Flyback Transformers - kickback transformer Page 1 of 4

Flyback Transformers - Kickback Transformers

A simple and low cost power supply is bound to be quite popular. The single ended
flyback circuit topology fits this description. The flyback transformer utilizes the
"flyback" action ( also known as "kickback" ) of an inductor or flyback transformer
to convert the input voltage and current to the desired output voltage and current.
Figures 1A and 1B show simple flyback transformer schematics for an inductor and
a flyback transformer. These schematics do not show any parasitic effects ( such
as leakage inductance and winding capacitance ). Modern flyback transformer and
circuit design now permit use in excess of 300 watts of power, but most
applications are less than 50 watts.

By definition a transformer directly couples energy from one winding to another

winding. A flyback transformer does not act as a true transformer. A flyback
transformer first stores energy received from the input power supply (charging
portion of a cycle) and then transfers energy (discharge portion of a cycle) to the
output, usually a storage capacitor with a load connected across its terminals. An
application in which a complete discharge is followed by a short period of inactivity
(known as idle time) is defined to be operating in a discontinuous mode. An
application in which a partial discharge is followed by charging is defined to be
operating in the continuous mode. See figures 2A and 2B for illustration.

Gapped core structures increase the magnetizing force needed to reach saturation
and lower the inductance of the flyback transformer (or inductor). Consequently, a
gapped flyback transformer (or inductor) can handle higher peak current values,
and thereby storing more energy, most of which is stored in the magnetic field of
the gap. For these reasons almost all flyback transformers (or inductors) are
gapped. The gap may be a discrete physical gap, several smaller discrete physical
gaps or a distributed gap. Distributed gaps are inherently present in low
permeability powdered cores. The bulk of the stored energy is stored in the
magnetic field of the gap(s). Most modern flyback transformers are operated at
high frequency hence gapped ferrite core materials are typically used.

Butler winding can make (and has made) flyback transformers in a wide variety of
shapes and sizes. This includes; various standard types of “core with bobbin”
structures (E, EP, EFD, EC, ETD, PQ, POT, U and others), toroids, and some
custom designs. We have experience with foil windings, litz wire windings, and
perfect layering. For toroids, we can (and have done) sector winding, progressive
winding, bank winding, and progressive bank winding. Butler winding has a variety
of winding machines, bobbin/tube and toroid. That includes two programmable
automated machines and a taping machine for toroids. To ensure quality, Butler
Winding purchased two programmable automated testing machines. Most of our
production is 100% tested on

these machines. For more information on our capabilities, click on our "capabilities"
link.

How does a flyback transformer ( or inductor ) work?

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Flyback circuits repeat a cycle of two or three stages; a charging stage, a

discharging stage, and in some applications idle time following a complete
discharge. Charging creates a magnetic field. Discharging action results from the
collapse of the magnetic field. The typical flyback transformer application is a
“unipolar” application. The magnetic field flux density varies up in down in value ( 0
or larger ) but keeps the same ( hence unipolar ) direction.

Charging Stage: The flyback transformer ( or inductor ) draws current from the
power source. The current increases over time. The current flow creates a
magnetic field flux that also increases over time. Energy is stored within the
magnetic field. The associated positive flux change over time induces a voltage in
the flyback transformer ( or inductor ) which opposes the source voltage. Typically,
a diode and a capacitor are series connected across a flyback transformer winding
( or inductor ). A load resistor is then connected across the capacitor. The diode is
oriented to block current flow from the flyback transformer ( or source ) to the
capacitor and the load resistor during the charging stage. Controlling the charging Bookmark Our Site!
time duration (known as duty cycle) in a cycle can control the amount of energy
stored during each cycle. Stored energy value, E = ( I x I x L ) / 2, where E is in
joules, I = current in amps, L = inductance in Henries. Current is defined by the
differential equation V(t) = L x di/dt. Applying this equation to applications with
constant source voltage and constant inductance value one obtains the following
equation; I = Io + V x t / L , where I = currents in amps, Io = starting current in
amps, V = voltage in volts across the flyback transformer winding ( or inductor ), L
= inductance in Henries, and t = elapsed time in seconds. Note that increasing L
will decrease the current. Stored energy will consequently decrease because
effects of the “current squared decrease” will more than offset the effects of the
inductance increase. Also be aware that the flyback transformer ( or inductor )
input voltage is less than the source voltage due to switching and resistive voltage
drops in the circuit.

Discharge Stage: The current ( which creates the

magnetic field ) from the source is then interrupted by opening a switch, thereby
causing the magnetic field to collapse or decrease, hence a reversal in the
direction of the magnetic field flux change ( negative flux change over time ). The
negative flux change induces a voltage in the opposite direction from that induced
during the charging stage. The terms “flyback” or “kickback” originate from the
induced voltage reversal that occurs when the supply current is interrupted. The
reversed induced voltage(s) tries to create ( induce ) a current flow. The open
switch prevents current from flowing through the power supply. With the voltage
reversed, the diode now permits current flow through it, hence current flows into
the capacitor and the load across the capacitor. If current can flow, then the
resulting flow of current is in the direction, which tries to maintain the existing
magnetic field. The induced current cannot maintain this field but does slow down
the decline of the magnetic field. A slower decline translates to a lower induced
flyback voltage. If current cannot flow, the magnetic field will decline very rapidly
and consequently create a much higher induced voltage. In effect, the flyback
action will create the necessary voltage needed to discharge the energy stored in
the flyback transformer or inductor. This principle, along with controlling the
duration of the charging stage, allows a flyback inductor to increase or decrease
the voltage without the use of a step-up or step-down turns ratio. In the typical
flyback circuit, the output capacitor clamps the flyback voltage to the capacitor
voltage plus the diode and resistive voltage drops. For a sufficiently large & fully
charged capacitor, the clamping capacitor voltage can be treated as a constant
value. The equations V(t) = L x di/dt, and I = Io + V x t / L can also be applied to
the discharge stage. Use the inductance value of the discharging winding and the
time duration of the discharging stage. The time will either be the cycle time minus
the charging time ( no idle time ), or the time it takes to fully discharge the
magnetic field thereby reaching zero current. The cycle time equals the period
which equals 1 / frequency.

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Idle Stage: This stage occurs whenever the flyback transformer ( or inductor ) has
completely discharged its stored energy. Input and output current ( of the
transformer or inductor ) is at zero value.

Other Principles of Operation

Equal Ampere-Turns Condition: A magnetic field is created by the current flow

through the winding(s). The current creates a magnetizing force, H, and a
magnetic field flux density B. A core dependent correlation will exist between B and
H. B is not usually linear with H. By definition H is proportional to the product of the
winding turns and the current flowing through the winding, hence ampere-turns. In
classical physics, the magnetic field flux cannot instantaneously change value if
the source of the field ( the current flow ) is removed. When the source current is
removed from the flyback transformer ( or inductor ) the charging stage ends and
the discharge stage begins. The value of the magnetic field will be the same for
both stages at that point in time ( cannot instantaneously change to another
value ). The same magnetic core is used for both stages, hence if the magnetic
field is the same, then the magnetizing force, H, must be the same. Consequently
the ampere-turns at the end of the charging stage must equal the ampere-turns at
the start of the discharge stage. If there are multiple outputs then the total amperes
turns of all outputs at the start of the discharge stage must equal the ampere-turns
at the end of the charging stage. The same condition applies at the start of the
charging stage. The total ampere-turns of all outputs at the start of the charging
stage must equal the ampere-turns at the end of the discharge stage. Note that
there are zero ampere-turns at both the start and end of an idle stage when an idle
stage exists.

Zero Average Voltage: During steady state operation, the

average voltage across the charging winding must equal
the average voltage across the discharge winding, or equivalently, the volt-
seconds of the charging stage must equal the volt-seconds of the discharge stage.
If not, flux density increases over time and the core saturates. Assuming a 1:1
turns ratio, then from V1 x t1 = V2 x t2 one can obtain t1 / t2 = V2 / V1 for both
continuous and discontinuous modes of operation. For continuous mode operation,
t1 + t2 = 1 / operating frequency.

Conservation of Energy: Power out cannot exceed power in. Sum up output
power ( V x I ) of each output at maximum steady state load plus allowances for
parasitic output power losses ( diode and resistive losses ). Divide power in watts
by operating frequency. The result is the energy in Joules that must be discharged
each cycle into the output storage capacitor during steady state operation. It is also
the amount of energy that must be added to the flyback transformer ( or inductor )
during the charging stage. The energy being transferred equals ( Ipeak x Ipeak –
Imin. x Imin. ) x L /2. If operating in the continuous mode, the stored energy will
exceed the energy being transferred because the starting level of stored energy is
above zero ( Imin. > 0 ). The flyback transformer ( or inductor ) must be designed
to handle the peak stored energy, Ipeak x Ipeak x L / 2. The power source will
have to supply the transferred energy plus the parasitic switching and resistive
losses of the charging circuit, plus some power allowance for transient conditions.
Take this value and divide by the power supply voltage. The result will be the
average input current.

Need additional information about Flyback Transformers?

Contact Butler Winding. Ask for engineering assistance.

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