FlyBack Converter

Objective:
Design and calculations of FlyBack (10V -14V to 48V)

Flyback convertor Operation:

A dc-dc converter that provides isolation between input and output is the flyback circuit .It uses
the transformer model which includes the magnetizing inductance Lm. The duty ratio of the
switch is D, being closed for time DT and open for (1- DT). The basic operation of the flyback
converter is similar to that of the buckboost converter. Energy is stored in Lm when the switch is
closed and is then transferred to the load when the switch is open. The circuit is analyzed for
both switch positions to determine the relationship between input and output.

When Switch is Closed:

When the switch is closed, transistor Q1 conducts, energy from the dc source Vs is stored in LM.
Since the diode is off, i2=0, which means that i1=0. So while the switch is closed, current is
increasing linearly in the magnetizing inductance Lm, and there is no current in the windings of
the ideal transformer in the model. In the actual transformer, this means that the current is
increasing linearly in the physical primary winding, and no current exists in the secondary
winding.

When Switch is Open:

When the switch opens the current cannot change instantaneously in the inductance Lm, so the
conduction path must be through the primary turns of the ideal transformer. The current iLm
enters the undotted terminal of the primary and must exit the undotted terminal of the secondary.
This is allowable since the diode current is positive. Assuming that the output voltage remains
constant at Vo, the transformer secondary voltage v2 becomes -Vo. The secondary voltage
transforms back to the primary.
Circuit Diagram:

Calculations:
Design a converter to produce an output voltage of 48 V from a 12 V source. The output power
is 50 W. Design for an output ripple voltage of 1 percent. Include ESR when choosing a
capacitor. Assume for this problem that the ESR is related to the capacitor value by rC = (10^-5)
/C. Frequency should be greater than 25 kHz.

Let the duty ratio be 0.4. The transformer turns ratio is calculated to be
𝑁 VO (1−𝐷) 48(1−0.4)
(𝑁2 ) = = =6
1 𝑉𝑆 𝐷 12∗0.4

To determine Lm, first compute the average current in Lm.

As Power is 50 W so, I0 =P/V0=50/48=1.04 A
Now Ro=V0/I0 =48/1.04= 46.15 Ω
A standard value of 47 Ω will be used in design.

O V 𝑁 48∗6
𝐼𝐿𝑚= (1−𝐷)𝑅 ∗ 𝑁2 =(1−0.4)∗46.15 = 10.4 𝐴
1
Let the current variation in Lm be 40 percent of the average current: ∆iLm = 0.4(10.4) = 4.16 A.
As another somewhat arbitrary choice, let the switching frequency be 100 kHz.
𝐕𝐃 𝟏𝟐∗𝟎.𝟒
𝑳𝒎 = ∆𝒊 𝐬 𝒇=𝟒.𝟏𝟔∗𝟏𝟎𝟎𝟎𝟎𝟎 = 𝟏𝟏. 𝟓 µ𝑯
𝑳𝒎

Maximum and minimum currents in Lm are:

V D 𝑁 𝑉 𝐷𝑇
s
ILm,max = (1−𝐷)2𝑅
∗ (𝑁2 )2 + 2𝐿
𝑆
=10.4+2.086=12.48 A
1 𝑚

V D
s 2 2 𝑁 𝑉𝑆 𝐷𝑇
ILm,min = (1−𝐷)2 𝑅 ∗ (𝑁 ) - 2𝐿𝑚
= 10.4 − 2.086 =8.314 A
1

The output voltage ripple is to be limited to 1 percent, which is 0.01(48) = 0.48 V. Assume that
the primary cause of the voltage ripple will be the voltage drop across the equivalent series
resistance iCrC. The peak-to-peak variation in capacitor current is the same as in the diode and the
transformer secondary and is related to current in Lm by
𝑁1 12.48
𝑖𝐶 = 𝐼𝐿𝑚,𝑚𝑎𝑥 ∗ = = 2.08 𝐴
𝑁2 6
∆𝑉0 ,𝐸𝑆𝑅 0.48
rc = = 2.08=0.230 Ω
∆𝑖𝐶

Now
𝟏𝟎−𝟓
C= = 𝟒𝟑 µ𝑭
𝒓𝑪

A standard value of 47 µ𝐹 will be used in design.

The ripple voltage due to the capacitance only is obtained from

∆𝑉0 𝐷 0.4
= 𝑅𝐶𝑓 = 46.15∗0.000043∗100000=0.002%
𝑉0

The turns ratio of the transformer, current variation, and switching frequency were selected
somewhat arbitrarily, and many other combinations are suitable.
For the flyback converter, let L1 = Lm and determine L2 using :

Simulations:

Figure 1 Output voltage 48 Volts

Figure 2 Source current

 Figure 3 Diode Current

Figure 4 Capacitor Current

Summary:

Hence when the switch is closed in the flyback converter, the source voltage is across the
transformer magnetizing inductance Lm and causes iLm to increase linearly. Also while the
switch is closed, the diode on the output is reverse-biased, and load current is supplied by the
output capacitor. When the switch is open, energy stored in the magnetizing inductance is
transferred through the transformer to the output, forward-biasing the diode and supplying
current to the load and to the output capacitor. The input-output voltage relationship in the
continuous-current mode of operation is like that of the buck-boost dc-dc converter but includes
a factor for the turns ratio.

The flyback converter is commonly used at the 50-100W power range, as well as in high voltage
power supplies for televisions and computer monitors. It has the advantage of very low parts
count. Multiple outputs can be obtained using a minimum number of parts: each additional
output requires only an additional winding, diode, and capacitor. The peak transistor voltage is
equal to the dc input voltage Vg plus the reflected load voltage V/n; in practice, additional
voltage is observed due to ringing associated with the transformer leakage inductance. A snubber
circuit may be required to clamp the magnitude of this ringing voltage to a safe level that is
within the peak voltage rating of the transistor.