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Efficient Flyback Converter Transformer Design Guide

Understanding the requirements of a Flyback Converter transformer is crucial for efficient power conversion. This guide explores the necessary elements such as Energy Storage, Electrical Isolation, and Current Limiting Inductance. Learn about the impact of DC input changes on core properties and the approximations involved in transformer design. Discover key considerations like Core Size, On-Time of Circuit, and Working Flux Density Swing. Calculate the Number of Turns for primary and secondary windings, factor in core air gap effects, and ensure proper flux saturation levels. Benefit from tools like PExpert for faster design iterations. Appreciate the significance of transformer application specifics and the importance of practical knowledge alongside technical resources.

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Efficient Flyback Converter Transformer Design Guide

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Presentation Transcript

  1. Presented by: Will Lockhart 12/19/03

  2. What does the Flyback Converter need from the transformer ?  Energy Storage  Electrical Isolation  Current Limiting Inductance  Support Considerable DC Component

  3. ac change on input  causes  Bac in core  causes  Hac DC on input  causes HDC in core  causes BDC

  4. Calculation method of transformer design has a number of approximations that must be initially made  Core Size  ‘On Time’ of Circuit  Minimum DC Input  Working Flux Density Swing

  5. Nomogram for Core Material

  6. Flux Density Saturation Vs. Temperature

  7. Start Calculating  Number of Turns on Primary  Number of Turns on Main Secondary  Readjust Earlier Approximations  Number of Turns on Any OtherSecondary

  8. Core Air Gap Affects Primary Inductance Affects Current Waveforms Affects Stress on Components Affects Flux Retention, Br Affects Working Range of Flux Density, Bac And Effect of DC generated Flux

  9. Check Saturation  By Measurement  By Calculation Bac + BDC = Bmax < Bsat

  10. Another Way to Design  PExpert

  11. A Selection of Options---------Quickly

  12. Core and Material Data is Readily Available

  13. In Conclusion  I learned that there is a lot of variation in transformer design and the transformers intended application is more critical than I realized  PExpert can be much faster for designing and trying variations  Even with fancy programming tools or cookbook recipes you still have to understand what you are doing

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