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Flyback Transformer Tutorial Function and Design

The flyback transformer is a popular solution for power supply designs below 100-150W due to its low cost, simple design, and intrinsic efficiency. It provides isolation between the primary and secondary windings and can output multiple voltages. Flyback transformers store energy in the primary winding when the switch is on and transfer it to the secondary winding and load when the switch is off. Key design parameters include primary inductance, peak current, duty cycle, operating frequency, core size, air gap, and number of primary and secondary turns. Custom flyback transformers can be optimized for specific applications based on design requirements.

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382 views

Flyback Transformer Tutorial Function and Design

The flyback transformer is a popular solution for power supply designs below 100-150W due to its low cost, simple design, and intrinsic efficiency. It provides isolation between the primary and secondary windings and can output multiple voltages. Flyback transformers store energy in the primary winding when the switch is on and transfer it to the secondary winding and load when the switch is off. Key design parameters include primary inductance, peak current, duty cycle, operating frequency, core size, air gap, and number of primary and secondary turns. Custom flyback transformers can be optimized for specific applications based on design requirements.

Uploaded by

Dany Newby
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Flyback transformer tutorial: function and

design
Steve Chyo senior design engineer, and Vithi Singh is product manager, Tyco Electronics
Magnetics - April 24, 2006

The low cost, simplicity of design and intrinsic efficiency of flyback transformers have made them a
popular solution for power supply designs of below 100W to 150W. Other advantages of the flyback
transformer over circuits with similar topology include isolation between primary and secondary and
the ability to provide multiple outputs and a choice of positive or negative voltage for the output.

This article discusses design parameters for the flyback or swinging choke type of transformer used
in flyback converters. The latter has been used for many years and its topology is unique within the
transformer-isolated family of regulators.

Flyback transformer function

When the switch is turned on, energy is stored in the primary (within the core material). As shown in
Figure 1, the polarity dots on the transformer and the diode are arranged such that there is no
energy transferred to the load when the switch is on. When the switch is turned off, the polarity of
the transformer winding reverses due to the collapsing magnetic field, the output rectifier conducts
and the energy stored in the core material is transferred to the load. This activity continues until the
core is depleted of energy or the power switch is once again turned on.

Figure 1. Typical flyback transformer circuit

The flyback regulator can operate in either discontinuous or continuous mode. In the discontinuous
mode (see Figure 2), the energy stored in the core when the FET is on/off is completely emptied
from the core during the flyback period. In the continuous mode, (see Figure 3) the FET is turned on
before the core empties of flyback energy. A typical flyback transformer may operate in both modes
depending on the load and input voltage.
Designers should consider the maximum load at low voltage, including all conditions within the
operating range of the flyback, as it will simply shut down (discontinuous mode) between cycles and
wait for the load demand to catch up with the power-delivery capability. This is one of the most
dynamic characteristics of the flyback, regulated over a wide range of input voltage and load.

Figure 2. Flyback transformer in discontinuous mode

Figure 3. Flyback transformer in continuous mode

Flyback design parameters


Design parameters for a flyback transformer

The following equations are frequently used to specify a flyback transformer. They are followed by a
typical design example.
Let V= L dj/dt, and Vin,min =
(LpIppf)/(δmax)
Where Vin = input voltage, V
Lp = primary inductance, mH
Ipp = peak current, A
δmax = maximum duty cycle, μs
f = operating switching frequency, kHz

For discontinuous mode,


Power out = ½*Lp*Ipp*f
Ipp = (2Pout)/(Vin,min* δmax)

In the flyback transformer, as mentioned above, regulation is accomplished by PWM. If the


transformer Vin varies from Vin,min to Vin,max, then
δmin = (δmax) / ((1- δmax)C + δmax)
where C = Vin,max / Vin,min

Since Ipp is known,


Lp = (Vin,min* δmax) / (Ipp*f)

Although designers may rely on experience for core selection, that can only result in an
approximation. The following formula is recommended for a better estimate.

Ac*Ae = (((6.33*4)*Lp*Ipp*D)*108) / Bmax.


Where Ac = winding area, cm
Ae = core effective area, cm
Bmax = Bsat/2, Gauss. Consult core manufacturers for material and loss vs. frequency
D = diameter of wire, inch

Air gap must be calculated for the flyback transformer, since it is operating single-ended and uses
only half the flux capacity. This may create potential for driving the core into saturation.

Gap (cm) = lg = ((0.4*Π*Lp*Ipp)*108) / (Ae*Bmax)

After the air gap length is determined, the primary and secondary number of turns can be found.

Npri = (Bmax*lg) / (.4*Π*Ipp)


Nsec = (Np(Vp + Vd) (1-δmax)) / (Vin,min* δmax)

The following example demonstrates the design of a flyback transformer in the discontinuous mode.
Modern designs utilize PFC (power factor correction), positioned immediately after rectification.
Boost topology is frequently used for its dynamic characteristic and wide range of input voltage. PFC
will not be covered in this example.

Design parameters

Vinput = 85 to 132 VAC


Voutput = 5VDC @ 10A = 50Watts
Frequency = 100kHz
Assume δmax = .45

Discontinuous Mode
1) Calculate the peak Ipp
Since Vin,min = 85VAC, then Vin,min = 85*1.4-20V for ripple and diode drop gives about 100VDC.
Thus, Ipp = 2Pout / (Vin,min* δmax) = 100 / (100*.45) = 2.22 A

2) Calculate the δmin


Vin,max = 132VAC*1.4 = 185VDC
Allowing a 10% margin, Vin,max = 203VDC, say 200VDC
Allowing a 10% margin for Vin,min = 90VDC
This gives us an input voltage ratio C = 200/90 = 2.22
Therefore δmin = .45 / ((1-.45)*2.22+ .45) = .27
As is evident from these results, the transformer will operate over the duty ratio of 0.27 to 0.45 for
the Vin range of 200VDC to 90VDC.

3) Calculate primary inductance


Lp = 90*.45 / (2.22*100kHz) = .18mH

4) Select core
In this example we will use a current density of about 300 cm/A. Since Ipp = 2.22A, a total
centimeters will be 300*2.22 = 666 cm. From wire chart, 22 AWG has diameter of 0.028 inch. We
chose Magnetics, Inc material type “P” and from their catalog selected Bmax = 500 Gauss. This will
give us about 100mW/cm.
Therefore,
AcAe = (6.33*4) *(.00018Hy)*2.22*(.028)*(108) / (500) = 1.59 cm4.
From the catalog PQ43230 (PQ3230) size has AcAe = 1.60 cm4.

5) Calculate the air gap length


Lg = (.4*Π*.00018*(2.22)*108) / (1.37*(500)) = .30 cm (approx) at center leg of the core.

6) Calculate primary and secondary number of turns


Npri = 500*.30 / (.4*3.14*2.22) = 54 turns
Nsec = 54*(5 + 1) (1 - .45) / (90*.45) = 4.4 turns.
We will use 5 turns because there will be losses from winding, PCB and other parasitic losses which
we did not include. Next select wire for the output. For 10A, a wire of 10*300 = 3000cm, we choose
16AWG for the secondary. To minimize copper losses due to skin effect, we propose using multiple
strands of thinner wires (4 strands of 22 AWG is equivalent of single 16 AWG).

Design engineers must also check for bobbin fill factor and temperature rise calculations, as
implementation of safety requirements will increase the size of the flyback transformer.

Custom flyback transformers

CoEv Magnetics offers a wide range of SMPS transformers to meet customer needs and
requirements. Designed to optimize size, cost and performance for specific applications, custom
transformer packages are developed using a wide range of parameters, including: - Turns ratio -
Current Handling Capability
- Drive Levels - Inductance
- Leakage inductance - Self Resonant Frequency
- DC Resistance - Mounting Configuration
- Isolation Voltage

About the Authors:


Vithi Singh is CoEv magnetics Product Manager for Tyco Electronics. He received his BE in
Electrical engineering from REC Durgapur, India, 1993, and an MBA from Duke University in May
1995. He has extensive and diverse functional experience in managing change through strategic
business initiatives in a manufacturing environment. [email protected]

Steve Chyo is a Senior Magnetics Design Engineer for CoEv products. He received a BSEE in 1986
from Northwestern Polytechnic University. Currently, He has over 30 years of experience in the
power industry, with specific specialties in the areas of designing, consulting, and manufacturing of
magnetics and power supplies. [email protected]

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