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This course introduces the operating principles of and the uses for Flyback converters. It describes the similarities between the Flyback converter and the Buck-Boost converter and introduces the basic equations use in Flyback converter design. Potential design issues are discussed and a design example is provided.
3. Flyback Converter Operating Principles 1. 3.1 Key Waveforms 2. 3.2 Study State Analysis 3. 3.3 Study State Analysis Continued 4. Flyback Converter Design Issues 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 4.1 Key Design Issues 4.2 Flyback Transformer 4.3 Example - Design Specifications 4.4 Primary Turns Ratio, Core Selection 4.5 Bobbin Area Use 4.6 Secondary Winding 4.7 Copper Losses 4.8 Gapping the Core 4.9 Core Gapping Formula 4.10 Inductance Flow Factor 4.11 Flux and Ripple Calculations 4.12 Auxiliary Winding 4.13 Other Components 4.14 Filter Capacitors
5. Controller Selection 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 5.1 Controller Choices 5.2 Current Mode vs. Voltage Mode 5.3 LM5020 Controller 5.4 Load Compensation 5.5 Right Half Plan (RHP) Zero 5.6 Slope Compensation 5.7 LM5020 Slope Compensation 5.8 Loop Compensation 5.9 Error Amplifier Design 5.10 Loop Gain Results
6. Flyback Circuit Examples 1. 2. 3. 4. 5. 6. 7. 6.1 Isolated Flyback Design 6.2 Non-isolated Flyback Design 6.3 Sync Rectifier Modification 6.4 LM5020 Demo Board 6.5 Demo Board Efficiency 6.6 Primary Switch Drain Voltage 6.7 Ripple Voltage
1. Course Navigation
1.1 Course Navigation 1.2 Course Objectives
1. Course Navigation
1.1 Course Navigation 1.2 Course Objectives
The left navigation bar takes you to any chapter. It also contains the bookmarking buttons, 'save' and 'go to.' To save your place in a course, press the 'save' button. The next time you open the course, clicking on 'go to' will take you to the page you saved or bookmarked. The 'Go to Final Test' button on the left navigation bar takes you back to the Analog University course listing, where you started. Take the course final test by clicking on 'Test Yourself.' The top services bar contains additional information such as glossary of terms, who to go to for help with this subject and an FAQ. Clicking home on this bar will take you back to the course beginning. Don't miss the hints, references, exercises and quizzes which appear at the bottom of some pages.
In these three fundamental topologies, the two switching elements, namely the switch and rectifier diode, are under different voltage stresses. In a Buck, the voltage stress is Vin, while in a Boost it is Vo, and in a Buck-Boost, it is Vin+Vo. The higher stress in the Buck-Boost implies that it is only suitable for lower power level applications.
In these three fundamental topologies, the two switching elements, namely the switch and rectifier diode, are under different voltage stresses. In a Buck, the voltage stress is Vin, while in a Boost it is Vo, and in a Buck-Boost, it is Vin+Vo. The higher stress in the Buck-Boost implies that it is only suitable for lower power level applications.
A major limitation of these three fundamental topologies is that they do not provide electrical isolation between the input and output. In many applications electrical isolation is desirable.
The forward topology is evolved from the Buck, and the flyback topology is evolved from the Buck-Boost. Isolation is realized with the power transformer. The transformer turns ratio brings in more flexibility to optimize the design for duty cycle, stress, efficiency, etc. It is obvious that the flyback is the simplest and hence the cheapest isolated topology. In contrast, the forward converter needs the following four extra elements: a tertiary reset winding Nr on the power transformer, a blocking diode in the reset circuit, an additional rectifier diode and a separate filter inductor in the secondary.
This chart summarizes the comparison between the forward and flyback topologies. It is obvious that the flyback is more advantageous over the forward for power levels lower 50W.
This graphic shows key waveforms of the flyback topology. It is assumed that the converter is in continuous conduction mode, which means I(Q1)+I(D1) is always greater than zero at any time during steady state operation.
More steady state analyses. Note that the average current through the rectifier diode is the load current Io.
Thus the key component and design issue in the converter design is the flyback power transformer which acts as a coupled inductor.
Core selection is generally done by trial and error. Verification and refinement of the core selection is always required in each design.
Using the this formula, determine the smallest gap that can be used for the core and material you have chosen where: Np = Number of primary turns (26) Ipk = Peak primary current in amperes (1.71A X ~1.2) lg = Center leg gap in centimeters (0.0254cm) le = Effective length of core (from manufacturer) in centimeters (4.7) ui = Initial permeability (ur, from manufacturer, 2,000) Dont go any higher than where the amplitude permeability decreases by more than 10% on the 100°C curve. But stay close, it is the delta flux density that causes losses, not the DC. Now the inductance and several other parameters can be determined to verify that the design is viable.
The estimated core losses from the manufactures data = 0.06W and is acceptable.
The LM5020s internal startup regulator produces a Vcc of 7.7V for the controller to use. However, since the startup regulator is powered from high input voltage, its efficiency is low, and the loss will heat up the controller IC. Using a bias winding to produce an elevated Vcc at about 11V will block the internal startup regulator, provide an optimal gate drive voltage of about 10V, and improve the efficiency. Higher Vcc is not recommended as it will increase the power dissipation in the IC and the gate drive, and may even damage the Vcc pin due to excessive voltage stress.
5. Controller Selection
5. Controller Selection
5.1 Controller Choices 5.2 Current Mode vs. Voltage Mode 5.3 LM5020 Controller 5.4 Load Compensation 5.5 Right Half Plan (RHP) Zero 5.6 Slope Compensation 5.7 LM5020 Slope Compensation 5.8 Loop Compensation 5.9 Error Amplifier Design 5.10 Loop Gain Results
Due to advantages such as cycle-by-cycle peak current limit, inherent voltage, inherent voltage feed forward and simplified loop compensation, the current mode control is normally selected as the control scheme for flyback regulators.
When the load decreases, i.e. Ro increases, the RHP Zero moves toward the higher frequency range. When the duty cycle decreases, i.e. the input voltage increases, the RHP Zero moves to a higher frequency. An extremely large inductance results in a lower RHP Zero. Be reasonable. Therefore, the worst case to consider is the maximum power at the minimum input voltage. Vin_min = 30V RHP_Zero_min = 23 kHz Vin = 48V RHP_Zero = 57 kHz Maximum loop bandwidth: 1/3 of 23 kHz about 8 kHz; or 1/6 of Fsw, whichever is lower.
Solution: Slope compensation: adding a slope to the current signal, which is equivalent to subtracting a slope from the error voltage (Ve). Then the disturbance decreases at the end of the cycle.
Note: Self driving of the sync FET, i.e. driving the FET with an additional transformer winding, is possible and would cost less. However, the performance would not be as good as that achieved with the circuit shown in the graphic.
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Note the power loss breakdown. 83% is a decent efficiency in this design, considering there is about a 12% efficiency drop caused by the rectifier diode. To further improve the efficiency, the best approach is to replace the diode with a sync FET.
Note: Ripple is a matter of filtering, not a problem of the controller. Filter components and layout both contribute to filtering performance.
7. Conclusions
7.1 Conclusions
7.1 Conclusions
The Flyback topology is the simplest topology for isolated power supplies. Most applications are in telecommunication and PoE, in which the power level is below 50W. Flyback operating principles were discussed, and steady state analysis presented to provide design guidelines. Key design issue is the flyback power transformer.
The Flyback topology is the simplest topology for isolated power supplies. Most applications are in telecommunication and PoE, in which the power level is below 50W. Flyback operating principles were discussed, and steady state analysis presented to provide design guidelines. Key design issue is the flyback power transformer. Design was demonstrated using an example. Loop compensation is straightforward. The National LM5020, and the LM507x series which is based on the LM5020, provide convenience in design.
BGA
Ball Grid Array
CSP
Chip Scale Packaging - A direct surface mount package with an area no more than 1.2 times the die area.
DIP
Dual In-line Package
FBGA
Fine pitch Ball Grid Array
MEMS
Micro Electro Mechanical Systems - Micrometer size mechanical devices (i.e. pressure sensor) combined with elecrical components on a die.
MSOP
Mini Small Outline Package
PGA
Pin Grid Array
QFP
Quad Flat Pack
SOP
Small Outline Package
SSOP
Shrink Small Outline Package
Substrate
A small glass or epoxy board used in high pin count packages in place of a leadframes. It is similar to a printed circuit board in that it has conducting traces on one side and contact pads on the other. The traces are connected to the pads with vias. Substrates are used in packages such as BGAs, FBGAs and Laminated CSPs.
TQFP
Thin Quad Flat Pack
TSSOP
Thin Shrink Small Outline Package
Contact/Help Information
For additional information on getting started go to http://www.national.com/analog/training/getting_started To contact us, and send feedback go to
Contact/Help Information
For additional information on getting started go to http://www.national.com/analog/training/getting_started To contact us, and send feedback go to http://wwwd.national.com/feedback/newfeed.nsf/newfeedback?openform&category=pwdesignuniv For Frequently Asked Questions go to http://www.national.com/analog/training/faqs Thank you, PowerWise Design University Team