Flyback Converter

Group Members:

HAMID ALI 170913

AQEEL ABBAS 170880
SAAD AHSAN 170889
SULEMAN SALIM 170949
M. ABDULLAH 170910

BE ELECTTRICAL (POWER) (2017-2021)

Submitted to

Eng. Seema Tahir

Department of Electrical and Computer Engineering

Faculty of Engineering

Air University, Islamabad

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Table of Contents
List of Figures............................................................................................................................................3
1. Abstract:.............................................................................................................................................4
2. INTRODUCTION.............................................................................................................................4
3. DESIGN METHODOLODY............................................................................................................4
3.1. Flyback converter perameters..................................................................................................5
3.2. MATLAB SIMULATION.........................................................................................................6
4. COST OF EQUIPMENT..................................................................................................................7
5. COMPARISON.................................................................................................................................7
6. CONCLUSION..................................................................................................................................8

List of Figure

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Figure 1. Flyback converter.........................................................................................................................4
Figure 2. On state equivalent circuit..........................................................................................................5
Figure 3. Off state equivalent circuit..........................................................................................................5
Figure 4. Flyback Transformer Core............................................................................................................6
Figure 5. Matlab Simulation.......................................................................................................................6
Figure 6. Output Voltage Graph.................................................................................................................6

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1. Abstract:
Flyback converter is widely used in DC-DC conversion and isolation, due to its simplicity, low
part count, multiple isolated outputs, high output voltages, high efficiency and low cost. This
paper presents a complete design of a 20W flyback converter for DC-DC application. Analytical
analysis of different associated circuitries are discussed. A suitable core, ETD39TH-H-14Pin is
selected to design the flyback transformer.

2. INTRODUCTION
Flyback is the most widely used SMPS topology for low power application from 100W down to
under 1W, whenever the output needs to be isolated from the input. Its best features are low
system cost, simplicity, and relative ease of implementation. For low current output and power
levels below 50W, DCM flyback is the usually the preferred operating mode, due to it’s simpler
control loop implementation and lower turn on loss. The objective of this paper is to develop a
comprehensive, practical and easy to follow approach in designing an off line DCM Flyback
power supply. This includes component selection guide, design knowledge and practical tips for
a fast and well optimized design.

3. DESIGN METHODOLODY

Flyback converter is widely used in dc-dc conversion and isolation, due its simplicity, low part
count, multiple isolated outputs, high output voltages, high efficiency and low cost. The circuit is
simple as illustrated in Fig.1 composed of relative few components Only one switch is required
for controlling the voltage. Main features of flyback converters are simple design, low
component count, low cost, no additional inductor at the output circuit and wide input range.

Figure 1. Flyback converter

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The converter basically operates in two [Link].1 is during Switch on period and Mode.2 is
during Switch off period. During the on period the primary winding is supplied by voltage which
supplies a primary current to produce magnetic flux .The magnetic flux in the transformer core
increases to store energy in the transformer. The output voltage on the secondary side is negative
which makes diode reverse biased and zero voltage is preset at output side as shown in Fig. 2.
Mode.1: During time interval 0≤ t ≤T ,. Mosfet is ON
V1 = Vs (1)
N2
V2 = V 1=aV (2)
N1
During this period secondary side is open
circuited and it draws only no-load magnetization
current increases from 𝐼𝑚𝑖𝑛 to 𝐼𝑚𝑎𝑥 to store the
energy in the transformer.
Figure 2. On state equivalent circuit

Mode.2: During off period the primary current and magnetic flux drops which results in positive
secondary voltage. The output diode is forward biased, and the current flow to load as shown in Fig.3.
Time interval Ton ≤ t ≤ T . Mosfet is OFF The output of the flyback converter during off time is

N2 D
V o= V (3)
N 1 1−D s
Where, D is the duty cycle of MOSFET switch.

Every switch mode power supply

Figure 3. Offdesign process starts
state equivalent
with suitable selection of components and its specifications. The
circuit
following parameters are defined and determined for the proposed
converter.

3.1. Flyback converter perameters

 Output Power = 20W
 Input Voltage = 12V DC
 Output Voltage = 5V DC
 Output Current = 4A
 Primary Reflected Voltage (VOR) = 7V
 Primary Inductance = 470μH
 Switching Frequency = 100 kHz
 Iprimary Peak (max-3.82A) Ipri rms (max 1.19A)
 Output Resistance (i.e maximum Load) = 1.2Ω
 Capacitance = 68μF

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TRANSFORMEER DETAILS
 Core Type: ETD39TH-H-14Pin
 Primary Inductance: 470μH
 Secondary Inductance: 30μH
 Leakage Inductance: 4.7 μH @100 kHz
 Maximum Flux Density: 300mt Figure 4. Flyback Transformer Core
 Required Gap Length: 0.7mm (Al: 204Nh/μH2)

3.2. MATLAB SIMULATION

The project is simulated at Matlab R2012a Simulink tool box with maximum Load. Circuit is
shown in Fig. 5 and output graph is shion in Fig. 6.

Figure 5. Matlab Simulation

Figure 6. Output Voltage Graph

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4. COST OF EQUIPMENT
FLYBACK TRANSFORMER = RS. 150
AC/DC CONVERTER (30V) = RS. 200
MOSFET & DIODES = RS. 30
CAPACITOR & RESISTOR = RS. 20
TOTAL COST = 150+200+50
= RS. 400

5. COMPARISON
Flyback:
The flyback topology is essentially the buck-boost topology that is isolated by using a
transformer as the storage inductor. The transformer not only provides isolation, but by varying
the turns ratio, the output voltage can be adjusted. Since a transformer is used, multiple outputs
are possible. The flyback is the simplest and most common of the isolated topologies for low-
power applications. While they are well suited for high-output voltages, the peak currents are
very high, and the topology does not lend itself well to output current above 10A.
One advantage of the flyback topology over the other isolated topologies is that many of them
require a separate storage inductor. Since the flyback transformer is in reality the storage
inductor, no separate inductor is needed. This, coupled with the fact that the rest of the circuitry
is simple, makes the flyback topology a cost effective and popular topology.
Buck-Boost:
The buck-boost topology can either step the voltage up or down. This topology is particularly
useful in battery powered applications, where the input voltage varies over time but has the
disadvantage of inverting the output voltage. Another disadvantage to the buck-boost topology is
that the switch does not have a ground, which complicates the drive circuit. Using only a single
inductor like the buck and the boost topologies, the buck-boost inductor and EMI components
are readily available.
Forward:
The forward converter is really just a transformer isolated buck converter. Like the flyback
topology, the forward converter is best suited for lower power applications. While efficiency is
comparable to the flyback, it does have the disadvantage of having an extra inductor on the
output and is not well suited for high voltage outputs. The forward converter does have the
advantage over the flyback converter when high output currents are required. Since the output
current is non-pulsating, it is well suited for applications where the current is in excess of 15A.

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Push-Pull:
The push-pull topology is essentially a forward converter with two primary windings used to
create a dual drive winding. This utilizes the core of the transformer much more efficiently than
the flyback or the forward converters. On the other hand, only half the copper is being used at a
time, thereby increasing the copper losses significantly in a similar sized transformer. For similar
power levels, the push-pull converter will have smaller filters compared to the flyback converter.
However the advantage that push-pull converters have over flyback and forward converters is
that they can be scaled up to higher powers. Switching control can be difficult with push-pull
converters, because care has to be taken not to turn on both switches at the same time. Doing so
will cause the equal and opposite flux in the transformer, resulting in a low impedance and a very
large shoot-through current through the switch, potentially destroying it.
The other disadvantage to the push-pull topology is that the switch stresses are very high
(2∙VIN), which makes the topology undesirable for 250VAC and PFC applications.

6. CONCLUSION
This report described an easy way to design a Flyback Converter. Flyback converters are widely
used due to its simplicity, low part count, multiple isolated outputs, high output voltages, high
efficiency and low cost. This report presented a complete design of a 20W flyback converter for
DC-DC application. Analytical analysis of different associated circuitries are discussed. A
suitable core, ETD39TH-H-14Pin is selected to design the flyback transformer.