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Abstract
The pervasivcocssof autumolivcpassiverestraint systems has emphasizedthe need for improvingsystem reliabilitywhile simu|lancously
reducing the cost and size of the system. This paper describes the integratedsiliconautumotiveaccelerometer (ISAAC). which consistsof a
silicon micromachieeddie fabricated in a dissolved-waferprocess arida CMOS ASICt[,at are combined in a standard plastic I~:kage. The
resullant device meets the functional,cost, and reliability~quimmentsof the next generationof automotivepassiverest~int systems.
0924-424"//96/$15.00~ 1996ElsevierS¢ienc~S.A.Allfightsreserved
$SD10924-4247( 95)01 !93.0
524 L.C. Soangler. CJ. Kemp~SensorsandActuators A 54 fl996) 523 529
3. Sense-element die
CA and Ca. As shown, this capacllive output is a nonlinear nOt pose a problem, since crash acceleration signals are very
function of acceleration. The interface circuit linearizes the 'busy'.
response by implementing the functioo shown in Fig. 6(b). An open-loop architecture is used because of its inherent
The quantity Fc is defined as (CA-- CB)/( CA + Ca ). simplicity. Although closed-loop (force-balanced) acceler-
Dimensioning of the air gaps, torsion beams and damping ometers are capable of higber performance in some areas, the
holes ereates a mechanical microstruclure that is overdampcd, simpler (and hence more cost etfeetive) open-loop approach
thus providing an antialias filter for the sampled-data inter- is sufficient for passive restraint systems. As previously men-
face circuit. The - 3 dB frequency response is typically 400 tioned, the mechanical frequency response of the sense ele-
Hz at room temperature, while the resonance frequency of ment itself, which is embedded in the first stage of the
the micromechanical structure is 2.7 kHz. modulator, provides antialias filtering for the sampled-data
circuit. Additional liltering of the acceleration wave form can
be performed digitally, downstream from the sensor.
4. Interface circuit The compensation lor sense-element offset and sensitivity
variations (calibration) is accomplished by the circuitry to
The interface circuit is fabricated in a 1.6 t~m CMOS proc- the left of nodes A and B in Fig. 7. A pair of calibration codes,
ess with EEPROM. The primary function of this circuit is to V~ and V=, is determined for a particular sensm during a
convert the femtofarad-level capacitance signals from the calibration operation and stored in EEPROM. These codes
sense element to a pulse signal suitable for digital signal determine the values of four voltages which are applied by
processing [31. The chip also provides compensation For the DAC to nodes A and B as described below.
sensor offset and sensitivity variations while providing the The circuit is continuously clocked between two clock
self-test and reset function. Design considerations for the phases, unity (U) and integrate (1). The positions of the
circuit include stabi lily over voltage, temperature and process various switches during each clock phase are shown in i:ig. 7,
variations, with low power and low cost also being primary The position of the switch on the far left is controlled by the
factors. polarity of the OUT signal. The V~ and V2 calibration codes
The circuit architecture of the signal path is shown in Fig. 7 contain the same number of bits. This number of bits ulti-
along with the required timing signals. The circuit consists mately determines the resolutions oftbe offset and sensitivity
of a first-order "charge-mode' delta-sigma modulator with calibrations.
built-in calibration capability. Delta-sigma modulators have The function of the 'code mirror circuit' requires some
become very popular in sensor applications because sensor explanation prior to a description of the operation of the
signals generally have low bandwidths, allowing a simple complete circuit. If (for example) OUT is low during the
low-order modulator to achieve good resolution through a integrate ph; the V~ code is applied to the DAC (as the
high oversampling ratio. Also, since precise component circuit, ows), causing the voltage V~ to be generated at the
matching is not required, circuit performance is affected very DAC output. During the U phase, however, the code mirror
httle by temperature changes or by component value aging. circuit modifies the Vj code such that, when this modified
The delta-sigma modulator delivers a digital (pulse-density- code is applied to the DAC, the voltage V~M= (2VM-- Vi ) is
modulated) output signal which can be fed directly to a generated at the DAC output. The 'minor voltage' Vr~ is a
microprocessor or hardware DSP circuit for digital signal specific fixed reference voltage, The above equation implies
processing. In passive restraint applications, pattern noise (Vt - VM) = (VM-- V~M), SO a voltage VIM has been gener-
from first-order deha-sigma moduir,tton of d,c. inputs does ated which is either as many volts below 1/u as VI is above
sense element
t :
.,o. t {
Clm-
u A I [ - - I I..... (UNITY)
TIMING:
i ] I I [ - - L .... t t ~ r e ~ r E i
VM,or as many volts above Vr,t as V~ is below VM. Similarly, I phase, for both values of OUT. Note that VI and Vz• are
if the code V2 is applied to the code mirror circuit, the mod- symmetrically located about mirror voltage Vr~,as are 1,,'2and
ified code will produce the voltage VZM= (2VM-- V2) at the V2M,as dictated by the code ntirror circuit.
DAC output. In the actual circuit implemention, the code The fractional output pulse density (FPD) of the circuit is
mirror circuit and the DAC are combined using a modified defined as the number of clock periods per second having a
nine-bit resistor-string DAC. high OUT value, divided by the clock frequency. It is deter-
The operation of the complete circuit can be understood mined from the ratio of the Vo changes as follows:
by investigating the sequence ofevants that occurs during the
two phases of a given clock cycle. It should he noted that 1
FPD (3)
OUT is latched either high or low during both phases of a F~Volour~,l
clock cycle, depending on the eomparator output at the end '-l~l
(falling I edge) of the previous clock cycle.
Inserting Eqs. ( 1) and (2) intoEq. 13), esing the cede mirror
Starting with the U phase, assume that OUT is latched low.
conslraints VIM= (2VM -- VI ) and V2M= (2VM - V2), and
The V~ code is passed through the VtlV2 switch (on the far
manipulating leads to
left in Fig. 7 ) and routed through the code mirror circuit. The
DAC places voltage VIM on node A, while reference voltage FPD [ t + ( V , + V ~ ) / 2 - V M ~
Vn is placed on node B. Since acceleration-induced capaci-
tance changes occur very slowly compared to the clock
period, the values of CAand Ca are essentially constant during + ¢ V n - VM)~CA-Cs~ (4)
this or any clock cycle. ~ V,--V2P,CA + CBI
During the I phase, the V~code is fed directly to the DAC, Thus the fractional pulse density is expressed in the form
which places voltage V~on node B. Thus the voltage change
at node B from the U phase to the I phase is ( Vt - VR). Since FPD = B ~- G( Fc) (5)
reference voltage Va is now placed on node A, the voltage where the sensitivity calibration term G and the offset cali-
change at node A is ( Va - VIM). The. above vnlt,_~echanges bration term B depend only on the calibration voltages I/I and
on nodes A and B cause a change in the integrator output V2, and the fixed voltages VMand Vn.Calibration of the sensor
voltage, Vo, of is accomplished by the precise adjustment of the voltages Vt
and V2. As desired, the output pulse density is a linear function
A Vol our:~. = CA(VR-- VIM) ~- CB(VI - VR) (1) of Fc, as described in Fig. 6.
G~ An interesting feature of the calibration approach used here
If Vo remains negative at the end of the integrate phase, then is that, iftbe integrator opamp's common-mode voltage VcM
OUT will continue to be latched Inw for the next clock period. is set equal to the mirror voltage VM, then the average elec-
If Vo is now positive, however, OUT will be latched high for trostatic force on the Ca side of the sense element's tilt plate
the next clock period. is equal to that on the Cu side. A natural consequence of
Assuming that OUT is high during the next clock period, placing voltages across the sensor capacitors is the electro-
the V2 code is now passed through the V J V , switch. The static attraction between the tilt plate and the raetallized
change in the integrator output voltage for a clock cycle regions on the substrate. These metallized regions are, of
having OUT high is similarly shown to be course, nodes A and B in the circuit diagram. The electrostatic
force is proportional to the square of the applied voltage. An
AVolou t = ~= CA( Vr-- V.,M) + CB(V~. - Vr) (2) imbalance in the average forces exerted on the CA and Ca
Gm sides will cause the sense element to tilt. If this imbalance is
constant, it can be calibrated out. If it is pulse-density depend-
Fig. 8 shows graphically the voltage level changes that occur ent, however, it will contribute to nonlinearity in the sensor
on nodes A and B as the circuit goes from the U phase to the
response. Since the code mirror circuit guarantees that the
magnitude of ( V I - V M ) is equal to the magnitude of
VR [ U I U ( VM- VIM), and that the magnitude of (Van- VM) is equal
to the magnitude of (VM -- V2), the electrostatic attruetion on
A B A[ £ the Ca side of the tilt plate is identical to that on the Ca side
V2M ! for all pulse densities, as long as the tilt plate is driven to the
u mirror voltage VM. Thus no lilt is electrostatically induced.
V1
I In addition to the delta-sigma modulator and calibration
VM
circuitry, the interface circuit contains a serial pedpharal
VIM
U interface (SPI) that allows the accelerometer tocorereunicate
V2 directly with a microprocessor. The SPI interface is used for
1
OUT=0 OUT= 1 two primary functions: to allow calibration values to be
Fig.8. Voltagetransitionson nodesA aad B of the della-sigmamodulator. loaded into the sensor and to allow a microprocessor to issue
528 L.C Spangler, C]. Kemp/Sensors and Actuators A 54 (1996) 523-529
5. Packaging
30 20 10 0 -10 -20 -30 -40 -50
The packaging technology for the ISAAC is driven by four Acceleration (g's)
primary considerations: ( I ) to facilitate the use of low-cost.
Fig, 10.Typicald.c, performanceofthe ISAAC.
reliable plastic IC assembly and molding processes for high-
volume manufacturing; (2) to provide support for standard
lead configurations and body size to simplify automated han- I llll I t l llilll
dling and placement on the passive restraint module substratc; A a I Illl~""-J,. I I I llltl
(3) the package must orient the die so that the axis of sensi- [ Ill ~ f r Illrl
tivity is parallel to the module mounting surface; and (4) the
package must isolate the die and bond wires from contami- --Q. ill I NI I Itlt
nation or mechanical stresses while providing electrical con- E I Ill I I~1111
nection between the die and the traces on the module I Ill I I I NII[
substrate. "~' I It1 t l lll\ll
The ISAAC uses a nine-pin package and due to the axis of 20 50 100 aGO 500 lk
sensitivity of the sense element, the package must orient the Frequency (Hz)
die perpendicular to the substrate. While :nitial ISAAC pro- Fig I I. Typicala.c. perfonrtanceof the ISAAC.
totypes were configured in ceramic side-braze siugle-in-line
packages (SIPs), current devices are packaged in an epoxy- while still meeting all performance criteria. The ISAAC typ-
based transfer molded package in a SIP configuration ically draws less than 1 mA of current over all conditions.
(Fig. 9). Conventional epoxy die attach and gold wire bond- The [SAAC requires a clock input that is ideally :.hated with
ing processes are used to assemble the accelerometer, m sur- the system microprocessor. Typical applications run an exter-
face-mount plastic package is currently under development. nal clock speed of 4 MHz. On-chip dividers generate the
clock signals required by the circuit.
The d.c. performance of the ISAAC is shown in Fig. 10
6. Results although the offset and gain are programmable ove a wide
range through the EEPROM. The offset of 100 Az and
Design parameters have been selected that allow the sensitivity of 3 kHz g i have temperature coefficients that
ISAAC to meet the performance specifications of a passive are less than 60 ppm °C- i calculated using the worst-case
restraint system, while providing a device that is inherently voltage and temperature conditions. The device has a linearity
insensitive to process variations. The device operates from a of better than 2%. Further improvements to these character-
5 V supply and can withstand a 5% variation in supply voltage istics are currently being pursued.
The a.c. response is shown in Fig. I l, which demonstrates
the overdamped nature of the microstrocture. As temperature
and voltage change over the operating range of the sensor,
the - 3 dB pointcac change l~yup to 20%. For aocelerometers
used in passive restraint sy,~tems, however, these changes in
frequency response are accer,table.
The ISAAC crash sensor :aleets all automotive reliability
specifications including sh(.+ck survivability, temperature
cycling, vibration endurance, life and retention testing, ESD,
and latch-up. Characterization testing for reliability has util-
ized a multitude of sequential stress tests including combi-
nations of drop testing, vibration endurance, cold and hot
bakes, autoclaves and temperature cycling. These are
intended primarily to evaluate the hermcticity of the wafer-
level cap on the sense element. The sense-element micro-
Fig.9 Photographof the iSAACin a nine-pinsing]e-in-linepackage structure has been oscillated at a level greater than full scale
L C Spangler+ CZ Kemp/Sensors andActuators A 54 (1996) 523-329 529
7. Condn~ons
Biographies
The aeeelerometer described in this paper incorporates sil- Leland "Chip" Spangler received his BSE, MSE and Ph.D.
icon micromachining, hermetic encapsulation, precision cir- degrees from the University of Michigan in 1982, 1984 a~d
cuitry, EEPROM calibration, and plastic packaging to 1988, respectively. His doctoral work involved a single-orys-
provide superior performance in the automotive environment. hal silicon on glass process for sensors and circuits. From
It has been designed for a specific set of system applications 1988 to 1989, Dr Spangler worked in the areas of m/cxoscn-
in a modular way, which promotes a wide range of product sors and fabrication processes, circuit design, computer and
families that can take advantage of continued technology network archituclore and associative memories. In 1989 I'm
improvement, enhanced manufacturability, and continued joined the staff of the Electronics Division of Ford Moxor
cost reduction. Company, where he worked on sensors for automotive appli-
cations including Hall, pressure and temparatmm sensors and
silicon valves and nozzles. Chip cunenfly works as a Prin-
ciple Engineer for Ford Microeloctronios, Inc., where he is
Acknowledgemen~ responsible for advanced product and system developmcnL
Chris Kemp received the B.S. and M.S. degrees in electri-
The authors would like to acknowledge the entire staff at cal engineering from the University of Cincinnati in 1971
Ford Microelectronics, Inc., who have worked tirelessly to and 1975, respectively, and has worked in the semiconductor
make this project successful. I n ad6,'tion, the guidance, vision, industry for over 22 years. Since 1987, he has been with Ford
and suppnrt provided through the Ford Automotive Compo- Micrcclectronics in Colorado Springs, CO, where be has
nents Division and other Ford Motor Company activities have designed analog and mixed-signal integrated circuits for a
been essential. The staff at Silicon Designs, luc. (Issaquah, wide variety of automotive applications. He is currently
WA, USA) are also to be recognized for their creativity and involved with the development of aecelerometers for auto-
assistance on this program. motive passive restraint systems.