label{eq:iretmeancorr}
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\end{align}
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\begin{figure}[H]
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\centering
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\vspace{-1cm}
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\hspace*{-.15\columnwidth}
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\includegraphics[width=1.3\columnwidth]{../pitstop/20180828/reticle_ihist.pdf}
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\caption{Distribution of analog current draw for all reticles on the PowerWafer (which were possible to measure)}%
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\label{fig:ihist}
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\end{figure}
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The \autoref{fig:ihist} was obtained by measuring the increase in current draw for each reticle, for each of the 4 patterns (\autoref{fig:wpattern}).\\\\
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To obtain \(R_0\), the pattern in \autoref{fig:wafer-ret5} was used to take measurements for both the neighborhood as well as the farthest reticles.
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\begin{figure}[H]
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\centering
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\hspace*{.1\columnwidth}
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\includegraphics[width=.6\columnwidth]{../pitstop/processing/neighborhoood_5.pdf}
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\vspace{-1cm}
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\caption{Reticles used to determine correlation between distance and Voltage Drop}%
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\label{fig:wafer-ret5}
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\end{figure}
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\begin{figure}[H]
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\centering
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\vspace*{-1cm}
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\hspace*{-.15\columnwidth}
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\includegraphics[width=1.3\columnwidth]{../pitstop/20180828/reticle_corr}
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\caption{Voltage drop vs current for both Reticles in direct neighborhood and farthest possible Reticles}%
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\label{fig:ret5corr}
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\end{figure}
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From \autoref{fig:ret5corr} it is possible to see that the distance between reticles that are used gives different behavior of the voltage drop. Both Inclines happen to be the extreme cases, while either being completely uncorrelated, the case for farthest Reticles, or being directly correlated by their distance, here observable for the neighboring Reticles.
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Therefore we obtain two values for \(R_0\):
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\begin{align}
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\pyval{r0_from_neighbor}\nonumber\\
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\pyval{r0_from_farthest}\label{eq:r0}
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\end{align}
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from the same measurement it is also possible to extract \(R_1\) by extrapolating to 0, which results in:
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\begin{align}
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\pyval{r1_from_neighbor}\nonumber\\
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\pyval{r1_from_farthest}\label{eq:r1}
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\end{align}
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here the values obtained are within error margin of each other.
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So applying these Values, the following behavior for regulation can be visualized:
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\begin{figure}[H]
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\centering
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\hspace*{-.16\columnwidth}
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\includegraphics[width=1.3\columnwidth]{./data/theory/reg.pdf}
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\caption{Possible \(P_{val}\) curves after SWRM, dotted lines represent not achievable values. This plot is generated from the obtained SWRM parameters, leaving only V\(_\text{off}\) to vary.}%
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\label{fig:regswrm}
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\end{figure}
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The in \autoref{fig:regswrm} visualized values show the theoretical \(P_{val}\) for the corresponding current.
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All of the dotted parts depict with this setup unachieveble values.
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This reaults in the PowerIts inability to correct for any change in current above a certain threshold.
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In the domain above this threshold the resulting voltage would behave the same as before regulation.
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Note that the 1.8V regulation, should fail at about 80A of current draw.
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Now voltage drop per reticle, in a single reticle power state, was observed:
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\begin{figure}[H]
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\centering
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\vspace*{-1cm}
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\hspace*{-.15\columnwidth}
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\includegraphics[width=1.3\columnwidth]{../pitstop/20180828/reticle_vdiphist.pdf}
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\caption{Initially observed voltage drop, red values are ignored for corrected mean}%
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\label{fig:vdiphist}
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\end{figure}
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The histogram in \autoref{fig:vdiphist} has amean of
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\begin{align}
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\pyval{vdipmeancorr}
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\end{align}
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\autoref{fig:wrdist} shows how those Voltages are Distributed over the complete PowerWafer.
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All white Reticles are not measurable, either because they were not functional or could not be read.
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The occurances marked in red in \autoref{fig:vdiphist} are reticles \#11, \#20 and \#28, which were outliers and are excluded in the calculation of corrected values.
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This results in a distribution, which when combined with the spread of \(R_0\) from \autoref{fig:ret5corr}, gives an approximate range for all reticles voltage drop at a given current draw (\autoref{fig:vrange}).
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To be able to obtain the through AnaB pins measured voltages it should also be possible to use the CUREs voltage readout.
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The voltages obtained from these boards, should be comparable.
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THe reason for that is that we can assume a constand R\(_1\) for all reticles.
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In \autoref{fig:vcure40} these voltages are visualized, in comparison to the AnaB voltages.
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\begin{figure}[H]
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\centering
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\vspace{-1cm}
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\includegraphics[width=.7\columnwidth]{../pitstop/20180828/reticel_rdist.pdf}
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\vspace{-.5cm}
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\caption{\(V_\text{drop}\) distribution over full Power Wafer; White have no measurement; Red an Orange are marked red in \autoref{fig:vdiphist}}%
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\label{fig:wrdist}
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\end{figure}
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\begin{figure}[H]
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\centering
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\vspace{-1cm}
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\includegraphics[width=.9\columnwidth]{../pitstop/20180828/reticle_vcure.pdf}
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\vspace{-.7cm}
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\caption{%
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Comparison of AnaB and CURE measured voltage drop.
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Colors indicate their respective relative values for each measurement.
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White reticles have no measurement.
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}%
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\label{fig:vcure40}
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\end{figure}
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This comparison shows no discernable relation between both measurements.
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The reason for this is most likely a problem in the assumption, that R\(_1\) is the same for all reticles, which would result in a voltage difference that is constant.
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Additionally the distribution of CURE voltages would look similar to the AnaB measurement. |