Suitability of Standard Connecting Hardware for Automotive Twisted Pair Ethernet Transmission

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1 Suitability of Standard Connecting Hardware for Automotive Twisted Pair Ethernet Transmission TE Connectivity Bert Bergner, Jens Wülfing, Andreas Engel 3 rd Ethernet & Automotive Technology Day Leinfelden-Echterdingen September 25 th to 26 th 2013

2 Connector Systems for Infotainment & In-Vehicle Networks Specific High Speed Styles Consumer Equipment Styles Scope of this Presentation Miniaturized Automotive Styles page 2

3 Presentation Overview Topology of single pair Ethernet communication channels and important electrical parameters Signal integrity parameters of connectors Cause & typical values of Return Loss and Insertion Loss Tolerance impact on channel performance Mode conversion, cross talk and cross conversion as relevant connector parameters for EMI in unshielded systems Conclusion page 3

4 Physical Layer Topology Proposal for RTPGE (*) Link Segment 15m Single Twisted Pair with 4x Inline Connectors MII PHY Silicon Chip CMC Passive Filter MDI Board Header EC ECU Connector C Inline Conn. C Inline Conn. C Inline Conn. C Inline Conn. EC ECU Connector MDI Board Header CMC Passive Filter PHY Silicon Chip MII ECU 1 ECU 2 Link Segment including Board Connectors Definition of system boundaries (length, number of connectors, etc.) Definition of electrical interface parameters between the segments (signal integrity, balance, etc.) Budget calculation from link segment to individual components (cables, connectors, etc.) (*) RTPGE Reduced Twisted Pair Gigabit Ethernet page 4

5 Physical Layer Important Parameters & Effects Transmission ECU Echos ECU X-Talk X-Conversion Echos Differential to Common Mode Conversion Assumptions: ECU Unshielded Twisted Pair (UTP) Full Duplex on 1 Pair Transmission Signal integrity within the link Transmission (Insertion Loss) Echo (Return Loss) Interference with environment (EMI emission & immunity) Mode Conversion (TCL, TCTL, etc.) Interference within harness (EMI regarding neighbor lines) Cross Talk & Cross Conversion All parameters take effect in both directions. page 5

6 Signal Integrity Measurements & Modeling for Complete Link Link Topology 3m 3m 3m 3m 3m Example: 0.64mm Pin Size / 0.35mm² Cable - Return Loss -2 0 PCB Header Inline Connector Inline Connector Inline Connector Inline Connector PCB Header m total length Test Setup with Cable Assembly - RL [db] f [MHz] Insertion Loss IL [db] f [MHz] Measured Simulated Proposed 100MBit Limit ISO Class E A Limit Proposed (?) RTPGE Limit Suitable first measurement results / Good correlation to simulation page 6

7 Signal Integrity of Connectors Inline Connector Example Connector Geometry (Example) Transmission Line Model Connector Housing Section A Section B Section C Section D Section E Transmitted Signal Impedance Z A Length l A Impedance Z B Length l B Impedance Z C Length l C Impedance Z D Length l D Impedance Z E Length l E Reflected Signal Parameters Insertion Loss due to frequency dependent attenuation (resistance, skin effect, dielectric loss) Return Loss due to reflections at discontinuities page 7

8 Signal Integrity of Connectors Inline Connector Example Simulated TDR Response Same Connector with Different Excitation Rise Times Connector Geometry 35ps rise time 10GHz bandwidth 70ps rise time 5GHz bandwidth 175ps rise time 2GHz bandwidth Z [Ohm] ps rise time 1GHz bandwidth 700ps rise time 500MHz bandwidth Range of Interest for RTPGE Frequency bandwidth of interest for 100MBit Ethernet: up to 100MHz t [ps] Time Domain Reflectometry (TDR) analysis depends on signal rise time Suitable results for miniaturized Automotive connector systems page 8

9 Signal Integrity of Connectors Impact of Wire Termination Termination Zone Example Cable 350 Impedance vs. Wire Distance (Stripped Pair) - Simulation 300 Impedance [ohm] Wire Size 0.35mm² (7x Ø0.25mm) Ø1.30mm Termination Zone Length 150 D 100 1,3 1,8 2,3 2,8 3,3 3,8 4,3 4,8 5,3 Center to Center Distance D [mm] 101 Ohm nominal at 20 C 115 Ohm with jacket stripped off 200 Ohm with 1mm gap Impact of wire termination zone is significant Termination effects and tolerances need to be considered page 9

10 Signal Integrity of Connectors Impact of Wire Termination Impact of Wire Termination Zone Length on Impedance Simulated TDR Response, 700ps Signal Rise Time 140 Length Length Termination zone impedances 150 Ohm Simulated Geometry mm 10mm mm 5mm Z [Ohm] mm 0mm (connector only) t [ps] page 10

11 Tolerance Analysis for the Complete Link Worst Case Worst Case Scenarios - Examples MDI EC C C C C EC MDI Return Loss 0.64mm pin size connectors from shelf 5 segments with same length m segment length assumed Case 1 20mm termination zone lengths, 115 Ohm 0.35mm² cable with jacket 101 Ohm nominal cable impedance Case 2 20mm termination zone lengths, 115 Ohm 0.35mm² low loss cable 95 Ohm cable impedance Case 3 10mm termination zone lengths, 115 Ohm 0.35mm² low loss cable 95 Ohm cable impedance Case 4 (for 100MBit) 1.5m segment length 20mm termination zone lengths, 150 Ohm 0.35mm² low loss cable 90 Ohm cable impedance -RL [db] f [MHz] Proposed 100 MBit Limit ISO Class E A Limit Proposed (?) RTPGE Limit Works for 100MBit Case 1 Case 2 Case 3 Case 4 Feasibility for RTPGE demonstrated Optimization/modification of all components & processes necessary to define economic system solution for 1GBit. page 11

12 Tolerance Analysis for the Complete Link Monte Carlo Simulation Random Parameters: (uniform distribution, 300 trials) Number of segments: Segment length: Cable impedance: Term. zone length: 1 5 0,5 3,0m Ω 17,5 22,5mm Term. zone impedance: Ω -RL [db] - Return Loss ISO Class E A Limit Proposed (?) RTPGE Limit Probability Fix Parameters: Attenuation for cable & termination zone Propagation velocities PCB header definition Inline connector definition f [Hz] Limit definition in process (OPEN Alliance SIG / IEEE802.3bp) Focus on economic system solution! page 12

13 Connector Parameters Measurement Setup Test Setup Example A B Test Fixture DUT Device Under Test Test Fixture C D Analyzer Ports PCB SMA Connector PCB SMA Analyzer Ports 4 Port S-Parameter Acquisition (single ended) Calculation of Mixed Mode Parameters (Sdd, Sdc, etc.) Appropriate test fixtures (specific for individual connector types) De-embedding techniques to remove impact of test fixture (if needed) page 13

14 Typical Return Loss Values for Standard Connectors 0 - Return Loss - RL [db] Connector A Fixture A Connector B Fixture B Connector C Fixture B Proposed 100MBit Limit ISO Class E A Limit ,00E+06 1,00E+07 f [Hz] 1,00E+08 1,00E+09 Good results for small pin size Automotive contact system Optimized test setup and/or de-embedding techniques required page 14

15 Typical Insertion Loss Values for Standard Connectors 0,0 - Insertion Loss - IL [db] -0,1-0,2-0,3-0,4-0,5-0,6 Connector A Fixture A Connector B Fixture B Connector C Fixture B Proposed 100MBit Limit ISO Class E A Limit -0,7-0,8-0,9-1,0 1,00E+06 1,00E+07 f [Hz] 1,00E+08 1,00E+09 Good results for small pin size Automotive contact system Optimized test setup and/or de-embedding techniques required page 15

16 Mode Conversion Important Parameter for UTP Systems Differential Mode (Odd Mode) Driver Voltage to GND Common Mode (Even Mode) Driver Voltage to GND V 1 V 1 V 2 V 2 V 1 = -V 2 Conversion V 1 = V 2 I Common Ground I V 1 V 2 I/2 I/2 Common GroundV 1 V 2 Common mode causes EMI in UTP systems. (increased emission / reduced immunity) Mode conversion due to different propagation times and/or different attenuation on the individual pair wires Mode conversion by asymmetric cross talk from/to other lines or pairs Reasons for mode conversion in cables and connectors are geometric and/or material unbalances between the pair wires. page 16

17 Impact of Asymmetries to Balance Values of Connectors Free Inline Connector No surrounding metal close to the connector [db] Transverse Conversion Transfer Sdc21 Scd21 DUT Sdc12 Scd12 Proposed (?) RTPGE Limit Proposed 100MBit Ethernet Limit Connector with Metal Plate Conductive plate touches the housing [db] -80 1,00E+06 1,00E+07 1,00E+08 1,00E f [Hz] Proposed 100MBit Ethernet Limit Proposed (?) RTPGE Limit -60 Connector Housing Floating Metal Plate ,00E+06 1,00E+07 1,00E+08 1,00E+09 f [Hz] page 17

18 Typical Cross Talk Values for Standard Connectors 0 Near End X-Talk Configuration 1-10 NEXT, NEXT Sdd21 [db] [db] Configuration 2 Configuration Configuration ,00E+06 1,00E+07 f [Hz] 1,00E+08 1,00E+09 Differential mode cross talk depends on pair configuration and segregation Aggressor Pair Victim Pair page 18

19 Typical Cross Conversion Values for Standard Connectors 0 Near End X-Conversion Configuration 1-10 X-Conversion, Scd21 [db] Configuration 2 Configuration Configuration ,00E+06 1,00E+07 f [Hz] 1,00E+08 1,00E+09 Cross conversion depends on pair configuration and/or pair segregation Aggressor Pair Victim Pair page 19

20 Conclusion Miniaturized multi-pin connectors provide sufficient margin for 100MBit Automotive Ethernet General feasibility for 1GBit Ethernet (RTPGE) demonstrated with small size standard contact systems Modified components & processes necessary for RTPGE to provide sufficient margin for process capability and tolerances Methods for channel analysis and modeling necessary to define economic and reliable systems for future data rates Work on specification for modeling, budget calculation and limit definition for the RTPGE physical layer ongoing and progressing in OPEN Alliance SIG and in IEEE802.3 page 20

21 Authors of this Presentation Bert Bergner Jens Wülfing Andreas Engel Tyco Electronics AMP GmbH a TE Connectivity Ltd. company Ampèrestrasse Bensheim Germany

22 About this presentation About TE Connectivity TE Connectivity (TE) is a $13 billion world leader in connectivity. The company designs and manufactures products at the heart of electronic connections for the world s leading industries including automotive, energy, automation and control, intelligent buildings, rail, broadband communications, consumer devices, healthcare, and aerospace and defense. TE Connectivity s long-standing commitment to innovation and engineering excellence helps its customers solve the need for more energy efficiency, always-on communications and ever-increasing productivity. With nearly 90,000 employees in over 50 countries, TE Connectivity makes connections the world relies on to work flawlessly every day. To connect with the company visit: Legal Disclaimer While TE has made every reasonable effort to ensure the accuracy of the information in this presentation, TE does not guarantee that it is error-free, nor does TE make any other representation, warranty or guarantee that the information is accurate, correct, reliable or current. TE reserves the right to make any adjustments to the information contained herein at any time without notice. TE expressly disclaims all implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions in this presentation are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult TE for the latest dimensions and design specifications. Trademark Note: TE connectivity (logo) and TE Connectivity are trademarks. Other logos, product and Company names mentioned herein may be trademarks of their respective owners. page 22

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