THE 11th INTERNATIONAL SYMPOSIUM ON ADVANCED TOPICS IN ELECTRICAL ENGINEERING

March 28-30, 2019

Bucharest, Romania

The Design of the Secondary Electrical Circuit of a

Flyback Transformer with Hybrid Magnetic Core
Yelda Veli1, Alexandru M. Morega1,2, Senior Member, IEEE, Lucian Pîslaru-Dănescu3, Mihaela Morega1, Senior Member, IEEE,
Gabriela Telipan3
1
Faculty of Electrical Engineering, University POLITEHNICA of Bucharest, Romania
2
”Gh. Mihoc – C. Iacob” Institute of Statistical Mathematics and Applied Mathematics, Romanian Academy
3
National Institute for Research and Development in Electrical Engineering ICPE-CA, Bucharest, Romania
[email protected], [email protected], [email protected], [email protected], [email protected]

Abstract— We present numerical modeling results for a planar, 100 nm, suspended in a carrier fluid (usually water or organic
miniature flyback transformer (FBT) powered by a pulse with solvent) [6–8,10-11]. Magnetic nanoparticles used in
modulated (PWM) voltage supply, whose magnetic core is hybrid, ferrofluid synthesis comprises iron oxides magnetite Fe3O4,
made of ferrite, magnetic nanofluid and non–magnetic parts. The
central column, made of the ferrite, has an air gap for enhanced maghemite γ–Fe2O3, hematite α–Fe2O3 [12–17] ferrites with
energetic performance. This paper is concerned with the analysis general formula MFe2O4 where M = Fe, Co, Cu, Ni, Zn, Mg,
of the electrical secondary (load) circuit with the aim to adapt it to Mn, Ba [18,19], Co1-xZnxFe2O4 where x = 0.25; 0.5; 0.75
optimally transfer the energy stored within the transformer and to [19]. Other magnetic materials comprise: ceramic oxides
minimize the losses during the switching time. Al2O3, CuO, carbide SiC, TiC, nitride AlN, SiN, metals Au,
Keywords: flyback transformer, converter, numerical simulation, Ag, Cu, semiconductors as TiO2, carbon materials as carbon
discontinuous conduction mode, superparamagnetic magnetic nanotube and alloy Al70Cu30 [6,21].
nanofluid, finite element method Fe3O4 is the common magnetic material used in ferrofluid
synthesis, because possesses high saturation magnetization in
I. INTRODUCTION bulk 92 emu/g and small particles size [22,23]. The structure of
Energy harvesting (EH) has become recently a matter of Fe3O4 consists in cubic inverse spinel based on 32 O2– ions and
concern in low power applications and new solutions for energy close packed along [111] direction. Fe3O4 contains the both
storage and conversion are under current research. A central ions Fe2+ and Fe3+, where the Fe2+ ions occupy half of the
device, in most EH packages, is the flyback transformer (FBT). octahedral sites and Fe3+ are split evenly across the remaining
In some applications FBTs are powered by PWM (pulse width octahedral sites and the tetrahedral sites [24].
modulated) sources and their role is to sequentially store and For technological and medical applications, the colloidal
deliver magnetic energy to an electrical load. suspension in ferrofluid must be very stable, because for a long
The FBT works mainly in two operation modes, which are period the magnetic nanoparticles become unstable through the
ruled by the amount of energy delivered to the load: the aggregation phenomenon and lead to unwanted phenomena:
continuous conduction (CCM), and the discontinuous loss of dispersibility the small magnetic nanoparticles tend to
conduction mode (DCM) [1–3]. Due to this working mode, aggregate and form large particles to reduce the surface energy
which is unlike true transformers whose role is to change the and the loss of magnetic properties because the magnetic
electrical parameters (voltages, currents) at which energy is nanoparticles are easily oxidized in air this is the case of Fe3O4
provided to the load, FBT is sometimes termed inductor and γ–Fe2O3 [25].
rather than transformer. To eliminate the aggregation phenomena of magnetic
In the quest for FBT magnetic circuit designs able to store nanoparticles, they are treated with different surfactants or
larger amounts of energy, attention is given to new magnetic functionalizing agents as: of fatty acids as oleic, amine
materials such as the super–paramagnetic nanofluids MNF. MNFs derivatives (tetramethylammonium hydroxide, ethylene diamine
are widely used in various applications, for cooling purposes, tetra acetic acid), polymers (dextran, polyvinyl alcohol) [26].
magnetic particle delivery, coupling elements, etc. [3–8]. Generally, the composition of a ferrofluid is composed of 5%
A novel type of FBT that is using MNF as part of its magnetic solid nanoparticles, 10% surfactant and 85% liquid
magnetic core (mainly ferrite) is presented in [9], and design carrier as oil [27]. Depending on composition, reaction
aspects, and numerical and experimental results are found also parameters, dimension magnetic nanoparticles and surfactant,
in [3–5]. This paper is concerned with the analysis of the FBT ferrofluids are used in many applications: cooling agent, heat
to load adaption concerning energy transfer optimization. transfer, several actuation process, optic, medical, lubrication,
mass transport, boiling phenomena, electronic [10, 28–31].
II. MAGNETIC NANOFLUIDS In transformers, the magnetic nanofluid (MNF) is usually
used for cooling and insulating purposes. In this paper, the
Ferrofluids are stable nanoscale colloidal solutions made transformer oil–based magnetic nanofluid (MNF/UTR 40) is
of magnetic nanoparticles with dimension between 1 and used because the values of magnetization and hysteresis.

978-1-7281-0101-9/19/$31.00 ©2019 IEEE

III. THE FLYBACK TRANSFORMER – PROTOTYPE AND MODEL load, by discharging the secondary circuit capacitance, C, until
Figure 1 shows the FBT that is using a super– a new cycle begins. This operation mode, by discharging all the
paramagnetic 500 Gs MNF as part of its magnetic core [3,9]. stored energy accumulated in the magnetic circuit of the
This is a 1:1 planar FBT aimed to be powered by a PWM flyback converter is known as the DCM operation mode. It is
voltage supply at high frequency. It has four circular, pancake the opposite of the CCM operation mode, in which part of the
coils, coupled two by two in series, forming the primary, and magnetic energy is still located in the core of the device when a
the secondary winding, respectively. Because of the magnetic new ON interval begins.
properties and the additional coupling factor given by the Figure 3 shows the equivalent circuit of the FBT model
MNF material, the non–magnetic spacers between the analyzed in [3], for which different values for the load of the
primary and secondary winding are replaced with the MNF. secondary circuit (resistance and capacitance), and different
RC time constant values are analyzed.

Fig. 1. The FBT prototype with hybrid, ferrite and MNF core (left) and its
pancake windings (right). Fig. 3. Equivalent electrical circuit for the FBT with a PWM voltage supply,
working at 10 kHz, with an RC load.
In this study we consider a simplified design of FBT that
preservers its main functionality though, Fig. 2. Previous work [3] was concerned with finding and
optimizing the air gap of the FBT energized by a high
frequency PWM voltage source, for a specific duty cycle,
(namely, for τ1 = RC = 0.03 ms) when different magnetic
media are used, respectively MNF.
The model used in [3–4] is further analyzed here for the
same ON and OFF intervals and different τ = RC time
constants, considering the highly magnetic properties of the
MNF that fill–in the space between the windings and the ferrite
core, except for the gap in the central column, which is always
occupied by a non–magnetic medium, e.g., air. The model is
further analyzed for different R and C values of the secondary
circuit and different secondary loads.
IV. THE MATHEMATICAL MODEL
a. The detailed model of the FBT [2].
A. The Electromagnetic Field
The quasi–stationary physical model, for the electromagnetic
field, is described by Faraday’s law
∂B
∇× E =− , (1)
∂t
the magnetic circuit law
∂D
∇× H = J + , (2)
∂t
where E is electric field strength, and B is magnetic flux
density, H is the magnetic field strength, D is electric flux
b. The simplified FBT model (axial symmetry is used). ∂D
Fig. 2. The FBT with an air gap in the central column.
density, is displacement current density, and J is
∂t
The central column of the FBT in Fig. 2 has an air gap [3,5] conduction electric current density.
to enhance energy storage. The electric flux law, ∇⋅ D = 0 , the magnetic flux law,
When the secondary circuit diode, D2, is reverse biased ∇⋅ B = 0 , the conduction law, J = σE, and D = εE, and
(Fig. 3), the OFF interval of the PWM voltage supply starts, B = μH constitutive laws, where σ is the electric conductivity,
the electrical current through the primary circuit is zero and all ε is the electric permittivity, and µ is the magnetic
the stored energy during the ON interval is delivered to the permeability, close the physical model.
 The partial differential equation that describes the The load time constant (τ = RC) is adjusted for both
magnetic field inside design (A) FBT is design models and are divided in the following: (A) τ =
0.03 ms; (B) τ = 0.3 ms, and (C) τ = 0.1 5ms. The R and C
(
∇× μ −1 −1
0 μ r ∇× A = 0 , ) (3) values are also independently varied, making the object of
further study cases: (I) R = 1 Ω, and C = 0.03 mF; (II) R = 1
where A is the magnetic vector potential, µ0 is the magnetic mΩ and C = 0.03 F, and (III) R = 0.5 mΩ and C = 0.3 mF.
permeability of the free space, and µr is relative permeability.
The magnetic field for design (B) (hybrid core, with
MNF) is described by

(
∇× μ −1
0 ∇× A− M = 0 , ) (4)

where M is the magnetization (isotropic).

The MNF in design (B) “works” in its linear magnetic
range, approximated out of the M–H relation:
M = α arctan(βH ) ≈ αβH = χH , (5)
where α = 7.668·10-8 m2/s and β = 6.78·10-4 s/m2 are empiric
constants, and χ is the magnetic susceptivity.
Insulation for the magnetic and electric field boundary
conditions (BCs) and circuit BCs for the terminals of the coil, a. The FBT PWM supplied voltage (lower wave) and load current
close the mathematical model. (upper wave), duty cycle 50%, at 999.9 kHz, 4.44 V peak–to–peak,
Figures 4, 5 show the equivalent electrical circuit of the experimental data.
device for different secondary circuit loads, including
different light emitting diodes (red, blue, and green LEDs).

Fig. 4. Electrical equivalent circuit for the FBT with a PWM voltage source at
10 kHz, with RC and a led load (C = 0.3 mF, R = 1 Ω).
b. The FBT PWM supplied voltage (lower wave) at 10 kHz, duty cycle
We further analyze the case, which has two additional 30% – synthetic, analytic signal used in numerical simulations.
light emitting diodes (LEDS), with different forward voltage Fig. 6. The PWM FBT primary voltage.
values in the secondary circuit, Fig. 4.
Figures 7 and 8 render the magnetic flux density during an
ON interval for the maximum amount of energy stored for the
specified air gap size. Only the δ = 0.22 mm case (where δ is
the size of air gap slot in the central column) is shown here.

Fig. 5. Equivalent circuit for the FBT with a PWM voltage source at 10 kHz,
with RC load and different light emitting diodes (D3, D4, respectively D5).

The resistance value of the secondary resistor, Rs, (Fig. 2)

is divided equally between the other resistors, R3, R4,
respectively R5, so that RC time constant (Fig. 4) is kept.
V. NUMERICAL SIMULATION RESULTS AND DISCUSSION
Although the PWM prototype works to frequencies up to 1
MHz (Fig. 6,a), in this study the source delivers 6 V at 10 kHz,
with a duty cycle D = ton/T = 0.3 (Fig. 6,b). The designs presented
in [3] are analyzed here from the load circuit perspective: design
(A), without MNF, and design (B), with MNF. a. Design (A) – FBT with FR4 and air for circuit (B) III (τ = 0.3 ms).
 the optimal air gap size for which the maximum amount of
magnetic energy is stored, is about δ = 0.24 mm.
Figures 9 and 10 present the electric power of the
capacitance for design (B), with the MNF, for different values
of the load R and C circuit elements, during the OFF interval.

b. Design (B) – FBT with MNF, for circuit (B) III (τ = 0.3 ms).

Fig. 7. Magnetic flux density at t = 0.12 ms, for primary ON, secondary OFF,
for δ = 0.22 mm, C = 0.3 mF and R = 0.5 mΩ. Values are in Tesla.

The magnetic flux density increases with increasing RC

time constant. The displacement current density, depicted by
the horizontal red field lines, appears as a result of the high Fig. 9. The electric power of the load capacitor for design (B) – MNF, and
case (A) I (RC = 0.03 ms).
frequency working conditions of the device.

a. Design (A) – FBT with FR4 and air for circuit (A) II (τ = 0.03 ms). Fig. 10. The electric power of the load capacitor for design (B) – MNF, and
case (A) II (RC = 0.03 ms).

Case (I) presents a lower capacity storing capacitance, C =

0.03 mF and R = 1 Ω; Case (III) presents a maximum storing
capacitance for C = 0.03 F and R = 1 mΩ, and Case (II)
stands for intermediate values C = 0.15 mF and R = 0.2 mΩ.

b. Design (B) – FBT with MNF for circuit AII (τ = 0.03 ms).
Fig. 8. Magnetic flux density at t = 0.12 ms, for primary is ON, and secondary
OFF, for δ = 0.22 mm, C = 0.3 mF and R = 0.5 mΩ. Values are in Tesla.

It is also worth to notice that, although the magnetic flux

density amount is higher for the air gap of δ = 0.22 mm, which
increases with increasing RC time constant, this gap size is Fig. 11. The magnetic energy for design (A), case A = 0.03, ms and different
optimal only for case (A), where the RC = 0.03 ms. For case (B), values of the load circuit elements: (I) C = 0.03 mF and R = 1 Ω; (II) C = 0.15
where the RC time constant is 10 times higher (τ = RC = 0.3 ms), mF and R = 0.2 mΩ, (III) C = 0.03 F and R = 1 mΩ).
 Figure 11 shows the dynamics of the magnetic energy resistance is needed for an optimal delivery of the magnetic
storage inside the air gap (with respect to initial state) when energy accumulated inside the device. Decreasing the value
δ = 0.22 mm, for design (A) without MNF, and different of the load capacitance C will result in an increase of power,
values for the R and C of the load circuit, during the ON but the device will not discharge completely when the OFF
sequence of the PWM source. time interval begins at 0.03 ms and will take over only a
The magnetic energy inside the air gap is computed, for small amount of the stored energy in the air gap. It is
both design models, design (A) (air and FR4), respectively important to properly select the values of the secondary
design (B) (air, FR4 and MNF), by integrating, at the end of circuit, since a small value of the capacitance C will result in
the ON interval, the magnetic energy density over the volume a desynchronized secondary circuit versus the primary PWM
of the slot in the central column of the FR4 core, for different
voltage supply that conducts the switching. Between 0.03 ms,
sizes of the gap (Fig. 12).
when the OFF time begins, and 0.04 ms, the energy
“switching” between the primary and secondary windings
begins. At 0.04 ms the ON – OFF switching is completed, but
energy is not entirely transferred, as reflected by the electric
power of the load capacitance. For a lower capacitance value,
the device will still store energy, until 0.04 ms (when the
loading of the capacitance is completed and the discharge to
the load resistor begins), resulting in less energetic efficiency.
By increasing the RC time constant value, the maximum
amount of magnetic energy that can be stored at a specified
size of the air gap domain is found around 0.24 mm, so by
increasing the time constant value, the air gap size for which
the maximum amount of energy occurs increases too.
Between design (A) and design (B), the maximum amount
Fig. 12. The magnetic energy for different air gap sizes, for design (B) with of stored magnetic energy is found for the same air gap size,
MNF, case (A) = 0.3 ms. for the same RC time constant values, and values for the load
circuit elements, but design (B) with MNF, exhibits a larger
Figure 13 presents the electric power of the capacitor for
amount as compared to design (B) without MNF.
case (B) (τ = 0.3 ms) and different loads, one blue LED with
the highest amount of forward voltage, and a group of three ACKNOWLEDGMENTS
LEDs: red, green and blue.
This research is a follow–up of project “Environment
energy harvesting hybrid system by photovoltaic and
piezoelectric conversion, DC/DC transformation with MEMS
integration and adaptive storage” accomplished with the
support of the Romanian National Authority for Scientific
Research UEFISCDI, PNCDI II Programme – Joint Applied
Research Projects, Romania, under the Contract 63/2014.
The FBT prototype, the energy–harvesting ensemble, and
the experiments were developed at ICPE–CA. Mathematical
modeling and numerical simulations were conducted in the
Laboratory for Multiphysics Modeling at the Faculty of
Electrical Engineering, UPB.
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