Experience from design, prototyping and production of a DC-DC conversion powering scheme for the CMS Phase-1 Pixel Upgrade

The CMS Collaboration has adopted a DC-DC conversion powering scheme for the Phase-1 Upgrade of its pixel detector. DC-DC buck converters with a conversion ratio of around 3 are installed on the support structures, outside of the sensitive tracking region, requiring a re-design of the low and high voltage distribution to the pixel modules. After several years of R\&D, the project has entered the production phase. A total of 1800 DC-DC converters are being produced, and rigorous quality assurance and control is being employed during the production process. \\ The testing program is outlined, results from mass production are presented and issues that have been encountered are described. In addition, two system level challenges, namely the choice of output voltage in the presence of large, load-dependent voltage drops, and the thermal management required to remove the heat load caused by the DC-DC converters, are discussed.