AEi Systems | WCCA Training

2 Day Worst Case Circuit Analysis Workshop

November 13th & 14th, 2008 Los Angeles, CA

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Class Syllabus (PDF)

Benefits
This course provides the perfect opportunity to learn about worst case circuit analysis, its methods and its processes. The course also emphasizes the product reliability improvements that are possible when WCCA is combined with MTBF, FMECA, and Stress and Derating analyses.

The course is designed to provide the participant with the fundamental skills and knowledge required to perform a Worst Case Circuit Analysis (WCCA or WCA). Participants learn the importance of this analysis and the different methods which can be utilized. The proper documentation format for communicating the analysis results is introduced with detailed and complete examples allowing the participant to gain a full understanding. In-depth tolerance studies and their evaluation are presented for most common electronic components.

The “WCCA Savvy Workshop” is taught personally by Steve Sandler, renowned WCCA expert and founder of Analytical Engineering.

This two day seminar is beneficial for both the novice wanting to learn worst case analysis concepts, as well as the engineering manager looking for an update on this vital technology.

Each class is specially tailored to the individuals and the disciplines (power, RF, IC) chosen by the students attending the particular seminar. Circuit examples, issues, and documentation techniques will be used that address the specific problems and pitfalls that the students are encountering in their daily jobs.

Upon completion, participants will be able to:
1. Learn the importance of why we perform a worst case analysis.
2. Learn the methods used in performing the analysis, and when to use each method.
3. Learn the proper documentation methods.
4. Learn to deal with poorly defined tolerances.

Materials and Time Frame

WCCA Workshop Handouts Book (230+ Slides and Notes pages)

WCCA Workshop Examples Book (260+ pages) including a full WCCA for a typical DC-DC Converter

Additional Applicable Articles and Source Materials

Breakfast, Lunch and Refreshments

Two Days, 8 Hours a day

Course Background
The “WCCA Savvy” workshop has been taught at major corporations across the USA including Motorola, DELL, Canadian Space Agency, Raytheon, and General Dynamics. The AEi instructors are experienced at teaching worst case analysis to engineers with all levels of engineering background.

Topics To Be Covered

Introduction to Worst Case Circuit Analysis

WCCA Structures, Templates, and Methodologies

Component Tolerances and Design Concerns

Analog, Digital, and RF WCCA Guidelines

Knowing what to analyze and how to analyze it

Documentation and Essential Formats

Reviewing a WCCA

Analysis Tools and Techniques

Selected Examples

Detailed Course Outline
DAY 1
1. Introduction to worst case analysis

What is a Worst Case Circuit Analysis?

Why do we do it?

When do we do it?

To what extent do we do it?

Who should perform it/Review it?

Why is it so important to validate it?

WCCA as Failure Analysis

Cost of doing or not doing a worst case analysis

Electrical test as an alternative: reasons, methods and limits

2. WCCA Methodologies

Methods of analysis
      Sensitivity
      EVA and RSS Computations
      Monte Carlo Analysis

Comparison of methods and templates

Tolerance Database Setup

Determining Critical Parameters

Dealing with Poorly Defined Tolerances

Computing EVA-RSS Results
Example: Three Terminal Regulators
Accounting for SAT’s

Correlating Hardware-WCCA Results

3. Part tolerances / Design Concerns

Tolerance Database Structures

Calculating Tolerances

Radiation and Aging Tolerances

Mean Shifts

Tolerances for Resistors, Capacitors,

Diodes, Zeners, BJTs, Mosfets,

Magnetics, Digital IC’s, Analog IC’s

Low Beta (hFE) Analysis

4. Selected Examples

Oscillators

Switching Frequency Analyses

Control Loop Stability

Signal Integrity/IBIS Simulation

Gate Drive

Regulation and Ripple

DAY 2
5. Analysis Task Compilation

What to Analyze

Determining Critical Parameters

WCCA Task Description Pitfalls

Handling Compliance Requirements

6. Documentation

Why is documentation important?

Formating a report

What must be included in a report?

Example: Report

Document and File Storage

Reviewing a WCCA

Dealing with Design Changes

Dealing with Non-Compliances

7. Analysis Tools

Digital, Analog, RF

MathCAD and the Benefits of Mathematical Computations

SPICE Simulation Pitfalls

SPICE Modeling
      Reviewing Vendor libraries
      Modeling Pitfalls
      Diodes and Zener Modeling
      Subcircuit Model Examples

Solving Convergence Problems

8. Selected Worst Case Circuit Analysis Examples

CLR79 capacitor model

LM193 Oscillator Analysis

Mixed Mode Example

LDO and Three Terminal Regulator Example

Mosfet Voltage Regulator

Conducted Susceptibility/Emissions

Current Limit and Overvoltage

Transient Response

Inrush, Turn-On Monte Carlos

9. Extended Topics

State Space “Average” Modeling

MTBF: Parts Count vs. Stress-Based

FMEA, FMECA and Fault Simulation

Stress and Derating Analysis Guidelines

Radiation Analysis: Single Event Effect, TID, Neutron Fluence, SEU, SET, SEL, SEGR, SEB

Course Instructor: Steve Sandler, Founder and Principal Engineer
Mr. Sandler has over 20 years experience in the design and analysis of power conversion equipment for military and space applications. In his current position Mr. Sandler is responsible for the design, worst case analysis, reliability analysis, and FMECA analysis of satellite & power electronic systems. Past projects include: Milstar II Defense Satellite, International Space Station, GMI, MUOS, CMIS, Tempo, P-81, HS-702, ICO, LS-1300, Mabuhaysat, Globalstar, Omegasat, NSTAR and many others.

Mr. Sandler also personally designed and directed the development efforts behind AEi’s own line of space, military and commercial DC to DC converters, and developed a comprehensive power IC model library for SPICE simulators.

Mr. Sandler is author of several books and numerous articles on power supply modeling and simulation including, “Switchmode Power Supply Simulation with PSpice”, and “The SPICE Handbook of 50 Basic Circuits”. From 1985 – 1995 Mr. Sandler worked for ST Keltec Corp. Space Power Group as an application engineer and sales and product manager. Before 1985, Mr. Sandler held positions with Telephonics Corp. Signal Technology, Aerospace Avionics Inc., and Lambda Electronics.