UCC28810 LED Flyback Transformer Design Calculations

UCC28810 25W FLYBACK PFC LED LIGHTING POWER

CONTROLLER Transformer Design
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Yellow highlighted regions are User-Input parameters, regions outlined are
calculated results
VACmin := 85V Minimum Line Voltage, V ACmin

VACmax := 305V Maximum Line Voltage, V ACmax

VOUT := 36V Output Voltage, V OUT

POUT := 25W Output Power, P OUT

POUT
IOUT :=
VOUT

IOUT = 0.694 A Output Current, IOUT

η := 0.85 Predicted Efficiency, η

POUT
PINavg :=
η

PINavg = 29.412 W Predicted Average Input Power, PINavg

VF := 0.7V Forward voltage drop of the output rectifier at 100C, V F

Graph the minimum and maximum line voltage:

π
x := 0 , .. 2π
100
VSINmin( x ) := VACmin⋅ 2 ⋅ sin( x )

VSINmax( x ) := VACmax⋅ 2 ⋅ sin( x )

Line Voltage
450
405
360
315
V SINmax( x)270
225
V SINmin( x)180
135
90
45
0
0 0.31 0.63 0.94 1.26 1.57 1.88 2.2 2.51 2.83 3.14
x

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UCC28810 LED Flyback Transformer Design Calculations

Flyback Inductor Design: Select the desired minimum switching frequency over the 60 Hz line: for
small transformer size, select 80kHz or greater at low line; for optimum EMI performance, select
less than 150kHz at high line.

fSWvmin := 80kHz Selected switching frequency at low line, f SWvmin

1
TSWvmin :=
fSWvmin

TSWvmin = 12.5 μs Switching period at minimum line, T SWvmin

fSWvmax := 135kHz Selected switching frequency at high line, fSWvmax

1
TSWvmax :=
fSWvmax

TSWvmax = 7.407 μs Switching period at maximum line, TSWvmax

Maximum voltage stress on the switch is at V ACmax at π/2. Will use an 800V switch and allow a 300V
margin to account for the leakage spike, input surges, and device reliability. The reflected output
voltage, Vflyback, can then be estimated:

VDSrated := 800V Rated VDS of selected MOSFET, V DSrated

Vmargin := 300V Selected VDS margin of MOSFET for reliability, V margin

⎛π⎞
Vflyback := VDSrated − VSINmax⎜ ⎟ − Vmargin
2 ⎝ ⎠
Vflyback = 68.665 V Allowed reflected voltage to meet reliability requirements, V flyback

The Primary to Secondary Turns ratio, N PS, can be calculated:

Vflyback = VOUT⋅ NPS

Vflyback
NPS :=
VOUT

NPS = 1.907 Calculated Primary to Secondary turns ratio, N PS

NPS := 1.957 Actual Primary to Secondary Turns Ratio

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UCC28810 LED Flyback Transformer Design Calculations

K is the constant ratio between the input voltage and the primary side peak switch current, I PRIpk,
that is determined by the Current Reference Generator in the UCC28810. We need to determine
the waveshape of the average input current at 60Hz, since the Current Reference Generator will
force the peak switch current to match the input voltage waveshape and the peak current is not
linearly related to the average input current.

Calculating K at the minimum line voltage, K vmin, and at the maximum line volage, KVmax

⎛⎜ ⌠ π ⎞⎟
( )
1
⋅ NPS ⋅ VOUT ⎮
2
2 ⎜ VSINmin( x ) ⎟
Kvmin := ⋅ ⎮ dx
PINavg ⋅ π ⎜⎮ N ⋅V + VSINmin( x ) ⎟
⎜ ⌡0 PS OUT ⎟
⎝ ⎠
Kvmin = 51.096 Ω

⎛⎜ ⌠ π ⎞⎟
( )
1
⋅ NPS ⋅ VOUT ⎮
2
2 ⎜ VSINmax( x ) ⎟
Kvmax := ⋅ ⎮ dx
PINavg ⋅ π ⎜⎮ N ⋅V + V ( x ) ⎟
⎜ ⌡0 PS OUT SINmax
⎟
⎝ ⎠
Kvmax = 266.719 Ω

Now that K vmin and Kvmax are found, the primary side peak switch current at the minimum and
maximum input voltages, I PRIpk_vmin and IPRIpk_vmax, can be calculated:

IPRIpk_vmin ( x ) :=
VSINmin( x )
⎛π⎞
IPRIpk_vmin ⎜ ⎟ = 2.353 A
Kvmin ⎝ ⎠
2

IPRIpk_vmax ( x ) :=
VSINmax( x )
⎛π⎞
IPRIpk_vmax ⎜ ⎟ = 1.617 A
Kvmax ⎝ ⎠
2

Peak Primary Current vs Line Voltage

4
3.6
3.2
IPRIpk_vmin( x)2.8
2.4
2
IPRIpk_vmax( x)1.6
1.2
0.8
0.4
0
0 0.79 1.57 2.36 3.14
x

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UCC28810 LED Flyback Transformer Design Calculations

At the critical conduction point (minimum line, maximum load) there will be no deadtime so
the duty cycle, Dvmin, can be calculated:

(VOUT + VF)⋅ NPS TSWvmin

tONvmin :=
⎛π⎞
(
VSINmin⎜ ⎟ + NPS ⋅ VOUT + VF
2 ⎝ ⎠
)

tONvmin = 4.675 μs Estimated on-time at low line

tONvmin
Dvmin :=
TSWvmin

Dvmin = 0.374 Estimated duty cycle at low line

tOFFvmin := TSWvmin − tONvmin

tOFFvmin = 7.825 μs Estimated off-time at low line

Now calculate the Primary Inductance, L P, and the secondary inductance, L S, based upon
minimum line voltage and maximum on-time::

⎛π⎞
LP := VSINmin⎜ ⎟ ⋅
tONvmin
2 ⎝ ⎠ I ⎛π⎞
PRIpk_vmin ⎜ 2 ⎟
⎝ ⎠
LP = 238.881 μH Calculated primary inductance, L P

LP := 240μH Actual Primary Inductance

LP
LS :=
2
NPS

LS = 62.666 μH Calculated secondary inductance, L S

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UCC28810 LED Flyback Transformer Design Calculations

Calculate the varying switching frequency, f SW, and duty cycle, D, at minimum and maximum line
voltages

Low line:
LP⋅ IPRIpk_vmin ( x )
tONvmin ( x ) :=
VSINmin( x )

tONvmin ⎜
⎛ π ⎞ = 4.697 μs
⎟ Calculated on-time at low line, t ONvmin
⎝2⎠

NPS ⋅ LS⋅ IPRIpk_vmin ( x )

tOFFvmin ( x ) :=
VOUT

tOFFvmin ⎜
⎛ π ⎞ = 8.014 μs
⎟ Calculated off-time at low line, t OFFvmin
⎝2⎠
1
fSWvmin( x ) :=
tONvmin ( x ) + tOFFvmin( x )

⎛π⎞
fSWvmin⎜ ⎟ = 78.67 kHz
Calculated switching frequency at low line, f SWvmin
2 ⎝ ⎠

Dvmin( x ) := tONvmin ( x ) ⋅ fSWvmin( x )

⎛π⎞
Dvmin⎜ ⎟ = 0.37 Calculated duty cycle at low line, Dvmin
2 ⎝ ⎠

Frequency and Duty Cycle, Low Line

250 1

210 0.8

fSWvmin ( x)170 0.6

Dvmin ( x)
1000 130 0.4

90 0.2

50 0
0 0.31 0.63 0.94 1.26 1.57 1.88 2.2 2.51 2.83 3.14
x

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UCC28810 LED Flyback Transformer Design Calculations

High line:

LP⋅ IPRIpk_vmax( x )
tONvmax( x ) :=
VSINmax( x )

tONvmax⎜
⎛ π ⎞ = 0.9 μs
⎟ Calculated on-time at high line, tONvmax
⎝2⎠
NPS ⋅ LS⋅ IPRIpk_vmax ( x )
tOFFvmax( x ) :=
VOUT

tOFFvmax⎜
⎛ π ⎞ = 5.509 μs
⎟ Calculated off-time at high line, tOFFvmax
⎝2⎠

1
fSWvmax( x ) :=
tONvmax( x ) + tOFFvmax( x )

⎛π⎞
fSWvmax⎜ ⎟ = 156.033 kHz
Calculated switching frequency at high line, f SWvmax
2 ⎝ ⎠
Dvmax( x ) := tONvmax( x ) ⋅ fSWvmax( x )

⎛π⎞
Dvmax⎜ ⎟ = 0.14 Calculated duty cycle at high line, D vmax
2 ⎝ ⎠

Frequency and Duty Cycle, High Line

1500 1
1350
1200 0.8
1050
fSWvmax ( x) 900 0.6
750 Dvmax ( x)
1000 600 0.4
450
300 0.2
150
0 0
0 0.31 0.63 0.94 1.26 1.57 1.88 2.2 2.51 2.83 3.14
x

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UCC28810 LED Flyback Transformer Design Calculations

Calculate the waveshape of the average input current to the PFC flyback. The shape is not
sinusoidal because the average input current does not have a constant relationship to the peak
switch current. The peak switch current is forced to be sinusoidal by the multiplier.

1
IAVGvmin( x ) := ⋅ IPRIpk_vmin ( x ) ⋅ Dvmin( x )
2

⎛π⎞
IAVGvmin⎜ ⎟ = 0.435 A Average input current at low line, I AVGvmin
2 ⎝ ⎠

1
IAVGvmax( x ) := ⋅ IPRIpk_vmax ( x ) ⋅ Dvmax( x )
2

⎛π⎞
IAVGvmax⎜ ⎟ = 0.114 A Average input current at high line, I AVGvmax
2 ⎝ ⎠

Average Input Current Over Line Voltage

0.5

0.4

IAVGvmin ( x)0.3

IAVGvmax ( x)0.2

0.1

0
0 0.31 0.63 0.94 1.26 1.57 1.88 2.2 2.51 2.83 3.14
x

Primary RMS input current calculations:

Dvmin( x )
IPRIrms_vmin( x ) := IPRIpk_vmin ( x ) ⋅
3

⎛π⎞
IPRIrms_vmin⎜ ⎟ = 0.826 A Primary RMS current at low line, I PRIrms_vmin
2 ⎝ ⎠
π
⌠
⎮ IPRIrms_vmin( x ) dx
⌡
0
IPRIrmsavg_vmin :=
π

IPRIrmsavg_vmin = 0.572 A Average primary RMS current over line cycle at

low line, IPRIrmsavg_vmin

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UCC28810 LED Flyback Transformer Design Calculations

Dvmax( x )
IPRIrms_vmax( x ) := IPRIpk_vmax( x ) ⋅
3

⎛π⎞
IPRIrms_vmax⎜ ⎟ = 0.35 A Primary RMS current at high line,
2⎝ ⎠ IPRIrms_vmax

π
⌠
⎮ IPRIrms_vmax( x ) dx
⌡
0
IPRIrmsavg_vmax :=
π
Average primary RMS current over line cycle at
IPRIrmsavg_vmax = 0.255 A high line, IPRIrmsavg_vmax

Secondary side current calculations:

ISECpk_vmin( x ) := IPRIpk_vmin ( x ) ⋅ NPS

Peak secondary side current at low line,
⎛π⎞
ISECpk_vmin⎜ ⎟ = 4.604 A
ISECpk_vmin
⎝2⎠

1 − Dvmin( x )
ISECrms_vmin( x ) := ISECpk_vmin( x ) ⋅
3

⎛π⎞
ISECrms_vmin⎜ ⎟ = 2.111 A Secondary RMS current at low line, I SECrms_vmin
2 ⎝ ⎠
π
⌠
⎮ ISECrms_vmin( x ) dx
⌡
0
ISECrmsavg_vmin :=
π

ISECrmsavg_vmin = 1.257 A Average secondary RMS current over line cycle at

low line, ISECrmsavg_vmin

ISECpk_vmax( x ) := IPRIpk_vmax ( x ) ⋅ NPS

Peak secondary side current at high line,
⎛π⎞
ISECpk_vmax⎜ ⎟ = 3.165 A ISECpk_vmax
2 ⎝ ⎠
1 − Dvmax( x )
ISECrms_vmax( x ) := ISECpk_vmax( x ) ⋅
3

⎛π⎞
ISECrms_vmax⎜ ⎟ = 1.694 A
2 ⎝ ⎠ Secondary RMS current at high line, I SECrms_vmax

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UCC28810 LED Flyback Transformer Design Calculations

π
⌠
⎮ ISECrms_vmax( x ) dx
⌡
0
ISECrmsavg_vmax :=
π

Average secondary RMS current over line cycle at

ISECrmsavg_vmax = 1.046 A high line, ISECrmsavg_vmax

Verify that the input power intagrated over a line cycle matches the calcultated average input power
π
⌠ 1
⎮ ⋅L ⋅I
2
( x ) ⋅ fSWvmin( x ) dx
⎮ 2 P PRIpk_vmin
⌡
0
PINavg_vmin := PINavg_vmin = 29.412 W
π

π
⌠ 1
⎮ ⋅L ⋅I
2
( x ) ⋅ fSWvmax( x ) dx
⎮ 2 P PRIpk_vmax
⌡
0
PINavg_vmax := PINavg_vmax = 29.412 W
π

PINvmin( x ) := VSINmin( x ) ⋅ IAVGvmin( x )

⎛π⎞
PINvmin⎜ ⎟ = 52.25 W Peak input power at low line, PINvmin
2⎝ ⎠

PINvmax( x ) := VSINmax( x ) ⋅ IAVGvmax( x )

Peak input power at high line, PINvmax
⎛π⎞
PINvmax⎜ ⎟ = 48.969 W
2⎝ ⎠

Input Power Over Line Voltage

60
50
P INvmin( x)40
30
P INvmax( x)20
10
0
0 0.31 0.63 0.94 1.26 1.57 1.88 2.2 2.51 2.83 3.14
x

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UCC28810 LED Flyback Transformer Design Calculations

Core Selection: Ferrite material is cost effective and widely used for SMPS. EE cores are widely
used for low power designs. For the flyback design, it is desired to keep the peak flux density
below 280mT for a flyback design: a 15% margin was given for B max with a result of 240mT.

−6 −3 −9
μJ := 10 J mT := 10 T nH := 10 H

Bmax := 240mT Maximum allowable flux density, Bmax

N87 material has a flux density of 390mT at 100C so this material shall be used. An E25/13/7
core is readily available (B66317) and suitable for power levels below 50W

2
Ae := 52.5mm Area of selected core, Ae

Determine number of primary turns:

LP⋅ IPRIpk_vmin ⎜
⎛π⎞
⎟
NP :=
⎝2⎠
Bmax⋅ Ae

NP = 44.812 Calculated required number of turns for primary side, N P

NP
NS :=
NPS

NS = 22.898 Calculated required number of turns for secondary side, N S

VPRIbias := 19V Desired primary side bias voltage, V PRIbias

VPRIbias⋅ NS
NBpri :=
VOUT

NBpri = 12.085 Calculated required number of turns for primary side bias,
NBpri

VSECbias := 15V Desired secondary side bias voltage, V SECbias

VSECbias⋅ NS
NBsec :=
VOUT

NBsec = 9.541 Calculated required number of turns for secondary side bias,
NBsec

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UCC28810 LED Flyback Transformer Design Calculations

Actual peak flux density over line voltage:

LP⋅ IPRIpk_vmin ( x )
Bvmin( x ) :=
NP⋅ Ae

LP⋅ IPRIpk_vmax( x )
Bvmax( x ) :=
NP⋅ Ae

Peak Flux Desity over Line Voltage

0.3

0.24

Bvmin ( x)0.18

Bvmax ( x)
0.12

0.06

0
0 0.31 0.63 0.94 1.26 1.57 1.88 2.2 2.51 2.83 3.14
x

Calculate required gap:

−7H 2
4 ⋅ 10 ⋅ π ⋅ NP ⋅ Ae
m
gap :=
LP

gap = 0.552 mm
Calculated air gap, gap in mm and in inches
gap = 0.022 in

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