Presentation

Student: Phi Nguyen (3631) Date: 12/06/2003

TRANSFORMER DESIGN FOR FORWARD CONVERTER AND HALF BRIDGE FORWARD CONVERTER

Agenda
1) Introduction 2) Circuit Illumination of DC to DC 3) Steps for Transformer design 4) Example for Transformer design Forward Converter Half Bridge Converter(optional) 5) Advantage 6) Conclusion 7) Question
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Introduction
- Transformer has two basic functions: to provide electrical isolation and step up or step down time varying voltage and current. DC-to-DC converter enables the transformer to be small. - It can provide multiple output voltage. - Throughout the design transformer, the core size, optimum induction is selected and the primary turns, secondary turns are calculated.

CIRCUIT ILUMINATION OF DC-TO-DC FORWARD AND HALF BRIDGE CONVERTER In general, the transformer for the half bridge converter follows the same general principal used for the forward converter. Buck dc-dc converter: Vo=VdD Forward & Half bridge conv.: Vo= Vd

N2 D N1

Figure 1 - Forward converter

D1 L1

Vd

Lm

N1

N3

N2

D2

C1

Vo

S1

D3

Figure 2 - Half bridge forward converter

D1 C1 S1 Lx

N2 Vd N1 N2' C2 S2 D2

Vo

THE STEPS FOR TRANSFORMER DESIGN

Step 1: Selecting core size. From the basic of transmitted power and the manufactures recommendation. (Figure 2.2.2) Step 2: Selecting optimum induction. Use manufactures published chart. (Figure 2.9.1) Step 3: Calculate primary turns. Step 4: Calculate secondary turns.
V 1 N1 = V 2 N2

Note: Maximum duty ratio: Dmax= 0.5 (ton=toff).

EXAMPLE FOR TRANFORMER DESIGN

* Forward converter: P = 100W at fsw 30 kHz. Input: Vi = 90 130 V (nominal 110V) 50-60Hz. Output Vo and Io : 5V at 10 A (50W) +12V at 2A (24W) -12V at 2A (24W) Total = 98W -Core size: Use figure 2.2.2 E 42-15. At 100W Core parameters: area Ae=181 mm2 -Optimum induction: Use figure 2.9.1 At 100W and f = 30kHz. Bopt=150mT (for push pull). . Bm=250mT (for forward conv.)

-Calculate primary turns: Tsw=

1 fsw

= 33s

ton =

Tsw = 16.5 s 2

-Calculate primary voltage (V1): Use the approximate conversion factor: V1 = Vi x (1.3) x (1.9) V1 = 110 x (1.3) x (1.9) = 272V Min. primary turns:
V1(V) . ton ( s ). Nmin = = 100 turns Bm (T) . Ae (mm2)

At V1 min = 90V in dc primary voltage V1min= 90 x (1.3) x (1.9) = 222 V V/turn = N min = 100 = 2.22 V/turn
V 1 min 222

-Calculate secondary turns:

Lx

V2

N2

D2

Vo

Figure 3 - Single output application Vo = V2 x Dmax Choose V2 = 12V N2min

12 = 2.22

Vo V2 = = 10V. D max

(2V drop D1 and Lx)

= 5.4 turns. Choose N2 = 5.5 turns.

V 1 min V 2 = N1 N2 N2 N1=V1min V 2 = 102

turns.

Similarly, we have: V2 (at 12V) = 2 V0 + Vdrop = 26 V N2 (at 12V) = 11.9 turns. Choose N2 (at 12V) = 12 turns (Confirm the result by Pexpt)
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Difference

Parameter V1(V) V2(V) N1(turn) N2(turn)

Calculation 110 12 102 5.4

PExpt 110 13.6 100 5.0

% Difference / 11.7% 2% 8%

*Half bridge Forward converter: This design is very similar to the method use for the forward converter example. Figure 2.11.1 - Typical core section graph P = 100W at fs50 kHz. Vi = 85 137 V (nominal 110V). Vo = 5V and Io = 20 A (100W). V1 = Vi x (1.3) x (1.9) V1min = 85 x (1.3) x (1.9) = 209V V1nominal = 110 x (1.3) x (1.9) = 272V V1max = 137 x (1.3) x (1.9) = 338V -Core size: Use figure 2.11.1, at 100W . We choose core type EC 41. Core parameter: core area Ae=120 mm2 -Optimum induction: Use figure 2.9.1 at 100W and f=50kHz. Bopt= 85 mT ( for P.P ) For half bridge, we choose the max. flux density Bm=210mT. [ Bm = (85 x 2) . V 1nom = 210mT ]
V 1 max

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Figure 4 - Multiple output application

D1

L1 +5v

N2

D2

C1

D3

L2 +12v

N1

N21

D4

C2

COMMON N22 D5 D6 L3 -12V C3

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CORE CONSIDERATION: Related formulas:

d max

Vd = N1 dt ; max = 2Bmax Ae =

Vd = N1 ton
Vd . ton N1

(Bmax = 2B) Bmax =

Vd 4N1. Ae . fsw

(ton =

D fsw

; D = 0.5)

For forward converter: Bmax < 0.5 (Bm Br) Bm = Bsat

-A large value of Bm allows Bmax large result to smaller Ae. Therefore, smaller core size. -Higher switching frequency result in smaller core size. (However fsw> 100kHz result in a smaller value of Bmax to be chosen to limit the core losses).
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Advantage
- Isolate the output from the input electrically. - Smaller core size. - Provide a multiple output voltage. - Low cost.
The design for the DC power supplies is

very necessary.

*Conclusion Transformer is designed in almost AC to DC and DC-DC converter. It is an important device in the DC power supply. Specially, in dc-dc converter, transformer has a small size and therefore a low cost.
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CONCLUSION: Transformer is designed in almost AC to DC and DC-DC converter. It is an important device in the DC power supply. Specially, in dc-dc converter, transformer has a small size and therefore a low cost.

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A list of References:
1-

Switch mode power supply handbook by Keith Billing, 2nd Edition. Mc Graw Hill, 1999.

2- Power Electrics: Converter, Application and Design, Mohan, Undeland and Robbin, Willey, 1989. 3- Introduction to Power Electronic by Daniel W. Hart, Prentice Hall, Inc. 1997. 4- Lecture note Power Electric by Prof. D. Zhou, Ph. D. (2003).
5-

Http://www.power designers.com/infoweb/disg/converter.sht.

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