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Switching Power Supply Design: A Concise Practical Handbook: February 2022

The document summarizes the key design considerations and equations for a flyback converter operating in discontinuous conduction mode (DCM). Some of the key points covered include: (1) how the flyback converter works by storing energy in the transformer's core during the ON state and releasing it during the OFF state, (2) the equations for output power, duty cycle, and output voltage in DCM, and (3) guidelines for selecting transformer parameters like inductance and turns ratio to ensure DCM operation over the input voltage range.

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223 views5 pages

Switching Power Supply Design: A Concise Practical Handbook: February 2022

The document summarizes the key design considerations and equations for a flyback converter operating in discontinuous conduction mode (DCM). Some of the key points covered include: (1) how the flyback converter works by storing energy in the transformer's core during the ON state and releasing it during the OFF state, (2) the equations for output power, duty cycle, and output voltage in DCM, and (3) guidelines for selecting transformer parameters like inductance and turns ratio to ensure DCM operation over the input voltage range.

Uploaded by

Wolfy gacha elamparo
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Switching Power Supply Design: A Concise Practical


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1.9 FLYBACK CONVERTER IN DCM

During ON state of the switch Q, energy is accumulated in the


core of the transformer (which acts as an inductor), while output
rectifier is reverse biased. During OFF state the transformer releases
its entire stored energy. Most of the energy is released via the
transformer’s secondary into the load and output capacitor Co, the
rest is dissipated in snubbers and primary clamp circuit (if any).
Switch Q turns ON at zero current but its peak current I1PK is higher
than in other topologies.

OUTPUT POWER

In discontinuous conduction mode (DCM):


Po=η∙ Lμ∙I1pk2∙F/2

where Po=Iout∙Vout – output power; η - efficiency of the converter;


Lμ – transformer’s magnetizing (primary) inductance in henry; F-
frequency in hertz; I1PK- peak primary current.
Peak primary current is controlled to regulate output voltage.

DUTY CYCLE
In steady-state fixed frequency operation:
�2Po ∙ Lμ ∙ F/η
D=
Vin
Switching Power Supply Design: A Concise Practical Handbook
where D=t1/T (D<1).

OUTPUT VOLTAGE

In steady state: Vout=ηVin2∙D2/(2Lμ∙F∙Iout).

TRANSFORMER
Peak primary current: I1PK =√(2Po/η·Lµ·F).
Peak secondary current: I2PK =I1pk∙N1/N2,
where N1/N2 - primary to secondary turns ratio.

If DCM is desired over entire input voltage range:

η ∙ VIN_MIN2 · DLL 2
Lμ <
2Po ∙ F

where DLL – desired maximum duty cycle at low line (DLL <Dmax,
where Dmax – maximum duty cycle of PWM).
In most controllers Dmax is 0.45 to 0.99. If Dmax is close to 1.0, it is
common to set DLL around 0.7 to limit maximum FET voltage.
For selected Lμ, duty cycle at low line:

�2Po ∙ Lμ ∙ F/η
DLL =
VIN_MIN

Turns ratio is usually selected such that at low line and full load the
transformer will be near the boundary of DCM and CCM:

N1 DLL ∙ VIN_MIN
≈
N2 Vout ∙ (1 − DLL)

The core’s reset time (the time it takes the transformer to completely
demagnetize) is given by:
Lμ ∙ I1 pk
tRESET =
(N1/N2) ∙ Vout

RMS value of primary current: I1_RMS=I1PK∙√(D/3).

Switching Power Supply Design: A Concise Practical Handbook 32


It reaches maximum at low line:

4 8 ∙ Po3
I1_RMS_MAX = �
9 ∙ Lμ ∙ F ∙ η3 ∙ VIN_MIN2

DC component of primary current: I1_DC=Vout∙Iout/(η·VIN)

RMS value of AC component of primary current:


I1_AC_RMS = �I1_RMS 2 − I1_DC 2

RMS value of secondary current:


treset ∙ F 4 8 ∙ Po3 · T 2
I2_RMS = I2 pk ∙ � =�
3 9 ∙ Lμ ∙ F ∙ η3 ∙ VOUT 2

DC component of secondary current: I2_DC=Iout.


RMS value of AC component of secondary current:
I2_AC_RMS = �I2_RMS2 − Iout 2
The required core and turns are determined by the N1·Ac product:
Lμ ∙ I1 pk ∙ 108
N1 ∙ Ac =
BPK
where Ac - core’s equivalent cross-sectional area in sq.cm, Bpk –
desired peak magnetic flux (Gauss).
See POWER INDUCTOR DESIGN (chapter 4.4) for selecting core
size.
Since in flyback the magnetizing current is primary current, in ferrite
cores an air gap must be introduced to prevent the magnetic material
saturation:
0.4 ∙ π ∙ N1 ∙ I1 pk lm
lg = −
BPK μr
where lg – net length of air gap (cm), lm – effective magnetic core
path length (cm), μr – relative permeability of ungapped core.

SWITCH Q
Switching Power Supply Design: A Concise Practical Handbook
Peak current: IQ_PK=I1PK;
Conduction losses: PQ_COND= I1rms 2∙Rdson, where Rdson - drain to
source resistance of Q in on-state.
Peak plateau voltage: VQ_pk=VIN_MAX+ Vout·N1/N2.

Note. Instantaneous peak voltage can exceed the plateau by


severalfold due to spikes caused by leakage inductance. Its actual
value depends on the leakage inductance, primary snubber and clamp
circuit (if any). As a rule of thumb, we select the MOSFET with rated
voltage 2-3 greater than VQ_PK, or use flyback either with two switches
or with active clamp reset (see 1.11).

If PWM controller limits switch peak current to IPK_LIM, maximum


achievable load current for given Vout:
η · Lµ · F ∙ IPK_LIM2
IOUT_MAX =
2 ∙ Vout

RECTIFIER D1
Peak current: ID_ PK =I2PK;
Average current: ID_av=Iout;
Reverse voltage plateau: VD_PK= Vout+VIN_MAX∙N2/N1.

Note. Instantaneous peak voltage can exceed the plateau by


severalfold due to spikes caused by leakage inductance. As a rule of
thumb, we select the diode with rated voltage 2-3 times greater than
voltage plateau VD_PK.

OUTPUT CAPACITOR Co
RMS current:
Ic_rms = �I2 rms 2 − Iout2

INPUT CURRENT
Average input current: IIN_AV=Vout∙Iout/(η·Vin);
AC component of input current, which is current through input
capacitor (not shown on the diagram): IIN_AC_RMS = I1_AC_RMS.

Switching Power Supply Design: A Concise Practical Handbook 34

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