ASICs Improve
Transducer Reliability
Our customers are aware that
we're rapidly incorporating ASICs (application-specific integrated
circuits) into our hybrids. ASIC technology allows us to reduce
component count while adding new features that improve reliability and
functionality. The oscillator ASIC is already in production; we hope
to have the Voltage Regulator and Frequency Counter ASICs qualified by the end
of 2008. Since that will total three ASICs in our hybrid by
2009, an explanation of each ASIC's function and benefits is given
below:
Oscillator
ASIC. This ASIC oscillates the pressure, temperature, and reference
crystals. It cuts startup time in half, eliminates half of the
components inside the hybrid, and reduces the probability of DLS failures.
(See our reliability technote below for an explanation of DLS.) We
finished qualifying the oscillator ASIC in late 2007. It is
used in all digital-output hybrid transducers and in all frequency-output
transducers where '1' occupies the first numeric digit of the transducer part
number, i.e., QHB108, QMB102, SPB115.
NOTE: Since
the oscillator ASIC runs at low voltage, our customers may need to reduce their
supply voltage: frequency-output ASIC hybrid transducers require a
3.6 to 5.5 VDC
supply. (The old hybrid required a 4.5 to 12.6 VDC
supply.) SPB (¾") customers may switch to
the lower voltage ASIC version at any time during
2008. After January 1, 2009, as we will not accept orders
for old (high voltage) SPB transducers. We kindly ask for your
cooperation as we phase in the oscillator ASIC on new SPB1xx transducer part
numbers and phase out the old SPB0xx part numbers.
Voltage Regulator
ASIC. This ASIC provides a stable 2.5 VDC voltage to the circuit core,
and does the function of nine discrete components inside the present
hybrid. It will lower the minimum supply voltage of frequency-output
hybrid transducers to 2.7 VDC, making digital- and frequency-output transducers
equivalent in supply requirements: 2.7 to 5.5 VDC. It has also
been designed to operate above 200°C--the present temperature limit of
digital-output transducers. (We presently use a REF191 in the digital
hybrid which cuts out at 204°C.)
Qualification of the Vreg ASIC
has begun this month, and we hope to finish qualification by the end of
this year.
Frequency Counter ASIC. This ASIC performs the
simultaneous, period-based counting of the pressure and temperature frequencies,
and replaces seven components inside the digital-output hybrid. It
will provide two new options for customers: a clock output (7.2 MHz
or 1 kHz), and a 5th byte checksum on the 32-bit pressure and
temperature counts.
Like the
Vreg ASIC, it has been designed to operate above 200°C. We also
expect that its current draw will be significantly less than the 42MX16 FPGA
that it replaces. This ASIC is due to arrive at Quartzdyne in
June.
Prior
to releasing any ASIC into production, we qualify ASICs as
follows:
•
functional testing from -40 through 250°C
•
quantify metrology effects by calibrating transducers over multiple
temperature ranges
• >1000 hours survival at 250°C in life-cycle test. (Hybrids with the
oscillator ASIC have surpassed 6500+ hours in our 250°C life-cycle
test.)
• >1000 hours operation in continuously powered tests at
225°C. (Hybrids with the oscillator ASIC have surpassed 5000+ hours in
our 225°C powered test.)
Quartzdyne Breaking Ground on a New 50,000 ft² [4650
m²] Facility
We are pleased to announce that Quartzdyne will begin
construction on a new facility this summer. It's projected completion
date is mid 2009, and it will be located five miles northwest of our
present location (closer to the airport.) We've designed it
with growth and flexibility in mind, and it will make a significant
improvement in our LEAN manufacturing initiatives. Those who
have visited our current facility know that we're running out of
space. We have over 90 employees, and it is increasingly difficult to
make room for additional people and equipment.
We're keenly aware that moving a company is a significant
disruption, and we will mitigate the disruption by carefully managing
inventory and moving manufacturing cells in stages. We
will also use outside resources to advise and assist in the relocation
process to minimize the impact on customer
orders.
Quartzdyne Electronics (QE) Presents
at HiTEC
Quartzdyne
launched QE two years ago in response to customers' needs to upgrade
circuits to hybrid technology. By leveraging our manufacturing and
test-qualification experience, QE will fabricate your hybrid to the high
standard you've come to expect from Quartzdyne transducer hybrids. To
demonstrate the long life at high temperature provided by our hybrid
electronics, we've deliberately destroyed thousands of circuits in our
lifecycle tests since 1998.
QE
will build your hybrid circuit, allowing
you to achieve longer life, higher temperature
operation, reduced circuit size, and rugged packaging for severe downhole
environments. Our techniques and specialized materials ensure
resilient component attachment and exceptional wirebonds. QE will screen
and qualify your custom hybrid circuit prior to shipment, just as we do
for the hybrids used in our transducers. Although the up-front costs of die acquisition and
layout are higher for hybrids, the revenue generated from increased tool
up-time can easily compensate for the
initial investment.