Designing Automotive Components for Guaranteed Compliance with Electromagnetic Compatibility Requirements

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4 In Compliance May 2013 www.incompliancemag.com CONTENTS l May 2013Volume 4 Number 5

Designing Automotive 22 Components for Guaranteed Compliance with Electromagnetic Compatibility Requirements

Todd Hubing

DEPARTMENTS FEATURES

News in Compliance Heading to the EU? 6 32 Get Your EMC Compliance Passport Ready! The iNARTE Informer When a manufacturer is thinking of the 12 European Union (EU) as the next market for its electronic equipment, EMC compliance is one of the must-haves on the list of Mr. Static approvals. 16 Neutralization of Static Charges by Air Ions Ozgur Ozturk Part II: Experimental Results

Product Showcase Engineering Our Future: 43 38 A View of Changes Facing Engineers Part 3 43 Events Gregg Kervill

EMC Education 48 The View from the Chalkboard A Sunny Day in Tennessee 44 The new Volkswagen plant at Chattanooga: An example of environmental innovation Authors being put into practice with too little fanfare 50 was the inauguration of the Volkswagen Passat Assembly Plant in Chattanooga, Advertisers Tennessee 50 Mary Ann Kahl

www.incompliancemag.com May 2013 In Compliance 5 News in Compliance FCC News

FCC Touts 4 Year Record on Europe, where investments in wireless The Commission’s summary is available networks are unchanged. Importantly, in Compliance at incompliancemag.com/news/1305_01. Broadband Deployment the Commission notes that investments The Federal Communications in wireless broadband infrastructure Commission (FCC) has released a have also created more than 1.6 million News Commission Proposes jobs over the past six years. summary of its significant actions and Action to Improve 911 key developments over the past four years in expanding Americans’ access to In connection with fixed, high-speed Reliability broadband communications. broadband access, the Commission estimates that average fixed broadband In an effort to ensure the reliability of emergency communications during Released in March 2013, the summary speeds have nearly doubled since 2009, natural and manmade disasters, the highlights record investments in fixed with more than 80% of U.S. homes now Federal Communications Commission and mobile broadband infrastructure. having access to Internet speeds of at (FCC) has proposed rule changes that According to the Commission, nearly least 100 megabits per second (up from would facilitate the identification of $250 billion in private capital has just 20% of U.S. homes in 2009). By network outages and speed service been invested in wired and wireless comparison, the Commission says that restoration. broadband networks in the U.S. since networks capable of 30 megabits per 2009, outstripping private investment in second reach only 50% of households in any other sector of the U.S. economy. the European Union.

In an effort to ensure the reliability of emergency communications during natural and manmade disasters, the FCC has proposed rule changes that would facilitate the identification of network outages and speed service restoration.

This investment includes nearly $30 The release of the Commission’s In a Notice of Proposed Rulemaking billion in U.S. wireless networks in summary of its broadband issued in March 2013, the Commission 2012 (a 40% increase since 2009), and accomplishments corresponds with has proposed the adoption of key a projected investment of $35 billion the resignation of FCC Chairman recommendations for bolstering in 2013. The growth in U.S. investment Julius Genachowski, who championed emergency communications services rates in mobile broadband far surpass expanded broadband access as a key part made by its Public Safety and those in Asia, where investment has of the Commission’s agenda during his Homeland Security Bureau. The grown a meager 4% in four years, and in four year term. proposed changes would establish

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AR’sEMCsolutionsmakecomplicatedtestprocesseseasierandmoreaccurate.Everythingissimplified–calibration,testingprocesses,DUTtroubleshooting, andgenerationofreportsdirectlyintoconvenientformats,suchasMicrosoftWordorExcel. Theseproductsalsohaveexcellentspeed,featureamodulardesignapproachandallowtheirintegratedcomponentstobeusedinavarietyofautomotivetest standardssuchasISO,SAE,CISPR,andOEMrequirements.Theseproductshavetheflexibilitytohandleengineeringdevelopment,mitigationandtestingto numerousotherstandardssuchas:MIL-STD-461,RTCADO-160,CISPR,EN,ETSI,FCC,ICES,AS/NZS,andVCCI. TheDER2018,with140MHzinstantaneousbandwidth,istheOneReceiverthatcatchesshortdurationtransientdisturbances,andscansinseconds. Bystreamliningtesting,thisCISPR16compliantEMIreceiverwillchangethewayyouapproachtesting. AR’sAS4000radiatedimmunitysystemgivesyouaturnkeypackagetoperform susceptibilitytests,inoneself-containedunitupto40GHz. Ourstandardsystemscanalsobecustomizedtoincludetestingtobothradiatedandconductedimmunityandemissionsrequirements. TheConductedImmunity(CI)platformoffersflexibilitytoaddressanyBulkCurrentInjection(BCI)testmethod,aswellastheabilitytoaccesscomponents fromtheCIhousing,suchasthepowermeterandamplifier,touseinothertestapplications.WiththreeConductedImmunityTestSystemstochoosefrom,you shouldneveragainhavetoperformlaboriousmanualCItestproceduresorworryabouttheaccuracyoftheresults. ARsuppliesamultitudeofuniqueRFsolutionstosomeofthebest-knowncompaniesworldwide. Ourproductsarebackedbythestrongest, mostcomprehensivewarrantyintheindustry,andaglobalsupportnetworkthat’ssecondtonone. CallyourlocalARsalesassociateforademonstration. Tolearn more, visit www.arworld.us/totalEMC or call us at 215-723-8181. ISO 9001:2008 Certified

rf/microwave instrumentation Other ar divisions: modular rf • receiver systems • ar europe USA 215-723-8181. For an applications engineer,call 800-933-8181. In Europe, call ar United Kingdom +44 1908 282766 • ar France +33 147 917530 • ar Deutschland +49 69 53054310 • ar Benelux +31 172 423000 www.arworld.us Copyright © 2013 AR. The orange stripe on AR products is Reg. U.S. Pat. & TM. Off. News in Compliance FCC News

emergency communications network Company Pays $1 Million in Under its agreement with the FCC,

in Compliance reliability requirements, and modify Level 3 has agreed to cease its use of Connection with Rural Call certification and reporting rules to poor performing least-cost routers and ensure compliance. The FCC would Completion Failures to achieve long-distance call completion also implement compliance reviews and rates to rural areas within 5% of News Level 3 Communications of Broomfield, completion rates in non-rural areas over inspections to ensure that emergency CO has agreed to make a “voluntary a two-year period. Further, the company communications service providers are contribution” of nearly $1 million has agreed to report compliance with meeting requirements and adhering to to the U.S. Treasury to settle charges this 5% benchmark every quarter prescribed practices. that it failed to meet rigorous new call completion standards imposed by the beginning in January 2014, and to pay an additional $1 million voluntary The Bureau’s recommendations were Federal Communications Commission contribution if it fails to achieve the 5% the result of an extensive investigation (FCC). benchmark in any quarter. into emergency communications service failures that occurred following According to the FCC, the higher rate of rural call completion failures is As part of its own effort to reduce a major storm that hit portions of the rural call failure rates, the Commission U.S. in June 2012. During the so-called attributable to long-distance carriers who attempt to reduce the intercarrier has proposed new data collection “derecho” storm, 77 emergency call compensation paid to local telephone and reporting rules in order to better centers operating in six states lost some companies by using third-party “least- monitor the performance of long- or all communications capabilities, cost routers.” Under the provisions distance carriers in rural areas. In affecting more than 3.6 million people. of the federal Communications Act, addition, the Commission is gradually long distance carriers are responsible phasing out intercarrier fees, thereby The Commission’s NPRM on emergency for correcting any network service- reducing the financial incentives that communications networks is available related issues that result in degraded it says contribute to call completion at incompliancemag.com/news/1305_02. communications service to certain areas. failures.

European Union News

EU Commission Updates of the Directive is equipment designed EU Council Makes Standards List for PPE specifically for private use (such as Electronic OJ Official seasonal outdoor clothing), equipment Directive for use by armed forces or law The Council of the European Union The Commission of the European Union enforcement personnel, and equipment (EU) has taken action to make the (EU) has an updated list of standards intended for the protection or rescue of electronic version of the Official Journal that can be used to demonstrate con- individuals on vessels or aircraft. of the European Union official. formity with the essential requirements The Official Journal is the definitive of its Directive 89/686/EEC concerning The extensive list of CEN and Cenelec record of all legislation, regulation and personal protective equipment. standards was published in March 2013 in the Official Journal of the European other legal acts implemented within Union, and replaces all previously the EU, and is available in all 23 of For the purposes of the Directive, the official languages of the EU. Until published standards lists for the personal protective equipment (or PPE) now, the printed version of the Official Directive. is defined as “any device or appliance Journal has been the only legally binding designed to be worn or held by an version of EU law, despite its long-time individual for protection against one The complete updated standards list for availability in electronic form. This has or more health and safety hazards.” the EU’s PPE Directive is available at required the printing and distribution Specifically excluded from the scope incompliancemag.com/news/1305_03. of each daily edition in each official

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language, creating immense logistical incompliancemag.com/news/1305_04. the EU has also established a framework challenges and perpetuating an outdated that created ecodesign requirements for in Compliance Access to the on-line version of and ecologically problematic mode of the Official Journal is available at a wide range of energy-related products, communication. incompliancemag.com/news/1305_05. as well as a 2010 directive addressing labeling and product information News In its Regulation issued in March 2013, requirements. In addition, the EU and the EU Council moved to give the EU Amends Energy the U.S. have recently signed an updated electronic version of the Official Journal agreement defining the coordination equal legal status with the printed Efficiency Labeling of their respective energy-efficiency version. Under the Regulation, the Regulations labeling programs for office equipment. electronic version “shall be authentic The amended EU regulations were and shall produce legal effects,” and The Parliament and the Council of the issued to accurately reflect these and be available online and free of charge European Union (EU) have amended the other changes. “in a non-obsolete format and for an EU’s energy-efficiency labeling program unlimited period.” The Regulation is regulations for office equipment. The amendments to the EU’s energy- expected to take effect as of July 2013. efficiency labeling program were The EU originally issued energy- published in the Official Journal The complete text of the Council’s efficiency labeling regulations in 2008 of the European Union in March regulation regarding the status of the to support its partnership with the U.S. 2013. The complete text of the EU’s electronic version of EU’s Official regulations amendments is available at Environmental Protection Agency’s Journal is available at ENERGY STAR program. Since then, incompliancemag.com/news/1305_06.

CPSC News

Company Recalls Air affected by this recall were sold between failures have resulted in damage to light Purifiers Due to Fire Hazard November 2008 and January 2013 for sockets, melted fixtures, and burned about $60. rugs, carpets and floors. There have been The 3M Company of St. Paul, MN has no reports of injuries. announced the recall of about 10,000 Additional information about this recall of its Filtrete-brand room air purifiers is available at incompliancemag.com/ The recalled 120-volt LED lighting bulbs manufactured in Taiwan. news/1305_07. were manufactured in 2010 and 2011, and marketed under the brand names According to the company, the ion Definity, EcoSmart, Sylvania and West- generator in the air purifier unit LED Light Bulbs Recalled inghouse. They were sold through various retailers nationwide, including hardware, can overheat, posing a burn and fire Due to Fire Hazard hazard to consumers. 3M says that lighting and electrical supply stores. it has received two separate reports Lighting Science Group of Satellite Further details about this recall are in connection with the recalled Beach, FL has recalled more than half a available at incompliancemag.com/ air purifiers, one in which the unit million LED light bulbs manufactured overheated and another in which the in China. news/1305_08. unit caught fire. However, there have been no reports of injuries. The company has reported to the U.S. Consumer Product Safety Commission Disco Lamps Recalled Due The Filtrete air purifiers were sold that the light bulbs can overheat, posting to Electric Shock Hazard at hardware stores and home goods a burn and fire hazard to consumers. centers nationwide, including Ace Lighting Science Group has received 68 Justice stores have recalled about 19,100 Hardware stores True Value Hardware separate reports of failures related to the of its “Style my Room by Justice” disco stores, and Lowes, as well as online recalled bulbs, including eight reports of lamps manufactured in China. through Amazon.com. Purifier models bulbs emitting visible smoke or fire. The Justice has reported to the U.S.

10 In Compliance May 2013 www.incompliancemag.com News in Compliance

The Knowledge. The Equipment. The Solution. The The Equipment. The Knowledge. Advanced Test Test Advanced Rentals Equipment some products contained two times two contained products some saturated or fat of the labeled amount fat. affirmed in was action FDA’s The in March issued decree a consent the and federal judge, a U.S. 2013 by producing from barred is company bakery until distributing products or regulations. FDA with complies it president, Bakeryits and Butterfly be also to subject may Isaac, Brenda violations. future for damages regarding news release FDA An at the case available is . incompliancemag.com/news/1305_10 Ringwave Ringwave w EFT/Surge EFT/Surge w

Automotive Automotive w (From our “You Can’t Make This Stuff Up” file) (From our “You No Wonder They Tasted So Good! They Tasted No Wonder The U.S. Food Drugand U.S. The down shut has (FDA) Administration bakery unlawfully Jersey a New for free” “sugar misbranded distributing food products. free” “fat and Butterfly the FDA, to According for NJ engaged Clifton, of Inc. Bakery, muffins in distributing several years contained that cakes snack and fat. and sugar undisclosed of levels that showed tests laboratory FDA free” certain foods labeled “sugar as other that and sugar, contained three as much as contained products declared sugar of times the amount addition, In labels. the products’ on ISO7637 w DO160 w EMC TEST SYSTEMS TEST EMC Narda · NoiseKen and more · CPSC News FCC · FCC

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For more information about this about information more For incompliancemag.com/ to go recall, news/1305_09. The recall disco lamps were in sold were recall The disco lamps at online and nationwide stores Justice through May from www.shopjustice.com $24. about 2012 for November Consumer Product Safety Commission Commission Safety Product Consumer the electrical that wiring in the lamp and consumers, to base accessible is posing a overheat, can the lamp that electrical and both burns shock of risk it that says company The consumers. to related incident one of beenhas notified well as overheating, the recalledto lamp in which a consumer incident one as the electric lamp. an from shock received Haefely Haefely Call us today 888-544-ATEC (2832) (2832) 888-544-ATEC Call us today IFI · ·

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The primary purpose of a job analysis survey is to validate the knowledge and iNARTE Informer iNARTE performance topics required within a job role that are measured as part of iNARTE Fully Integrated with the written examination. The survey results are also used to validate other RABQSA International, Inc. requirements applicants must meet before certification can be awarded. BY RABQSA STAFF To establish the validity of knowledge topics, respondents are asked to provide an importance and frequency rating, based on how the topic applies in their current role. The importance On May 6, 2012, iNARTE formally merged with RABQSA and frequency ratings are used to International. Since that time, the iNARTE staff members, ensure that the knowledge topics being measured within an examination are including Mr. and Mrs. Brian and Kathy Lawrence, have worked appropriate, important, and applied closely with RABQSA staff members to successfully merge frequently enough within the job role.

iNARTE operations and exam development into RABQSA. The results of the Product Safety Job Analysis survey administered in December 2012 validated the current certification requirements for the iNARTE Product Safety certification program. As reported in the prior issue hile the www.narte.org and Kathy Lawrence, ensuring the of InCompliance magazine, 78% of website continues to be the continuance of the legacy iNARTE the responders had over 10 years of main source of information certifications and continuing to add work experience in product safety and Wfor iNARTE certifications at this time, value to industry by identifying and 58% held at least a bachelor’s degree, the operations of iNARTE certifications developing new certification programs thus confirming the current work are fully managed by RABQSA out of to meet the needs of professionals experience and education requirements the Milwaukee, WI principal office. around the world. RABQSA thanks so that these requirements can remain Brian and Kathy Lawrence for their unchanged for the Product Safety Mr. Peter Holtmann, CEO of RABQSA, time and expertise over the last year, program. commented that the addition of ensuring the knowledge and content iNARTE products to the RABQSA transfer was a success so that iNARTE The data regarding the knowledge offering has provided great value and a will continue to thrive as a product of examination validated all examination broader scope of offering to our global RABQSA. topics except the topic titled “Military audience. “We see a bright future for and Civil Electrical Safety Standards”. the iNARTE product. The experience To learn more about the This topic had low importance and gained by merging of the non-profit iNARTE certification programs, visit frequency ratings, meaning that into RABQSA will serve us well for our www.narte.org this topic is neither important nor future pursuits.” used frequency enough in the role To learn more about RABQSA, visit of Product Safety Engineers and iNARTE would not be where it is www.rabqsa.com Technicians to be included as part today without the dedication of Brian of the examination process. More

12 In Compliance May 2013 www.incompliancemag.com iNARTE Informer importantly, given that most Product For more information regarding the version of test specifications, and Safety Engineers and Technicians are Product Safety Job Analysis Survey, validating or updating the certification in the United States and Japan, the please contact Mary Rehm, requirements. low ratings were consistent between RABQSA Psychometrician, at both countries. As a result, this topic [email protected] or visit The EMC Steering Committee is will be removed from all examinations www.narte.org/h/ps.asp seeking individuals to participate on beginning in June 2013. several Technical Advisory Groups RABQSA IS SEEKING (TAGs) who will meet in web (online) The results from the survey were INARTE EMC SUB- meetings to accomplish the following used to construct the final structure activities: COMMITTEE MEMBERS of the test specifications. A set of test • Item Writing: writing test questions specifications are the knowledge topics RABQSA International, in (items) for the EMC Engineer and and the number of test questions that partnership with the EMC Society, Technician exams will appear in each exam in support is currently facilitating the review Individuals who may participate of a certification program. More of the certification and examination on the Item Writing TAG are information on the final set of test requirements for the iNARTE EMC individuals who specifications for the Product Safety Engineer and Technician personnel • Are currently certified as an Engineer and Technician exams can be certification program. The process for iNARTE EMC Engineer or found at www.narte.org/h/ps.asp this review includes conducting a job Technician analysis survey, developing an updated • May be current or future instructors

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www.incompliancemag.com May 2013 In Compliance 13 iNARTE Informer • Item Review: review current test • Are currently certified as an your interest by sending your questions (items) and newly written iNARTE EMC Engineer or resume or CV to Mary Rehm, test questions for accuracy and Technician RABQSA Psychometrician, at appropriateness • May NOT be current or [email protected]. • Exam Review: review the pilot future instructors exam form for accuracy and RABQSA ONLINE PORTAL appropriateness All TAG members are required to iNARTE Informer iNARTE sign a confidentiality agreement To ensure you receive access to your • Cut Score Study: analyze the with RABQSA International prior to iNARTE records via the RABQSA content of the pilot exam form attending any meetings stating that Online Portal when it is made to aid in setting an appropriate no confidential information (i.e., the available, send your name, certificate passing (cut) score written test items) will be disclosed to number, and current email address to Individuals who may participate third-parties. Laura Funk, RABQSA Office on the Item Review, Exam Review Assistant, Certification Services, at and Cut Score Study TAGs are If you would like to participate on an [email protected]. individuals who iNARTE EMC TAG, please confirm iNARTE is a product of RABQSA International, Inc.

RABQSA’s mission is to provide world- QUESTION OF THE MONTH class products and services that add Last month’s question was from the EMC Design Engineer pool: value to professionals in industry through competency-based certification. When designing high-speed Printed Wiring Boards, should power and return RABQSA creates value for you and planes be on adjacent layers, and for what reason? your customers. We design, develop, A) Yes, to reduce noise on the power plane at high frequencies. and deliver personnel and training B) No, because the material that separates the power and return certification services relevant to your planes will often fail and short the power plane. industry. Our certification services are designed to be efficient, consistent and C) Yes, it is industry standard to design the connectors so that they are forced to feed the power and grounds on adjacent layers. relevant to Industry’s needs. We create and maintain value to industry, our D) Yes, if the planes are not routed next to each other, the boards certified professionals, and training may warp during fabrication. providers by ensuring that our While a case could be made for (A), the generally accepted answer is D) certification remains relevant and also Yes, if the planes are not routed next to each other, the boards may warp compliant to international standards. during fabrication. RABQSA International certification delivers the right people, with the right This month’s question is from the EMC Engineer pool: abilities, to achieve the right outcomes.

In Automotive EMC testing according to CISPR 25, what value of series RABQSA’s principal offices are located in capacitance is in the LISN (Artificial Network) between the power supply and Sydney, Australia, Milwaukee, USA and equipment under test (EUT)? Seoul, Korea and international offices A) 500 µF located throughout the world. B) 50 µF C) 5 µF D) A series capacitor is not used.

See next month’s iNARTE Informer for the correct answer to this month’s question.

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Don HEIRMAN Consultants Bureau Veritas In Compliance Magazine Consumer Products Services Washington Laboratories, Ltd. 7560 Lindbergh Drive • Gaithersburg, Maryland 20879 • 301-216-1500 • [email protected] • wll.com/academy MR. Static Consequently, it is not possible to use a CPM measurement to predict directly how fast an arbitrary item will be neutralized, even when both the CPM and the item are exposed to the same atmosphere. However, in many cases, Neutralization of Static Charges by the neutralization time for an item MR. Static can be deduced indirectly from CPM Air Ions measurements. Part II: Experimental Results THEORY OF A CPM

BY NIELS JONASSEN, sponsored by the ESD Association In Part I of this article, it was shown that the charge on a positively charged body suspended freely in air will be neutralized exponentially with a time This second installment on charge neutralization demonstrates constant of

that a CPM can be used to determine fundamental atmospheric (1) electric quantities. where r– is the resistivity of the air due to negative ions.1

The time constant in an exponential he most commonly used decay is the time it takes the decaying INTRODUCTION instrument for evaluating quantity to drop to 1/e of the the ionization state of an initial value, with e being the base Associate Professor Neils Jonassen Tatmosphere is the charged-plate of the natural logarithm (≈ 2.72). authored a bi-monthly static column monitor (CPM) shown in Figure 1. that appeared in Compliance Consequently, for any system with the Engineering Magazine. The series In the figure, a metal plate with the time constant t, there is the relationship explored charging, ionization, area A is placed a distance d from a explosions, and other ESD related ground plate in which is inserted a (2) topics. The ESD Association, working fieldmeter probe. The charged plate with In Compliance Magazine is re- can be charged to a selected voltage The time constant t (known as the publishing this series as the articles (usually 1 or 5 kV), and the voltage can o offer timeless insight into the field of be measured on the fieldmeter. fundamental time constant) given by electrostatics. Equation 1 is the lowest time constant When an atmosphere or ionization for any system in an atmosphere Professor Jonassen was a member of the ESD Association from 1983-2006. system is to be He received the ESD Association evaluated, the charged Outstanding Contribution Award in plate is exposed to the 1989 and authored technical papers, atmosphere, charged to a books and technical reports. He is selected voltage, and the remembered for his contributions to time, t10, for the voltage the understanding of Electrostatic to drop to one-tenth control, and in his memory we reprise of the starting voltage “Mr. Static”. is measured. This time ~ The ESD Association depends on the geometry of the CPM and the Reprinted with permission from: negative resistivity Compliance Engineering Magazine, Mr. Static Column of the air if a positive Copyright © UBM Cannon voltage is chosen. Figure 1: Charged-plate monitor

16 In Compliance May 2013 www.incompliancemag.com characterized by the parameters eo and r. (4) MR. StaticMR. Figure 2 shows a system consisting of The variable r is the (equivalent) radius where O is the circumference of a positively charged metal plate with of the metal plate plate A. The variable e is the relative the area A, separated from ground by r permittivity of the dielectric. a dielectric with the thickness The capacitance C of the metal d and the relative permittivity a plate relative to the air was e . In Part I, it was suggested r approximated by that the plate A, when exposed to an atmosphere with the + (5) fundamental time constant t o, would have a time constant t+ given by Introducing Equations 4 and 5 into Equation 3 gives

(3) (6) where Figure 2: Charged plate near ground MR. Static

It should be mentioned that, in some CPMs, the plate voltage is monitored by a

noncontacting voltmeter, which may add a stray capacitance Cs from the support.

MR. Static When applying Equation 3 on a CPM, as shown in Figure 1, Equation 6 (9) reduces to and (7)

(10)

because er = 1 for air.

It should be mentioned that, in some The constants in CPMs, the plate voltage is monitored Equations 4, 5, 9, and 10 by a noncontacting voltmeter, which had the following values: –2 may add a stray capacitance C from the r = 9 · 10 m, d = 1.5 · Figure 3: Experimental setup s –2 –12 support. In such cases, the factor 10 m, eo = 8.85 · 10 F · m–1, e = 1.6 · 10–19 C, k– ≈ 1.8 · 10–4 m2 · V–1 · s–1, and The setup shown in Figure 3 was used k+ ≈ 1.4 · 10–4 m2 · V–1 · s–1. Substituting for the experiments. An ionizer was these values into the relevant equations placed at a well-defined distance from should be replaced by results in the following capacitance and an ion-density meter. Because an ion decay-time values to be recorded on the blower was used as the ionizer, the air intake of the ion-density meter was CPM: Cd = 15 pF, Ca = 5 pF, placed perpendicular to the airflow so that the airflow would not be disturbed (11) through the meter. The CPM was EXPERIMENTAL RESULTS placed on top of the ion-density meter. and It is important that the field from the To verify experimentally the charged plate is insignificant at the air relationship expressed in Equation 7, intake, and the placement on top of the it is necessary to be able to establish (12) ion-density meter turned out to be the an atmosphere with a known value

for to. Although the fundamental

time constant, to, cannot be measured directly, Equation 1 may be reformulated, writing r– as + – + – Distance n n t 10 t 10 a (m) (1011 ions/m3) (1011 ions/m3) (seconds) (seconds) (8) Ion blower 1 3.2–3.6 2.5–2.9 11.8 12.3 where e is the electronic (and small- 1.5 2.2–2.6 1.8–2.2 16.9 17.7 ion) charge, k– is the mobility of 2 1.0–1.4 0.8–1.2 32.0 34.1 – negative ions, and n is the relevant 2.5 0.4–0.6 0.2–0.4 105 83.7 negative-ion concentration. Ion bar Combining Equations 1, 4, and 5 gives 1 0.20–0.24 0.16–0.20 180 190 the following results: Table 1: Ion concentrations and CPM decay times.

18 In Compliance May 2013 www.incompliancemag.com A series of experiments were performed in which the positive- and negative-ion density MR. StaticMR.

and the corresponding decay times (t10 values) were measured.

best because the CPM also needed to air capacitance Ca (Equation 5), which be exposed to the ionized airflow. overestimated the capacitance by about (7a) 19%. Therefore, Equation 5 should read A series of experiments were performed in which the positive- and negative-ion (5a) (9a) density and the corresponding decay times (t values) were measured. The 10 resulting in C = 4.2 pF for the CPM a and ion densities were varied by varying the investigated. Correspondingly, distance a between the ionizer and the Equations 6, 7, 9, and 10 become ion-density meter. For each distance, (10a) the average ion density and the decay times for positive and negative voltages (6a) were measured. The results are shown in Table 1. Each of the decay times is the average of five measurements.

To compare the experimental results with the predictions of Equations 11 Washington Laboratories, Ltd. and 12, the products

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www.incompliancemag.com May 2013 In Compliance 19 MR. Static

It has been demonstrated that it is possible to use a CPM with given dimensions to determine fundamental atmospheric electric quantities such as ion density and resistivity.

MR. Static DISCUSSION OF THE It is therefore possible to use a CPM shaped charged conductors, as well as RESULTS measurement to predict how fast for insulators, can be deduced from a charged metal plate, separated measurements of the neutralization The equations developed in this article from ground by a dielectric, will be time with a CPM. indicate that, by the use of a CPM neutralized. with given geometric and dielectric ACKNOWLEDGMENT characteristics, it is possible to predict Labeling the parameters of the the ion concentrations and resistivities CPM with c and of the item with The cooperation of Ion Systems of a given (ionized) atmosphere. i, the general equation relating a (Culemborg, The Netherlands) and However, a more-important predicted neutralization time with the Simco (Lochem, The Netherlands) for implication is that it is, in many cases, corresponding time measured by a allowing the use of their ion blower also possible to estimate how fast an CPM will be and ion bar, respectively, is greatly ordinary charged item (i.e., not just a appreciated. CPM) will be neutralized in a given atmosphere. REFERENCE

For example, if Equation 7a is applied 1. Niels Jonassen, “Neutralization of (16) on the CPM used in this investigation Static Charges by Air Ions: Part 1, (i.e., r = 9 ·10–2 m and d = 1.5 ·10–2 m), Theory” in Mr. Static, Compliance Equation 16 is valid for positive as well the result would be Engineering 19, no. 4 (2002): 28–31. as negative voltages, corresponding to ions of opposite polarities, and for time (7b) constants as well as for t10 times.

Equation 7b indicates that, for a given INSULATORS atmosphere, the CPM will measure a time constant that is 4.57 times greater As was explained in Part I, the than the fundamental time constant for neutralization of a charge located on the atmosphere in question. the surface of a dielectric follows the same rules as that of a charge located Now assume there is an item like that on the surface of a conductive plate.1 shown in Figure 2, with a charged The equations in this article are (the author)

metal plate A, an effective radius ri = therefore valid when ri is the radius 0.1 m, a thickness d = 10-2 m, and a of the charged area, e is the relative NIELS JONASSEN, i r,i MSC, DSC, e permittivity, and d is the thickness of relative permittivity r,i = 4.0. According i worked for 40 years at to Equation 6a, the time constant the dielectric. the Technical University should be of Denmark, where CONCLUSION he conducted classes in electromagnetism, (6b) It has been demonstrated that it is static and atmospheric possible to use a CPM with given electricity, airborne radioactivity, and indoor climate. dimensions to determine fundamental After retiring, he divided his time Combining Equation 6b with 7b atmospheric electric quantities among the laboratory, his home, and results in such as ion density and resistivity. Thailand, writing on static electricity Furthermore, it has been shown that topics and pursuing cooking classes. Mr. Jonassen passed away in 2006. (15) the neutralization time for commonly

20 In Compliance May 2013 www.incompliancemag.com Technology is advancing at a MILE HIGH pace and EMC testing is necessary to the success of this progress. No longer are the boundaries of EMC testing relegated to open area test sites, laboratories and text books; they are becoming part of our daily lives. The electric and hybrid vehicles and the Smart Grid, are two big arenas where EMC plays a major role.

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emc_savethedate_ad2013_8.375x10.875.indd 1 8/17/12 1:02 PM Designing Automotive Components for Guaranteed Compliance with Electromagnetic Compatibility Requirements

BY TODD HUBING

Automobiles typically have dozens of electronic systems operating interactively in a relatively compact space. These systems must operate reliably in a wide range of environments over extended periods of time. As a growing number of these systems play an ever expanding role in protecting the safety of a vehicle’s occupants, there is an increasing need to ensure that the integrity of these systems will not be compromised by electromagnetic interference.

he traditional design, build and are tested, and that compatibility will test approach to automotive not depend on the specific vehicle EMC compliance will not or system in which the components Tbe sufficient to ensure the safety or are installed. More work needs to be reliability of tomorrow’s automobiles. done before this concept reaches its A Design for Guaranteed Compliance full potential, but electronic system approach promises to ensure that designers can already derive significant automotive components will meet all benefit by applying this approach to EMC requirements the first time they products currently under development.

22 In Compliance May 2013 www.incompliancemag.com www.incompliancemag.com May 2013 In Compliance 23 INTRODUCTION In a graduate automotive electronics course at Clemson University (AuE 835), electronic systems are defined as systems that are managed or controlled by computers. By that definition, the number of electronic systems in automobiles has been zero for the majority of the automobile’s illustrious 120-plus year history. It was only in the 1980s that microprocessors started to see widespread use in automobiles, primarily for engine control. By the 1990s, they were required in automobiles for on-board diagnostics. Today, a typical automobile has dozens of embedded processors managing everything from passenger comfort and entertainment to critical vehicle safety systems. In fact it is no longer possible Prof. Hubing and Clemson graduate student, Dexin Zhang, making measurements on a to build vehicles that meet federal pickup truck with interior trim removed. requirements for passenger safety without microprocessors that control safety, ensuring the electromagnetic approach for assigning components systems such as the anti-lock brakes, compatibility (EMC) of these systems to various risk classes and defines tire pressure monitoring and electronic has never been more important. procedures for the development, stability control. operation and service of components The aerospace electronics industry depending on their class. Modeling Cars and trucks are safer than they is also concerned with reliability and and testing (including EMC modeling have ever been [1], due in-part to the electromagnetic compatibility. A failure and testing) play a key role in these implementation of various electronic in a critical system can ruin a multi- procedures. systems that can compensate for billion dollar space mission. Likewise driver error or unexpected obstacles. a critical failure in a commercial AUTOMOTIVE EMC Examples of some of these systems aircraft can jeopardize the lives of its include electronic stability control, passengers and crew. For these reasons, Prior to the widespread use of adaptive cruise control, automatic aerospace systems are generally electronic systems in automobiles, braking, lane departure warning and designed so that the failure of any one electromagnetic compatibility was blind-spot detection. However, as component won’t compromise a safety- a relatively minor concern in the automobiles begin to rely more heavily critical (or mission-critical) system. automotive industry. Any EMC on electronic systems for passenger Automobiles have not traditionally problems that arose in prototype safety, it becomes increasingly been held to the same high reliability vehicles were generally dealt with in an important to ensure that these systems standards as aerospace electronics, ad hoc fashion. Was the engine spark work reliably, and as intended, 100% of but this is changing. Unlike aerospace being picked up by the AM radio? Use the time. systems, an automotive electronic resistive spark plug wires. Was relay system that appears in a popular vehicle noise causing spurious transients that Less than a decade ago, none of the may experience hundreds of millions of burned out ignition components? electronic systems commonly found operating hours every year. In a safety- Apply snubber circuits or employ better in production of cars were designed to critical system, a failure rate as low as isolation. apply the brakes or turn the steering one for every million operating hours, without explicit driver input. Today, could affect hundreds of people every As electronics began to be used for a car may have several systems with year. more automotive systems, individual these capabilities plus nearly a dozen manufacturers began developing their that can actuate the throttle [2], and The new automotive safety standard, own EMC tests to ensure that the the number of systems that control ISO 26262, is designed to ensure that components or systems from their Tier safety-critical actuators increases with vehicle electronics meet certain criteria 1 suppliers would be unlikely to cause every new model year. As electronic for reliability and safe operation. interference problems when integrated systems play a bigger role in automotive The standard employs a risk-based in a vehicle. Eventually, there was an

24 In Compliance May 2013 www.incompliancemag.com and vehicle level. These tests give the manufacturer confidence that electromagnetic compatibility problems will not be a significant source of vehicle failures or customer complaints over the life of the product. However, the rate at which EMC standards are written and revised has been slow compared to the exponential growth in the number of automotive electronic systems and their role in ensuring vehicle safety. It is not realistic to expect to test for all possible sources of interference or anticipate all possible interactions between systems that various Tier 1 suppliers develop for a given vehicle. Also, current EMC test procedures are performed on components and systems that are new and in good working order. There is Clemson graduate student, Li Niu, setting up a radiated emissions test in the Clemson generally very little testing performed Vehicular Electronics Laboratory. on systems that have undetected failures or components that are out of specification (e.g. due to age or excessive heat).

In order to meet the requirements of ISO 26262 and ensure that electronic components and systems do not present an unacceptable risk, we must change the current development paradigm. Rather than designing the best we can and testing to ensure compliance, we need to use design procedures that ensure compliance and test procedures that validate compliance with the design criteria.

DESIGN FOR GUARANTEED PERFORMANCE Is it possible to design automotive components in a way that ensures Prof. Hubing and Clemson graduate student, Chentian Zhu, measuring the currents in a compliance with electromagnetic three-phase motor driver. compatibility requirements? Even the simplest electronic control units (ECUs) in an automobile typically have effort to consolidate these tests to and radiated EM emissions, conducted hundreds of circuits. The component make EMC testing more meaningful and radiated EM susceptibility, designers rarely have complete and cost-effective across the industry. transient voltages, power bus noise, information regarding the attached wire Standards organizations such as SAE electrostatic discharge and other forms harness routing or other key parameters and CISPR formed committees of of electromagnetic interference. that affect EMC performance. In interested parties, such as automobile addition, EMC test set-ups can vary manufacturers, Tier 1 electronics Today, automotive electronic systems depending on who is conducting the suppliers and EMC test houses. These are subjected to a wide range of EMC test, and results obtained for EMC committees developed standards and tests, both at the component level tests conducted at different test sites test practices for evaluating conducted (before being installed in a vehicle) can vary significantly [3, 4]. So is it

www.incompliancemag.com May 2013 In Compliance 25 A Design for Guaranteed Performance approach requires that an ECU design be reviewed circuit-by-circuit to ensure that the combination of electrical and geometric parameters cannot couple sufficient energy (in or out) to cause an EMC failure under any circumstances.

really possible to guarantee that a of power at a given frequency; then Performance can be implemented particular component design will meet the designer must ensure each circuit in order to meet radiated emission all automotive EMC requirements the on the board is incapable of supplying requirements. Note that this section first time it is tested? In most cases, the 4 nW of power at that frequency, either deals with actual radiated emissions, as answer is yes. alone or in conjunction with other opposed to electric- or magnetic-field circuits. In the event that a particular coupled emissions (i.e. coupling in the A Design for Guaranteed Performance circuit is required to supply more than near field). Since many automotive approach requires that an ECU design 4 nW of power at that frequency in “radiated” EMC tests actually measure be reviewed circuit-by-circuit to ensure order to meet functional criteria, then near-field coupling, a similar procedure that the combination of electrical and that signal path must be design in a must be employed for ensuring geometric parameters cannot couple manner that ensures that all power in near-field coupling in a particular sufficient energy (in or out) to cause an excess of 4 nW is accounted for and test environment does not exceed the EMC failure under any circumstances. dissipated within the ECU. corresponding limit. For example, if a given radiated emissions specification can be exceeded The following section demonstrates DESIGN TO MEET only if an ECU radiates at least 4 nW how Design for Guaranteed RADIATED EMISSIONS CRITERIA Step 1: Know Your Limits The first step in the process of designing for guaranteed performance The EMC Chapter of the is to know your limits. For example, if IEEE Rock River Valley Section your product specification requires that Presents the 2013 EMC Seminar the radiated field strength at a distance

of 10 meters is no greater than 30 μV/m Design for EMI and at 80 MHz, then the power radiated Signal Integrity must be less than: with Richard Hartley Senior Principal Engineer LL-3-3 Avionics Systems (1)

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For questions, please contact 80 MHz, so the directivity should not exceed 1.6.) Equation 1 indicates that Jamal Shafii 608-658-6830 a circuit that is incapable of supplying more than 1 nW of power at 80 MHz will not be capable of being the sole

26 In Compliance May 2013 www.incompliancemag.com Figure 1 shows a plot of the radiated emissions compared to an FCC radiated emissions test limit. Note that this component is capable of producing radiated emissions about 15 dB above the limit at 80 MHz.

source of a radiated emissions failure is 1.8 ns. The signal voltage at each odd at this frequency. For analog circuits, nth harmonic of the clock frequency (3) the maximum power supplied by the (assuming a trapezoidal waveform) source can be readily determined, and would be given by: is probably already known. For digital Figure 1 (page 28) shows a plot of circuits, the maximum power at any the radiated emissions compared to given frequency is probably not part of (2) an FCC radiated emissions test limit. any functional specification. Designing Note that this component is capable of producing radiated emissions about for guaranteed performance requires 15 dB above the limit at 80 MHz. that the maximum power these circuits where A is the peak-to-peak signal are capable of generating is known and/ voltage, t is the signal transition time, Now suppose we insert a 20-kΩ or controlled. r and T is the signal period. Now let’s resistor in series with the output of this assume that all of the power produced controller. For the same 5-pF load, the Step 2: Control Risetimes by the source is radiated (i.e. the source transition time would now be increased Any digital circuit source that cannot drives a lossless matched antenna). to 220 ns. Since the transition time is deliver at least 1 nW of power at 80 MHz cannot be the sole source of radiated emissions that exceed the specification in the example above. This is true no matter how poorly the circuit is routed and no matter what other circuits or structures the signal may be coupled to. A primary objective in designing for guaranteed compliance is to ensure that no source produces power capable of exceeding the specification unless that power is necessary for the circuit to serve its intended function.

For every digital circuit in the system that is operating at clock speeds of 16 MHz or less, the best way to control the emissions at 80 MHz and higher is to control the transition times. Slowing transition times to 20% of the bit width significantly reduces the energy in the signal at frequencies above the fifth harmonic. For example, suppose our signal source is an automotive microcontroller output with a 3.3-volt signal amplitude and a 165-ohm source resistance (i.e. 20 mA max current). If the operating frequency is 100 kHz and we’re driving a 5-pF load, the bit width is 10 μsec and the transition time

www.incompliancemag.com May 2013 In Compliance 27 about 2% of the bit width, the integrity Step 3: Control Current Paths calculations in the previous section of the digital signal is preserved. and Coupling assumed that the source was connected Figure 2 shows the radiated emission to a lossless impedance-matched that would result if all of the power After controlling all transition times, antenna. This is unlikely to happen in a produced by this source was radiated. the number of circuits capable of being real device, so the actual emissions will Note that this circuit is incapable of a radiated emissions source in a typical generally be lower than the maximum producing enough power to exceed the automotive ECU will be relatively possible emissions. Nevertheless, each FCC radiated emission specification small. It should be noted that circuits circuit capable of radiating above the at any frequency above 30 MHz. From capable of radiating a few dB above specification limit should be examined a design standpoint, this means that the limit are unlikely to do so. The to ensure that most of the power being this signal can be routed anywhere on the board or on any attached wiring harness. No matter how poorly the routing is done, or how many other circuits this signal couples to, it cannot be the source of a radiated emission failure.

For the purposes of meeting a radiated emissions specification, most of the digital circuits in most automotive ECUs can be eliminated from further consideration simply by controlling their transition times. Once the transition time has been slowed to between 10% and 20% of a bit width, only the faster circuits will remain viable sources of radiated emissions. Series resistors are one way to control transition times. The use of controlled slew-rate sources can also be effective. Figure 1: Maximum possible radiated emissions from a 100-kbps, 3.3-volt, 20-mA source Faster digital circuits cannot be with a 1.8-ns transition time eliminated as possible sources simply by limiting their transition times, but controlling these times reduces the amount of power available to be radiated. It also reduces the range of frequencies that must be considered. Figure 3 shows the maximum possible radiated emissions from the same automotive controller in the previous example when it is operating at 1 MHz. Note that it is capable of exceeding the limit by about 35 dB at 80 MHz, and is not guaranteed to meet the requirement at any frequency below about 600 MHz. Slowing the transition time down to 90 ns using an 8-kΩ resistor results in the maximum emissions plotted in Figure 4. Although the circuit is still not guaranteed to be okay at 80 MHz, it is within 5 dB of the limit, and the controlled transition time guarantees that the circuit will not exceed the limit at frequencies above 100 MHz. Figure 2: Maximum possible radiated emissions from a 100-kbps, 3.3-volt, 20-mA source with a 220-ns transition time

28 In Compliance May 2013 www.incompliancemag.com supplied at the offending frequencies and direct it elsewhere. Traces over a radiated power will be 20 dB lower reaches the load. The best way to do solid ground plane (microstrip traces) than the maximum available power this is to trace the signal current paths are relatively easy to examine, because calculated in the previous section. from the source to the load and back they present fewer opportunities for again. unwanted coupling. Levels of crosstalk Step 4: Recognize and between adjacent microstrip traces can Control Coupling to Antennas During the design review, it is easily be kept below −20 dB simply by important to recognize any structures following general design guidelines In many automotive ECUs, applying or coupling paths that could steal for trace routing. If your maximum Steps 1-3 above will eliminate the power from the intended signal path coupling is −20 dB, then the maximum vast majority of the circuits from consideration as possible sources of a radiated emissions problem. At this point, attention can be focused on the few remaining circuits/signals capable of being a problem source. By recognizing that all radiated emissions problems involve both a source and an antenna, and further recognizing that any antenna that is small relative to a wavelength will not be efficient, it is possible to examine every possible antenna structure in a system and evaluate the maximum possible coupling between every possible source and every possible antenna. Typically, in an automotive ECU the possible antennas are limited to one or more cable harnesses, one or more large heatsinks, and perhaps a metal enclosure or connection to the vehicle chassis. Evaluating 3 to 5 possible Figure 3: Maximum possible radiated emissions from a 1-Mbps, 3.3-volt, 20-mA source antennas against 1 to 10 possible circuit with a 1.8-ns transition time sources is a very manageable task.

While it is possible to gain some insight relative to the maximum possible coupling between a circuit and antenna structure using electromagnetic modeling tools, a more effective approach is to apply closed-form equations designed to calculate the maximum possible emissions from specific source-structure geometries typically found in electronic systems. Examples of these closed-form equations can be found in [5-14]. Several of these are implemented in a web-based calculator on the Clemson Vehicular Electronics Laboratory website [15]. Maximum emissions calculations basically assume that everything not known about a particular source/antenna geometry is worst case. For example, if a source drives a cable of unknown length, the Figure 4: Maximum possible radiated emissions from a 1-Mbps, 3.3-volt, 20-mA source calculator assumes that the cable is with a 90-ns transition time a lossless, resonant antenna at every

www.incompliancemag.com May 2013 In Compliance 29 frequency of interest. If a transition outlined above are often limited to a design rule can significantly degrade time is unknown, it is assumed to be few cents worth of components. On the EMC performance [16]. zero. While these calculations will other hand, the costs associated with generally overestimate the actual fixing an EMC problem in a product Another advantage of the design for measured radiated emissions, they that has already been prototyped guaranteed compliance approach is that provide an upper bound. For EMC can be relatively high. Routing and it does not rely on testing to establish work, an upper bound is generally placement options that would have the electromagnetic compatibility of preferable to an exact calculation been easy to implement early, may no the design. Testing alone can never be of emissions from a specific longer be available. Fixing problems thorough enough to anticipate all the configuration. Designing a system to that are discovered when testing a possible problems/interactions that can be compliant with a radiated emissions arise in modern automotive systems. prototype is much more likely to specification based on maximum With the design for guaranteed involve relatively expensive filters or emissions calculations ensures that the compliance approach, the compatibility shields and can cause delays to the specification will be met regardless of is designed in and the testing simply where it is tested or what it is product development schedule. confirms that the design performs as connected to. expected. Although there is much more CONCLUSION work to be done before this approach While the procedure outlined above reaches its full potential, it is likely that is relatively time consuming, it is not The previous section describes a design the design-for-compliance-and-test- procedure for guaranteeing compliance as difficult as it might first appear. for-validation concept will ultimately with radiated emissions requirements. It is true that every circuit on the define the methods used to ensure Similar procedures can be followed to board must be evaluated, and a board that increasingly complex automotive ensure compliance with other EMC with average complexity might have electronic systems meet all EMC requirements, although it is important performance requirements. hundreds of circuits. However with a to recognize that “radiated” automotive little experience, a designer will learn EMC test procedures are often to recognize many of the circuits that measuring near-field coupling over REFERENCES are incapable of being the source of much of their designated frequency 1. 2011 Safety Numbers Show a problem without explicitly doing a range. Also “conducted” emissions Decline In Traffic Fatalities—But calculation. Also, simple alterations tests measure both conducted and DOT’s Work Continues, Fast to many types of circuits that change field-coupled emissions. Procedures Lane: The Official Blog of the U.S. them from being possible sources to for guaranteeing compliance with Secretary of Transportation, negligible contributors will become susceptibility tests can guarantee a http://fastlane.dot.gov, Dec. 10, 2012. evident to the designer over time. maximum coupled signal, but they can’t 2. Automotive Electronic Systems This will make it easier to adjust guarantee that every part of the system website, Clemson Vehicular the design rather than calculate the will tolerate that signal unless that has Electronics Laboratory, possible emissions. Since many of the been previously determined for each calculations required for this procedure component. http://www.cvel.clemson.edu/auto/ can be automated, these calculations systems/auto-systems.html. can eventually be integrated with There are many advantages to a 3. Tae-Weon Kang and Hyo- existing computer-aided design tools. design for guaranteed compliance Tae Kim, “Reproducibility This will further reduce the burden approach. Although the technique and Uncertainty in Radiated on the design engineer and reduce requires more time and effort than a Emission Measurements at the level of EMC design experience design-rule based approach, it is much Open Area Test Sites and in required to implement the procedure. more likely to result in a low-cost, SemianechoicChambers Using a compliant design on the first pass. Spherical Dipole Radiator,” It is tempting to think that an The design for guaranteed compliance IEEE Trans. on EMC, vol. 43, no. 4, electronic system designed for approach also highlights the most Nov. 2001, pp. 677 – 685. guaranteed compliance will be over- vulnerable aspects of a design, making it easier to diagnose any problems 4. A. Kriz and W. Muellner, “Analysis designed and expensive. However, of the CISPR 25 Component Test most of the EMC design decisions that may occur in the field. On the other hand, the rigorous, but arbitrary Setup,” Proc. Of the 2003 IEEE Int. made early in a product’s development Symp. on EMC, May 2003, cycle have little or no impact on enforcement of EMC design rules can add cost and complexity to a pp. 229-232. the cost of the product. The costs design without necessarily improving associated with building a compliant 5. Y. Fu and T. Hubing, “Analysis of its EMC performance. In fact, the product based on the procedure radiated emissions from a printed misapplication of a well-intended circuit board using expert system

30 In Compliance May 2013 www.incompliancemag.com algorithms,” IEEE Trans. on 9. X. Dong, H. Weng, D. G. Beetner, planes in a populated printed Electromagnetic Compatibility, T. Hubing, “Approximation of circuit board,” IEEE Transactions vol. 49, no. 1, Feb. 2007, pp. 68-75. worst-case crosstalk at high on Electromagnetic Compatibility, frequencies,” IEEE Trans. on vol. 48, no. 1, Feb. 2006, pp. 74-81. 6. X. He and T. Hubing, “A closed- Electromagnetic Compatibility, vol. form expression for estimating 14. H. Shim and T. Hubing, “Model 53, no. 1, Feb. 2011, pp. 202-208. the maximum radiated emissions for estimating radiated emissions from a heatsink on a printed 10. H. Zeng, H. Ke, G. Burbui and from a printed circuit board with circuit board,” IEEE Trans. on T. Hubing, “Determining the attached cables due to voltage- Electromagnetic Compatibility, vol. maximum allowable power bus driven sources,” IEEE Transactions 54, no. 1, Feb. 2012, pp. 205-211. voltage to ensure compliance on Electromagnetic Compatibility, with a given radiated emissions vol. 47, no. 4, Nov. 2005, 7. C. Su and T. Hubing, “Calculating specification,” IEEE Trans. on pp. 899-907. radiated emissions due to I/O Electromagnetic Compatibility, vol. 15. Maximum Radiated Emissions line coupling on printed circuit 51, no. 3, Aug. 2009, pp. 868-872. Calculator (MREMC), Clemson boards using the imbalance 11. S. Deng, T. Hubing and D. Beetner, Vehicular Electronics Laboratory difference method,” IEEE Trans. on “Estimating Maximum Radiated website, http://www.clemson.edu/ Electromagnetic Compatibility, vol. Emissions from Printed Circuit ces/cvel/modeling/EMAG/ 54, no. 1, Feb. 2012, pp. 212-217. 12. Boards with an Attached Cable,” MaxEMCalc.html, March 2013. 8. C. Su and T. Hubing, IEEE Trans. on Electromagnetic 16. EMC Design Guideline “Improvements to a method for Compatibility, vol. 50, no. 1, Collection, LearnEMC website, estimating the maximum radiated Feb. 2008, pp. 215-218. http://www.learnemc.com/ emissions from PCBs with cables,” tutorials/guidelines.html. IEEE Trans. on Electromagnetic 13. H. Shim and T. Hubing, “A closed- Compatibility, vol. 53, no. 4, form expression for estimating Nov. 2011, pp. 1087-1091. radiated emissions from the power

(the author) DR. TODD HUBING is the Michelin Professor of Vehicle Electronic Systems Integration at Clemson University and Director of the Clemson Vehicular Electronics Laboratory (CVEL). His research focuses on the design of electronic components and systems that work safely and reliably in automotive environments. Dr. Hubing holds a BSEE degree from MIT, an MSEE degree from Purdue University and a Ph.D. from North Carolina State University. He was an engineer with IBM for 7 years and a faculty member at the University of Missouri-Rolla for 17 years before joining Clemson University in 2006. At Clemson, he teaches classes in automotive electronics integration to graduate students in the automotive engineering department. He also teaches classes in vehicle electronics, electromagnetic compatibility and digital signal integrity to graduates and undergraduates in the electrical engineering department. His company, LearnEMC, provides EMC instruction and design assistance to practicing engineers. He is a Fellow of the Institute of Electrical and Electronics Engineers (IEEE), a Fellow of the Applied Computational Electromagnetics Society, and a Past- President of the IEEE Electromagnetic Compatibility Society.

www.incompliancemag.com May 2013 In Compliance 31 32 In Compliance May 2013 www.incompliancemag.com Heading to the EU? Get Your EMC Compliance Passport Ready!

BY OZGUR OZTURK

When a manufacturer is thinking of the European Union (EU) as the next market for its electronic equipment, EMC compliance is one of the must-haves on the list of approvals.

nless a company has dedicated equipment’s EMC concept. Compliance correct standard. While most testing quality personnel to ensure with the EMC Directive alone does laboratories will help identify standards testing and certification is done not enable CE marking, a mandatory applicable to a particular piece of Uto the letter, the approval process can conformity mark for products placed equipment, the responsibility remains be quite complicated for engineers – on the market in the European with the manufacturer. It is a good idea from identifying the correct standards Economic Area; the product must to get acquainted with the standards to and models for testing to writing comply with all applicable directives to be able to choose the right one. the declaration of conformity and earn the mark. preparing the product for testing. This TOO MANY CHOICES? article will explain what engineers need THERE IS A STANDARD to do to demonstrate compliance. FOR YOU… Each standard in Directive 2004/108/ EC governs a particular type of WHAT THE EMC DIRECTIVE Out of hundreds of standards equipment, such as laboratory, IT, industrial or household. The standards IS AND … IS NOT featured in the EMC Directive, the manufacturer must pick the right determine the strength and the limits Most electronic equipment that will standard for the product and bears for every test used to evaluate the be sold in the EU needs to comply responsibility for the choice. This is product; this means that if equipment with the EMC Directive 2004/108/EC. often a point of confusion for the US is used in ITE applications, it will be While the directive sets rather tough engineers, who, if they work with a tested to requirements different from requirements to regulate the product’s third-party testing and certification those used for industrial equipment. electromagnetic disturbances, it is not body, believe that the registrar should Included below is the hierarchy of the a safety directive because it only covers be responsible for testing to the standards and where to find them.

www.incompliancemag.com May 2013 In Compliance 33 The conformity assessment procedure sets out steps to follow to demonstrate the product’s EMC compliance. Engineers should begin by reviewing harmonized standards to determine the one applicable to the product.

Top level generic and product family procedures used to test products for prepare documentation proof with standards describe the overall EMC compliance. The basic standards justifications, explaining why re-testing EMC requirements for the product. are listed in the Normative References is not necessary. Engineers should use generic standards section of the product family and only when there is no family standard generic standards. They are not listed COMPLIANCE STEPS covering the product. in OJ. The conformity assessment procedure Many organizations sell the standards, Testing the product to the latest sets out steps to follow to demonstrate including ANSI and Global Standards. version of harmonized standards the product’s EMC compliance. For CE marking, these standards is the main method of compliance Engineers should begin by reviewing are listed on the EU website as the with the EMC Directive. However, harmonized standards to determine harmonized standards list or are if a product had been tested to the the one applicable to the product. featured in The Official Journal of version of the standard that since then They need to decide how to actually the European Union (OJ), the only expired, manufacturers can perform test the product – themselves or with periodical published every working day a gap analysis to identify only new the help of a third-party laboratory. in all official languages of the EU. requirements to which the product Because of the procedure’s complexity, needs to be re-tested. If requirements most companies choose the latter and Basic standards are one step down the of the new version do not affect must find the right partner to work hierarchy. They explain the individual the product, the manufacturer can with. When looking for laboratories, engineers need to ensure that prospective registrars devote the time to educate them on what EMC testing involves, how long it takes and what is required because open communication is crucial to the success of the endeavor.

Some engineers may not be aware that they must review all the models, or versions, of the product to determine which ones need to be tested. The directive requires all possible product configurations be included in the EMC assessment. If there are five models, and each differs from the others in terms of design and has different electrical components, all five need to be tested. If the difference is not design-related, such as a color scheme or shape, If an electronic product is intended for export to the EU, EMC compliance is one of the must-haves on this model can be excluded the list of approvals. (photo courtesy of TÜV Rheinland) from the list.

34 In Compliance May 2013 www.incompliancemag.com Determining in advance what models need testing will help a testing provider give an accurate quote from the start. If a laboratory discovers that other models need testing after the initial quote was issued, it will need to issue another quote and schedule time to test additional models.

To select models for testing, many how it selected the “worst case” The directive does not specify a format companies take the so-called “worst representative. for the DoC and documentation file case” representative(s) approach. as long as they include the minimum They select one or more of the most Manufacturers must always keep their required information. If any of the advanced versions of the product technical files up-to-date. If a design minimum required content is missing, and apply the results of their tests to change is made to the product, the the DoC is considered incomplete models simpler in design. Engineers equipment might need to be re-tested – and invalid, which might lead to an should keep in mind that “the worst fully or partially – and the technical file appropriate action from the competent case” model for immunity testing needs to be updated accordingly. authorities of a member state. The may be different from the “the following standards are a good worst case” candidate for emissions Annex IV of the directive instructs reference on how to prepare a DoC: testing. The company may need to manufacturers to prepare the EMC EN ISO/IEC 17050-1:2005 and EN test more than one variation or use declaration of conformity (DoC) for the ISO/IEC 17050-2:2005. CENELEC different configurations for emissions EU as part of technical documentation. has also published a specific guide for and immunity testing. As with the According to Part 2 of the Annex, DoC the DoC: “CENELEC Guide 16 on standard selection, the manufacturer is must include the following: the implementation of New Approach responsible for identifying the “worst directives and the Low Voltage directive case(s)” and possible configurations for • Dated reference to the Directive with respect to the EC declaration of testing, but a laboratory can assist with 2004/108/EC conformity.” A testing laboratory may making the decision. • Identification of the product also provide engineers with a DoC • Name and address of the template to streamline the process. Determining in advance what models manufacturer need testing will help a testing provider The directive requires manufacturers give an accurate quote from the start. • Name and address of the authorized or their authorized representatives to If a laboratory discovers that other representative in the country of hold the technical documentation in models need testing after the initial distribution the country of distribution for at least quote was issued, it will need to issue • Dated reference to the specifications 10 years after the last manufacturing another quote and schedule time to test (A manufacturer must include the date. If the company does not have additional models, adding time to the date of the standard to which the a local representative, whoever process. product was tested. As new versions places the product on the market is of standards are issued, old versions responsible for providing the technical Once the company determined which become invalid and the product may documentation and DoC to competent product versions to test, it needs to need to be tested again to the new authorities upon request within a prepare technical documentation specifications.) reasonable timeframe. in accordance with Annex IV. The documentation file should contain • Date of declaration of conformity Of course, manufacturing products necessary information to easily • Identity and signature of the according to the technical identify the product, such as general responsible party documentation is paramount. This description, environments where it can way, the products are consistent in be used, warnings and manuals. Engineers do not need to list the basic quality and performance per EMC standards in the DoC, only harmonized phenomena. After the testing is done, test reports product family or generic standards. will go into the file to provide evidence They should remember that for a WORKING WITH A of compliance with harmonized product to be CE marked, it must NOTIFIED BODY standards. If the company did not comply with all the applicable directives have every variation of the product and related harmonized standards and Occasionally, manufacturers might tested, the file should explain why these directives and standards must be want to go the extra mile to ensure certain models were excluded and listed in the DoC. that products are tested to the correct

www.incompliancemag.com May 2013 In Compliance 35 standards and are in full compliance. In this case, the company has an option to send the technical file and EMC report to a Notified Body (NB) for review. Specifically, a NB does the following: • Reviews the technical file to ensure the essential requirements of the Directive are met; • Reviews the technical file to ensure that it clearly demonstrates that all the Directive requirements are met; and • If everything is in order and complete, issues a statement of opinion to be included in the technical file. In certain instances, a mobile EMC laboratory will come to the manufacturer’s site to test the MAINTAINING equipment. (photo courtesy of TÜV Rheinland) COMPLIANCE

Harmonized standards are movement of the product to liability for be able to test the product right away occasionally updated, with the revisions a fine and/or imprisonment. Typically, if other products are in the queue. listed in OJ well before they become a relevant enforcement authority will After the tests are done, there is a mandatory. When an existing version give a manufacturer a chance to fix lead time for the laboratory to issue of a standard expires, manufacturers the problem and ensure the product is a report. If a product fails part of the must use the new standard on the correctly CE-marked; the measures are test, the manufacturer will need to DoC as the old one no longer shows much stricter when consumer safety is make changes to it and have it re-tested compliance with the directive. Often, at risk. in that area, which will add more this means re-testing the product to the time to the process. Engineers should new standard. GETTING READY ask their testing partners about lead FOR THE TEST times before committing to working Revisions to basic standards are more together as lead times vary between challenging to keep up with; there is To make the testing process go laboratories. no publication comparable to OJ for smoothly, engineers are well advised the basic standards. If engineers use a to prepare for testing in advance. They When preparing to ship the product product family or generic standard that will need to get ready all of the product to the laboratory for testing, engineers has undated basic standard references, information, including the product’s need to include everything that is they must take into account changes or description, function and intended needed to operate the tested product, updates to basic standards. environments, product variations, including step-by-step operating as well as electrical specifications, instructions so that test personnel DON’T TEMPT FATE including clock speeds of all know how to properly operate microprocessors. the equipment. When necessary, If a manufacturer tries to place a non- supporting equipment that is not compliant product on the EU market, it Engineers sometimes forget to factor subject to the test also needs to be could face penalties. Penalties differ by into their schedules various lead times shipped. For example, if a printer is the country and range from removing involved in a testing procedure. In tested, a manufacturer needs to include the product from the market and addition to the lead time to issue a a computer, a USB cord, and power prohibition or restriction of the free quote, the testing provider may not cords for the computer and printer.

36 In Compliance May 2013 www.incompliancemag.com HOSTING THE EMC TEST CREW EMC evaluations typically take place in a specially equipped laboratory; however, there are three instances when a testing provider will travel to the manufacturer’s site to conduct tests. First, if a product is very large, such as a built-in-place industrial system, which cannot be fitted into the laboratory space. Second, if a product requires substantially more power than can be provided in the laboratory. Third, if a product requires special auxiliary equipment that cannot be shipped to the laboratory.

There are some differences EMC testing done in the open area test site (OATS).(photo courtesy of TÜV Rheinland) between the EMC testing performed in the laboratory and at the manufacturer’s site. When done in a laboratory, radiated immunity ACHIEVING COMPLIANCE engineers are advised to inquire if their testing takes place in an EMC chamber test laboratories can assist with other that is completely isolated from its After the testing is completed, the necessary approvals. Consolidating all surroundings and allows a full range of laboratory will provide the customer of the testing needs with one laboratory tests to be performed. When testing is with a report stating the test results. If eliminates the inconvenience of done onsite, only limited frequencies the product falls short in some area, the managing multiple laboratories, are permitted. The deviations in testing report will identify the problem. streamlines logistics, simplifies are allowed when at least one of the The customer can adjust the design documentation and results in a faster, three above-mentioned conditions or troubleshoot the problem and then more efficient and cost-effective are satisfied. The decision to test at send the modified version back to compliance strategy. the manufacturer’s site should be the laboratory to re-test it in the area documented and justified in the where it failed. While implementing technical file. changes to the product, engineers need to be aware that the modifications Before the testing crew arrives at the might affect the EMC phenomena in manufacturer’s site, the company more ways than intended. Depending personnel needs to prepare the tested on a modification, they may consider (the author) product and supporting equipment, testing the product in more areas OZGUR OZTURK clear the space around the tested than only where it previously failed. serves as Senior Business equipment and ensure that it runs in Once the product demonstrates full Manager, EMC and Telecommunication Services, a continuous operating mode. If more compliance, the laboratory issues a final at TUV Rheinland of North than one product variation needs to report to be included in the technical America, Inc. He has more be tested, all models should be ready documentation file. than 12 years of experience in regulatory compliance for evaluation in advance, whenever in testing and certification. possible. Reconfiguring equipment In addition to the EMC testing, a Ozturk graduated from University of while the laboratory team is waiting on product exported to the EU needs to Missouri-Rolla with a degree in Electrical Engineering, with an emphasis in EMC. site will add time and cost to the testing comply with a great number of other He can be reached at [email protected]. process. regulations. To save time and money,

www.incompliancemag.com May 2013 In Compliance 37 Engineering Our Future: A View of Changes Facing Engineers BY GREGG KERVILL

Editor’s Note: Over the past months we’ve explored one engineer’s view of historical patterns and events that have set the landscape for today’s economic challenges. In this final installment, Mr. Kervill brings us into the present and concludes the series by summarizing his predictions for the future.

FACTORS EFFECTING but there is a huge difference between INNOVATION need and want. Need is a key factor. It is the lower limit of payments that a Communication workforce can accept. Less than this limit and we will have a transitory Communication is so fast that it is not a workforce incapable of great innovation factor in restricting today’s technology. because it will be constantly changing. Not only is the world flat, as described 1 by Thomas Friedman , but it has only If pay is much higher than the basic one time zone. level of need, then business risks being unprofitable. Employee pay is a second This has the drastic effect of eliminating factor which can limit or restrict new communication as the prime factor that products being capitalized and turned limits growth of new ideas. into revenue. Consider this:

Thanks to the Internet and television A college student graduating with we no longer rely on explorers like $60,000 worth of debt must repay $5 for Marco Polo to bring back knowledge each working day for the rest of her life. of gunpowder, how to grow rice, or the If she is to be downsized at the age of 55 latest phone application! then the amount increases to $8 a day.

The cost of employment By age 30 most engineers will have Few of us would turn down a windfall added a mortgage to this financial of $3.5 million (Kubasik-Lockheed)2, commitment.

38 In Compliance May 2013 www.incompliancemag.com www.incompliancemag.com May 2013 In Compliance 39 This means that if we are to create US up residence in students as they move jobs they need to be high tech, well- toward becoming independent thinkers Can universities and colleges paid jobs – which leads us to the next and agents of their own lives. A liberal requirement. education provides students with a provide enough engineering broad set of capabilities such as critical graduates? LITERACY AND thinking, effective communication, quantitative reasoning, creative EDUCATION thinking, problem-solving, integrative The third factor to consider is the thinking, and personal and social technical, financial and global literacy responsibility. While not monetarily of our workforce. These qualities are quantifiable at graduation, there is essential as never before because, as no question of the value of these our businesses become more global capabilities for all individuals in the the potential for insulting or alienating workforce of the future, as citizens and fellow workers, partners or even as human beings.” customers increases exponentially. A warning for engineers In terms of literacy the US ranks poorly It does not matter if you agree – this is with Asia. Results from a 2002 survey the force that will drive the syllabi of reveal that only 3% of Americans have universities and colleges– and future sufficient literacy to work at the highest graduates will not only be looking to But in 2003, the situation changed. level of engineering. take your job but (thanks to the new Between 2003 and the first quarter of syllabi) may be better qualified than 2005, unemployment fell along with According to the 1992 National you are now! total employment, which declined from Adult Literacy Survey the average 363,000 in 2003 to 335,000 in March th U.S. adult reads between the 8 and New learning should not only include of 2005, almost 8 %. The only way the th 9 grade level. USA Today quoted a familiarity with new technology but the number of unemployed engineers and study showing that 1 in 7 Americans place of America in the Global Village – the number of employed engineers can (or 14%) could read its stories. This so add foreign newspapers and The both fall at the same time is if a large could have a serious impact on future Economist to your weekly reading list. number of engineers are simply leaving employment opportunities for 80% the profession. of the U.S. population. (Note: It is It may well take 10+ years before the possible that this is not indicative of majority of colleges are on-stream Harrison makes an excellent point – declining literacy but because such but we should see the first graduates “Declining employment can be as wor- information is increasingly available we arriving in less than 5 years. risome as increasing unemployment. are more informed than in the past.) The economy can still benefit from an Do we have enough unemployed engineer who has taken 3 THE LEAP REPORT engineers? a non-engineering job. But when an engineer leaves the profession, those In 2011 the Association of American The short answer is – unequivocally no! high-value skills may be lost for good.” Colleges and Universities published the And we knew there was a problem in LEAP Report 20054. Can universities and colleges provide enough engineering The leap study was created as a way According to Russell Harrison in the graduates? forward. first quarter of 2005, electrical engineers (EE) faced an unemployment rate The short answer is again – unequivocally no! Agree or not – this is coming that fell to 2.1%, just about its historic down the pike average. The rate had been declining Excerpt from The Economist on the since 2003 when electrical engineers Teagle Foundation President Future of Jobs Richard Morrill wrote a blog post faced an unemployment rate of 6.3% — for the Huffington Post titled “What the highest ever recorded for EEs. “In 2008, one in four workers in America is the Value of Liberal Education?” with a degree in science, technology, (November 6, 2012). Mr. Morrill notes Between 2000 and 2003, electrical engineering, or mathematics was 50 or that “The key to seeing the enduring engineers faced a typical, if bad, job over. Lockheed Martin, an aerospace power of liberal learning is to trace market: unemployment went up as total firm, expects nearly half its science how knowledge and its processes take employment fell. and engineering workforce to retire

40 In Compliance May 2013 www.incompliancemag.com by 2019 and will have to hire a total industries are well known and from the It will, however require industry to be of 142,000 engineers. Currently only perspective of investing money they are prepared to pay a much higher price 60,000 engineers a year graduate from assumed to give low risk and low return for the convenience of employing a American universities.5” rewards. consultant on a daily or even hourly rate on an as-needed basis. So how are the other 100,000 engineers Then there are sunrise industries – needed by Lockheed being trained? these industries weren’t here yesterday The fire-fighter, the engineer And what about other large companies and some won’t be here tomorrow. And and the plant7 that employ older workers and those some sunrise industries will grow and about to retire? become new entities that will shape Large corporations have a range of our environment. Google, Facebook, options available, including those Clearly there are not enough engineers. and solar power generation are new available to the SMEs (Small and Perhaps now is the time for senior and continue to spawn new infant Medium size Enterprises). managers to consider taking on more industries. interns, giving engineers an apprentice The classic solution has been to create who would assist engineers and in So what is the future? a small team of ‘firefighters’ (engineers doing so, learn what engineering is all placed into a project that needs help). We can expect many engineers leaving about while they are still in school? When the problems are found and the workplace to be older engineers solutions identified then the team retiring within the next 5 to 10 years moves on to the next project. This is JOBS, START-UPS AND and thus removing themselves from the a smart way for large employers to FUNDING market. maximize their scarce engineering resources. It also helps to create a team Until recently, most entrepreneurs As this happens we can expect to see an with a greater chance of a successful started their companies with their own acute shortage of experienced engineers outcome (see footnote – The Plant). money or some form of ‘angel’. Taking who will work at an artificially low rate on the whole financial risk means full created by downsizing. Companies will Small businesses have often employed control and remuneration. If significant be forced to pay higher rates until we a consultant engineer to perform capital was needed the entrepreneur return to previous (realistic) hourly specialist engineering tasks and then sought either a partner or an investor. rates. release them to work for another company – this is a logical way forward Now we have Crowd Funding – which Given that there will be a shortage for industries that cannot afford to is a huge benefit for getting start-up of engineers and that full-time employ experts in all fields. capital. Please note that in 2013 the employment of a specialist is always legislation around Crowd/Cloud funding inefficient then a logical natural WORK HAS CHANGED will change. solution is for more engineers to become contractors. FOREVER Technology has advanced. Computing Remember the massive layoffs between power is cheap – 3-D printing can The Dilbert effect and the 1996 – 2010? Well some of those jobs eliminate the need for machinists consultant have gone forever and will never come and many start-up and fully-fledged back. Let me repeat, some of those jobs From another perspective, the only businesses can operate from a couple have gone forever and will never come route to higher pay was for an engineer of laptop computers. Bricks and mortar back! have been replaced by the internet - so to transfer into management – the original investment associated with which led to the loss of some very It has happened before and will happen setting up business is a fraction of the good engineers and an even worse again. The word processor brought an cost 10-20 years ago. consequence of more than a few dreadful managers: a double loss to the end to the massive typing pools we saw in 1950s movies. So what became of Sunset and sunrise industry. (Dilbert is, indeed, alive and well!) all those typists? Did they starve; did If a business is established, has been they sit about for the rest of their lives around for ages, will always be there, For many years the only way that an waiting for another typist job to land and where there is little change of engineer could make good money on their lap? No! Some retired – others technology it is considered a sunset (as an engineer) was to become a retrained – others took new careers. industry, water, sewage, coal power consultant. Hiring a consultant is the generation, nuclear power generation, logical model to reduce the impact of When will the next transition in hospitals, teaching and insurance. our impending engineer shortage by employment happen? Look around The financial returns of sunset making better use of scarce resources. you: it is happening now!

www.incompliancemag.com May 2013 In Compliance 41 All change is positive – it just According to SEPH data7, in 2011 small Just remember: “If you get up one depends on your perspective businesses employed between 58% to more time than you fall you will 68% of professional service staff. make it through.” - Chinese proverb The modern capability to create new Small businesses are smaller, less products has just reached a new height. bureaucratic than large businesses One designer with a PC and a 3-D and can respond to changes and needs REFERENCES printer can now replace several design much quicker. draughtsmen, a buyer, a goods inwards 1. “The World is Flat” Thomas L. inspector, someone to run the stores It is small businesses that will change Friedman - read also “The Lexus and an inventory controller, plus all the face of industry, leading large and the Olive Tree” the bookkeepers needed to track the companies in employing surplus labor. time of all those individuals. This is It is small business that will stimulate 2. http://www.washingtonpost.com/ a good thing, and a good time for and sell into new markets. It is small business/capitalbusiness/ entrepreneurs. business that will lead the way into a kubasik-to-receive-35-million- successful future. separation-payment/2012/11/12/ The rise of small business e60a42f2-2cdd-11e2-a99d- Now is the time for small business. The Now is a good time to be an 5c4203af7b7a_story.html right ten people can outpace a 1990s entrepreneur 3. http://www.aacu.org/leap/index.cfm company of 100 or more in terms of Those of you who have read my books 4. http://www.todaysengineer.org/ design capability, throughput and on regulatory compliance and product ability to build a product. Computing 2005/Sep/pulse.asp safety may remember this quotation power is cheap. Laptops capable of 5. The Economist Magazine Special from Krishnamurti “In oneself lies the more than 50,000 MIPS are now Report September 10, 2011 Print whole world and if you know how to common and off-the-shelf. The need look and learn, the door is there and the Edition for a big centralized computer center is key is in your hand. Nobody on earth 6. http://en.wikipedia.org/wiki/Team_ relegated to specialist companies. can give you either the key or the door to Adobe and other software providers Role_Inventories open, except yourself.” have made their software Cloud based 7. http://www.ic.gc.ca/eic/site/061.nsf/ (or similar) and available for rent on a eng/02719.html Well, the key is in your hand. here is monthly basis. much help8 for start-up businesses – 8. See “Jobs, Start-ups and Funding” there is even Crowd Funding (also These are major milestones and will called Cloud Funding). So, do you lift restrictions from small design have the courage to open the door companies that will be able to pay before you? as they go and never need worry about updates, software or hardware compatibility issues again.

Individuals are now empowered to take an idea, build a company and take ownership. (It can be stressful but (the author) is infinitely preferable to pleading to spend $100 of the company’s money in GREGG KERVILL Kervill started out as a physicist but has spent all of his career in electronics order to save $1,000, or to spend hours because, as he puts it, it was more fun. Gregg career as an electronics design of your own time, writing proposals engineer began in the industrial controls, consumer electronics, space and to your employer justifying why the military markets. He completed a Diploma in Industrial Management (the company should patent your idea and forerunner of the MBA) in the 1980s with a thesis on the application of Kan Ban and JIT to highly variable product lines. Also in the 1980s, he became involved pay its shareholders millions. with product safety for military products, and became a CSA design verification engineer for Digital Corporation. In 1993, he formed GK Consultants Ltd, with whom he has Large versus small maintained a web presence. Whereas large businesses gain A registered consultant to the European Union (advising on Slovenia’s entry to the EU), Gregg headlines in the press whenever they has contracted to NIST and the US-Consumer Electronics Association, and has advised the UK, Northern Ireland, Slovenia and Hong Kong governments. He has also provided pro bono layoff a couple thousand people, small support to Virginia Governor Mark Warner’s VALET export program, as well as the planning and businesses seldom receive accolades for strategy committee of the City of Austin, Texas. Since 1995, he has lectured and consulted on employing more than half the workers three continents, published three engineering books, and created the first multi-media training software for electrical product safety. Currently he is developing web-based training material from in the US. world-class subject matter experts (SMEs) for the Phoenix Technical Group, an internet-based company with a presence in the US, UK, and Brazil.

42 In Compliance May 2013 www.incompliancemag.com PRODUCT Showcase PRODUCT Showcase AR’s Model CI00401A RF Conducted Immunity System

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EVENTS in Compliance EVENTS in Compliance

June 2013 25-26 9 EMC Essentials Understanding Ground Resistance Testing EMC Integrity, Inc. AEMC Instruments Denver, CO Meadowlands, NJ 17-19 www.incompliancemag.com/events/130625 www.incompliancemag.com/events/130709_1 Fundamentals of Vibration and Shock Testing with Emphasis on Fixture 9-10 Design Printed Electronics & Photovoltaics Asia Equipment Reliability Institute 2013 Sunnyvale, CA IDTechEx www.incompliancemag.com/events/130617 Tokyo, Japan July 2013 www.incompliancemag.com/events/130709_2 18-19 Electronic Systems Design for EMC 9-11 Compliance 8-11 Simultaneous Multi-Axis Vibration LearnEMC MIL-STD-810G Testing Testing Center for Quality Engineering San Jose, CA Equipment Reliability Institute Munich, Germany www.incompliancemag.com/events/130618 Burlington, WA www.incompliancemag.com/events/130708 www.incompliancemag.com/events/130709_3

www.incompliancemag.com May 2013 In Compliance 43 44 In Compliance May 2013 www.incompliancemag.com A Sunny Day in Tennessee The new Volkswagen plant at Chattanooga

BY MARY ANN KAHL

he lack of conversation around are the less glamorous corporate press into practice with too little fanfare the environment, climate releases, web article links and third- was the inauguration, two days after change, and our energy page news stories most of us only the President’s own this past January, Teconomy during the 2012 election stumble upon. One such example of of the Volkswagen Assembly Plant in season, while widely noted, still seemed environmental innovation being put Chattanooga, Tennessee (Picture 1). to attract little attention. Certainly health, financial The plant is nestled on and national security issues 1,400 acres between the were more immediate concern Appalachians and the for many voters. Yet, the lack Mississippi Embankment of initiative at the federal near the boarders of Georgia level has not kept technical and Alabama. Currently innovators, astute business employing over 3,200 and people and local governments growing, it is the first and only from moving forward with LEED Platinum Certified auto new ideas for addressing our plant in the world today. Plant environmental and energy components include a body concerns. shop, paint shop, assembly line, technical center, training On these fronts, there are academy, and supplier park plenty of encouraging news (expected to include eight items that don’t necessarily suppliers and indirectly make the headlines or feature Picture 1: Power-up ceremony at Volkswagen Chattanooga employ another 9,500 people). familiar political faces. These Plant on January 23, 2013 Bringing both

www.incompliancemag.com May 2013 In Compliance 45 The fixed-angle array system at Chattanooga is made up of 33,600 solar panels having a generating capacity of slightly more that 9.5 megawatts. The 3 x 6 poly- crystalline silicon modules were made in China and Mexico for the JA Picture 2: Aerial view of Chattanooga solar park Solar Company.

Picture 3: Inverter strings

46 In Compliance May 2013 www.incompliancemag.com good jobs and increased tax revenue, site, while wetlands and habitats of Solar Company. Each panel is rated the plant is a welcome boost to native vegetation have been identified at 285 watts. The field is designed as the regional economy. But even and protected. Even the impact of 10 inverters of 3,360 panels each. The more exciting is the wide-ranging shipping finished product has been panels of each inverter are arranged in environmental sensitivity exercised by considered, as 85% of vehicles are 168 strings with 20 modules per string business leaders and local government sent to dealers via rail to reduce diesel (Picture 3). The inverters are connected in engineering this great example of emissions and road traffic. to 5 transformers, which convert the combining economic growth with 9.58 megawatts of DC power generated sound environmental solutions. But possibly the most ambitious and by the field to 7.6 megawatts of AC high-profile aspect of the Chattanooga power at the plant substation. The Beginning in the paint shop, an plant’s environmental commitment Volkswagon plant consumes 100% of advanced painting process has been is a 66 acre solar park, the largest in the power generated by the park for car implemented which eliminates one the state of Tennessee (Picture 2). The manufacturing. This covers 12.5% of step of the painting procedure, thus park was designed and installed by the plant’s need during peak production reducing CO2 emissions by 20% Phoenix Solar Inc., the US subsidiary times. During non-production times while also bringing down cost and of Phoenix Solar AG headquartered in (weekends), the solar park is able to energy use. Furthermore, in this San Ramon, CA. Phoenix Solar is an provide 100% of the plant’s power improved painting system, a new industry leader in designing, building needs. Eco Dry Scrubber System avoids the and operating large commercial consumption of 20,000 gallons of water and utility-scale solar power plants. If the growing use of large-scale each day. The park is owned and managed solar power plants in Tennessee is by the Silicon Ranch Corporation, an indication, and we hope it is, the Also in the interest of water a Nashville-based developer and field of renewable energy is ready for conservation is the use of collected operator of solar facilities whose other a growth spurt. This is great news for rainwater for cooling and in the projects include a 1.4 megawatt solar all of us as citizens, as well as a great restrooms, saving up to 350,000 gallons energy campus in Pulaski, Tennessee, a opportunity for electrical engineering per month. Meanwhile, the use of rooftop installation for Second Harvest in general and compliance engineering low-nitrogen oxide gas burners in the in Nashville, Memphis Bioworks, in particular. As more of the general plant’s boilers reduce nitrogen oxide and Simon Solar Farm in southeast population becomes aware of our emissions into the atmosphere, and Tennessee. joined opportunities for immediately heat exchangers capture and recycle accessible alternative energy, the heat from the building. The fixed-angle array system at engineering community will need Chattanooga is made up of 33,600 solar to step forward with solutions for Other features incorporated into the panels having a generating capacity generating more efficient, low-cost design of the building itself are six- of slightly more that 9.5 megawatts. options in delivering that energy. The inch mineral rock wool insulation The 3 x 6 poly-crystalline silicon ability to respond to this need will panels that reduce building energy modules (model JAP6-72-285) were offer both individuals and companies a consumption by 35 percent, a T5 made in China and Mexico for the JA chance for industry leadership. lighting system that reduces energy consumption by 20 percent (over conventional lighting), and a specially designed white roof that reduces the heat island effect of the plant by reflecting the heat from the sun. The (the author) entire site is being operated under MARY ANN KAHL certified environmental management While her educational background is in architecture and English, Mary Ann’s systems (ISO 14001 and ISO 50001). professional editing experience began in the early 80s as a research assistant in the Epidemiology and Genetics Section at the National Cancer Institute (NCI). Leaving the office environment to be at home with her two sons, Mary Around the building, LED street Ann continued editing for NCI as an independent contractor. On moving to New lighting saves about 100,000 kilowatt England, she began looking for new clients (these were the nascent days of the hours per year and greatly reduces light internet, so local was better). Stumbling upon an electrical engineer who wanted help with a pocketguide to Taguchi and Robust Design, Mary Ann abandoned the pollution at night. During construction, doctors for the technical guys … and has spent the next 25 years helping bright and creative two creeks on the site were restored people articulate their ideas and inventions. The bulk of this work has been for QFD and TRIZ to enhance the wildlife habitat and articles, books and seminars. Mary Ann is very happy to have spent the past two years dotting “I”s, crossing “t”s, and adding or removing countless commas for In Compliance Magazine. provide a wildlife corridor around the

www.incompliancemag.com May 2013 In Compliance 47 EMC Education EMC Education The View from the Chalkboard BY MARK STEFFKA

One of the questions I get asked frequently is “What software exists that can be used to assist in the teaching of EMC?” This is a good question! For this month’s column I would like to ask you that same thing – with the hope that either (a) Others can learn from what you are using, or (b) This serves as a “thought starter” as to the type of software is needed or could be used in EMC education.

t has been my experience that to fully define the problem (such as capable electromagnetics modeling although some people have had identification of parasitic components) and simulation packages that also exist. success with adapting various which was then input to the circuit While both these methods have their Icircuit analysis programs (such as analysis. At the other end of the value, it seems like there is a gap in the SPICE) for EMC analysis purposes, spectrum, many of us are familiar needs of students and EMC educators it required significant up-front work (and/or have used) some of the highly to have software that can be used as a first introduction to EMC analysis using computer analysis methods.

The feedback that I have received when I have also asked this question of my colleagues is that what EMC

For additional Software Name Used for Operating System Feature information, contact: EMC educator’s name “A B C ” Classroom lectures To be determined Graphical interface or software company name. EMC educator’s name Produces “SPICE” “XYZ” To support lab experiments. To be determined. or software company compatible output. name.

48 In Compliance May 2013 www.incompliancemag.com educators are looking for is a way to important ones to address when what is currently being done and/or EMC Education be able to illustrate various concepts in incorporating software packages as a desired. I am proposing a simple matrix EMC without the students getting lost part of an EMC curriculum (or course). that can help answer some of these in the details of the analysis program questions. itself. Ideally, the software should be As I have done before on other topics able to demonstrate the basic concepts that we’ve discussed in this column – I’d If you have information that you of EMC, such as determination of like to have your feedback, comments, would like to share, please contact me, emissions levels for a certain hardware and questions that we can explore in I look forward to helping us all in this design (conducted and radiated), the upcoming months. To get started, important aspect of EMC education. effects of various electric and magnetic perhaps it would be useful to provide fields upon basic circuits and systems readers of this column an overview of Thank you in advance! (conditions of radiated susceptibility/ immunity) and methods to provide insight into shielding effectiveness for various conditions such as near and far fields, electric or magnetic field shielding, perhaps with identification of the dominant shielding mechanism for a specific conditions (such as reflection (the author) or absorption). These programs would MARK STEFFKA, B.S.E., M.S. is a Lecturer (at the University of Michigan - Dearborn), an Adjunct Professor (at ideally run on the most common the University of Detroit – Mercy) and an automotive company Electromagnetic systems in use today, and possibly some Compatibility (EMC) Technical Specialist. His university experience includes of them even be made available in the teaching undergraduate, graduate, and professional development courses on EMC, antennas, and electronic communications. His extensive industry “app” format for smartphone/tablet background consists of over 30 years’ experience with military and aerospace usage. communications, industrial electronics, and automotive systems.

Mr. Steffka is the author and/or co-author of numerous technical papers and publications on So – what do you think? Is it possible to EMC presented at various Institute of Electrical and Electronics Engineers (IEEE) and Society utilize computer packages to illustrate of Automotive Engineers (SAE) conferences. He has also written about and has been an various EMC concepts in an effective invited conference speaker on topics related to effective methods in university engineering education. He is an IEEE member, has served as a technical session chair for SAE and IEEE manner in the university classroom? conferences and has served as an IEEE EMC Society Distinguished Lecturer. He holds a radio What features or capabilities would communications license issued by the United States’ Federal Communication Commission (FCC) you like to see in order for this to be and holds the call sign WW8MS. useful to you? Should this software be restricted to “on campus” use or be made available for students via the internet? Where best this software Send your university EMC courses to be included in the matrix to would be used – in a classroom lecture or in a lab class? These are just some Mark Steffka at [email protected] of the initial questions that I see as

www.incompliancemag.com May 2013 In Compliance 49 We wish to thank our community of knowledgeable GREGG KERVILL authors, indeed, experts in their field - who come started out as a physicist but has together to bring you each issue of In Compliance. spent all of his career in electronics Their contributions of informative articles continue to because, as he puts it, it was more move technology forward. fun. Gregg career as an electronics design engineer began in the industrial controls, consumer electronics, space and military markets. He completed a DR. TODD HUBING Diploma in Industrial Management (the is the Michelin Professor of Vehicle forerunner of the MBA) in the 1980s Electronic Systems Integration at with a thesis on the application of Kan Clemson University and Director of Ban and JIT to highly variable product the Clemson Vehicular Electronics lines. For Gregg’s full bio, please visit Laboratory (CVEL). His research

) page 42. focuses on the design of electronic components and systems that work safely and reliably in automotive OZGUR OZTURK environments. For his full bio, please serves as Senior Business Manager, visit page 31. EMC and Telecommunication Services, at TUV Rheinland of North America,

uthors Inc. He has more than 12 years of NIELS JONASSEN, MSC, DSC, experience in regulatory compliance worked for 40 years at the Technical in testing and certification. Ozturk (A University of Denmark, where he graduated from University of Missouri- conducted classes in electromagnetism, Rolla with a degree in Electrical static and atmospheric electricity, Engineering, with an emphasis in airborne radioactivity, and indoor EMC. For Ozgur’s full bio, please visit climate. Mr. Jonassen passed away in page 37. 2006. For Mr. Jonassen’s full bio, please visit page 20. MARK STEFFKA is a Lecturer (at the University of MARY ANN KAHL Michigan - Dearborn), an Adjunct While her educational background is in Professor (at the University of Detroit – architecture and English, Mary Ann’s Mercy) and an automotive company professional editing experience began Electromagnetic Compatibility (EMC) in the early 80s as a research assistant Technical Specialist. His university in the Epidemiology and Genetics experience includes teaching Section at the National Cancer Institute undergraduate, graduate, and (NCI). Leaving the office environment professional development courses to be at home with her two sons, Mary on EMC, antennas, and electronic Ann continued editing for NCI as an communications. For Mark’s full bio, independent contractor. For Mary Ann’s please visit page 49. full bio, please visit page 47.

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