The Hidden Risks of Multi-Vendor Integration
However, problems can arise when system modules are procured from different sources, even if they are reputable. Products are characterized in their data sheets under specific conditions that often differ from one manufacturer to another. Temperature rating is a prime example—some parts are characterized by a maximum hot-spot temperature on their case, while others limit ambient temperature measured at an arbitrary distance from the converter. Similarly, the orientation of converters during derating characterization can vary, with some measured on a horizontal PCB and others with the PCB positioned vertically.
EMC performance can also be problematic, as suppliers are forced to assume external conditions—such as supply impedance—when measuring conducted and radiated emissions. Converters can also interact with each other through magnetic or electrical noise coupling along connections, which varies depending on product orientation. Furthermore, on-board filters that make an individual part compliant with an EMI specification on paper can combine with filters in other products to actually worsen overall EMI. This is typically due to unintended resonances and consequent voltage peaking.
A particularly insidious interaction occurs when a regulated switched-mode converter is fed directly from the output of another. Assuming constant efficiency and output load, the input power to a regulated switching converter remains constant; thus, if the input voltage increases, the current decreases, creating a negative resistance effect.
An upstream regulated converter is typically characterized for standard positive resistive and capacitive loads, meaning it can easily become unstable when subjected to this negative resistance. Similarly, a positive voltage transient from the upstream converter will cause a decreasing current in the downstream converter. This can trigger the control loop of the first converter to push the voltage even higher, amplifying the original effect to potentially damaging levels.