more than you expect Cookbook for Discontinuous Conduction Mode Flyback Converters Content Cookbook 2 www.we-online.com/midcom more than you expect Product overview 04 Introduction 05 Smart Transformer Selector 06 Transformer design 08 Step-by-step to flyback converter design 09 1st step: Compile specifications 12 2nd step: Define primary inductance and peak current 13 3rd step: Definition of turns ratio 14 4th step: Selection of the core 15 5th step: Define the number of turns and calculate core losses 16 6th step: Define wire thickness and calculate copper losses 18 Transformer construction 21 General example of step-by-step construction of a transformer 22 Glossary 23 3 Product overview Power Magnetics Transformers for AC/DC Converters Transformers for DC/DC Converters Power Inductors Sense Transformers Signal and Communications Analog Modem Transformers xDSL Transformers ISDN Transformers Metering Signal & Communications Transformers EMC Components Power Common Mode Chokes Signal Common Mode Chokes Filter Chokes 4 www.we-online.com/midcom more than you expect Introduction This cookbook shows you an example of how to design and wind a transformer. We hope it helps you to understand the foundation of transformer design. When you’re ready to move forward, we’ll design it for you and offer free samples. CUSTOM SOLUTIONS Possible Refer to our Custom Capabilities Catalog to find out what packages we offer for manufacturing. Ask for a copy of the Custom Capabilities Catalog or browse the electronic version at www.we-online.com/customcapabilities. more expect than you pabilities Custom Ca ers Transform Toroids PLEASE NOTE: Although great care has been taken to provide accurate and current information, neither the authors nor the publisher, nor anyone else associated with this publication, shall be liable for any loss, damage, or liability directly or indirectly caused by this book. All appropriate material is only valid for low power applications. For applications with 60VDC /48VAC or more, please refer to relating safety regulations. 5 Smart Transformer Selector Benefits Smart search for all flyback transformers on the website - Discontinuous Mode - Boundary Mode n Simple search needs only power supply parameters - Input voltage and switching frequency - Output voltages and current n Finds all parts for your application that will: - Not saturate - Provide acceptable output voltages n Samples available n Features n 6 RA Losses & temperature rise Compare multiple parts at once n Schematic showing how to connect n n R T Analyzes transformer in defined application - Voltage levels - Current wave forms R SELECTO TS S M ART S NSFORM www.we-online.com/midcom E Samples Available more than you expect Enter power supply input and output criteria and click on “Search Now”. STEP 3 STEP 2 STEP 1 Easy as 1 n 2 n 3! From the resulting list of parts, click on the transformer of choice. Review transformer performance in either summary tab or any of the other three tabs, which provide more detail. 7 Transformer design The following example gives you an idea how to design a transformer for a flyback converter. Compile specifications Fig. 1 shows a flowchart for the approach in designing a DCM flyback transformer. As you can notice, designing a transformer is a highly iterative process. Define primary inductance and peak current Further transformer designs for forward converters and push-pull converters are integrated in Würth Elektronik’s design guide, Trilogy of Magnetics. Define turns ratio Select the core Define the number of turns and calculate core losses Core loss ok? no yes Define wire thickness and calculate copper losses Order Code: English version 744 006 Copper loss ok? yes Fig. 1: Flow chart for the approach to design a DCM flyback transformer 8 www.we-online.com/midcom Document, build and test no more than you expect Step-by-step to flyback converter design Fig. 2 shows the basic schematics of a flyback converter. The switch S1 is a controlled switch, e.g. a MOSFET. To understand the basic function of the flyback converter, the switching processes are described as follows: Fig. 2: Circuit diagram of a flyback converter 1. Switch closed The closed switch applies the input voltage on the transformer´s primary winding. As a result of the inductance, a current rises linearly on the primary side. The polarity of the transformer is that the diode blocks the current on the secondary side. The energy fed is stored in the gap of the transformer. 2. Switch open With the switch open, the current is interrupted on the primary side. The inductance of the transformer tries to maintain the flow of energy, so that the polarity of the secondary side changes. The diode becomes conducting, and a linear declining current flows on the secondary side. Fig. 3 shows the current and voltage profile on the primary and secondary sides of the transformer. Fig. 3: Current and voltage profiles of a DCM flyback converter 9 Step-by-step to flyback converter design Two flyback converter operating modes are distinguished depending on the current profile. 1. Continuous mode: In continuous mode (trapezoid operation or continuous conduction mode, CCM) energy is still stored at the end of the switching cycle. The linear decline in current does not return to zero. 2. Discontinuous mode: In discontinuous mode (triangular operation or discontinuous conduction mode, DCM) the current on the secondary side will be zero at the end of the cycle. There are current gaps in which no current flows, neither on the primary nor on the secondary side. Prior to design, the following parameters must be known. n Input voltage range n Output voltage n Output power or output current n Switching frequency n Operating mode n Maximum duty cycle of the IC n Safety requirements n Ambient temperature n Size requirements Safety requirements such as dielectric withstand voltage, creepage distance and clearance distance should be especially considered in the design phase, as a transformer requires a larger package if these requirements are considered. Special care should be taken for offline applications. An idea about the creepage distance and clearance distance and the dielectric withstand voltages are given in Tab. 1 and Tab 2. The values, therein, are based on IEC 60950. 10 www.we-online.com/midcom more than you expect Creepage distances for working voltages according to IEC 60950 for pollution degree 2 RMS working voltage 50 63 80 100 125 160 200 250 320 400 500 630 800 1000 Creepage distance pollution degree 2 (mm) Basic insulation Reinforced insulation CTI>600 400<CTI<600 CTI<400 CTI>600 400<CTI<600 CTI<400 0.60 0.63 0.67 0.71 0.75 0.80 1.00 1.25 1.60 2.00 2.50 3.20 4.00 5.00 0.85 0.90 0.90 1.00 1.05 1.10 1.40 1.80 2.20 2.80 3.60 4.50 5.60 7.10 1.20 1.25 1.30 1.40 1.50 1.60 2.00 2.50 3.20 4.00 5.00 6.30 8.00 10.00 1.20 1.26 1.34 1.42 1.50 1.60 2.00 2.50 3.20 4.00 5.00 6.40 8.00 10.00 1.7 1.8 1.8 2.0 2.1 2.2 2.8 3.6 4.4 5.6 7.2 9.0 11.2 14.2 2.4 2.5 2.6 2.8 3.0 3.2 4.0 5.0 6.4 8.0 10.0 12.6 16.0 20.0 *CTI (Comparative Tracking Index) Tab. 1 Dielectric withstand voltages according to IEC 60950 Dielectric withstand voltage (V) Operating voltage peak value or DC Basic insulation Reinforced insulation 50 100 125 150 200 250 300 400 600 800 1000 1000 1000 1000 1000 1000 1500 1500 1500 1893 2164 2399 2000 2000 2000 2000 2000 3000 3000 3000 3000 3000 3000 Tab. 2 11 1 1st Step Compile specifications We will now show the step-by-step design process for a DCM flyback converter. The following example will help to illustrate the design steps. Input voltage range (VIN MIN – VIN MAX): 36 - 57V Output voltage VOUT: 5V Output current IOUT: 2A Operating mode: DCM Maximum duty cycle DMAX: 48% (use 45%) Switching frequency: 100kHz Safety requirements: Functional insulation Output diode drop voltage: VD = 0.5V D Assume transformer efficiency, η = 0.9. The on time will be TON = MAX f Output transformer power: POUT = (VOUT+Vd) · IOUT = (5+0.5) · 2 = 11W (including output diode loss Vd) Input power: PIN = POUT/ η = 11/0.9 = 12.22W 12 www.we-online.com/midcom more than you expect 2 2nd Step Define primary inductance and peak current In a discontinuous mode, all of the energy stored in the transformer is delivered to the output during each cycle. So, for each cycle, to make sure that the stored energy is delivered, we need to calculate the maximum inductance as: V2 D 2Ƞ 36 2 · 0.45 2 · 0.9 LMAX = IN, MIN MAX LMAX = = 107.36µH 2fPOUT 2 · 100,000 · 11 Consider 10% inductor tolerance + 5% safety margin = 15%. The new value of L is: LMAX = 91.25µH (Choose primary inductance L = 91µH ) The Primary Peak Current is determined from: IPK,PRI = 2 · POUT L· f · IPK,PRI = 2 · 11 = 1.64A 91x10 -6 · 100000 · 0.9 13 3 3rd Step Definition of turns ratio Turns ratio and duty cycle determine each other; i.e. if one of the parameters is defined, so is the other. The maximum duty cycle and the highest currents are occurring at the minimum input voltage. This is the worst case. In fast transient response, the duty cycle can be higher for a short time. Design Tip 1: Keep a little safety margin to the maximum allowed duty cycle of the IC. The relationship between maximum duty cycle and turns ratio is given by the following formula: NS (V + VD)(1 - DMAX) = OUT VIN,MINDMAX NP For our example, we calculate a turns ratio of: Care should be taken on the breakdown voltage of the MOSFET. The voltage between drain and source of this MOSFET during the off time is: DMAX VIN,MIN TON, OFF NP, NS VOUT VD Maximum duty cycle: DMAX = TON /(TON+TOFF) Minimum input voltage MOSFET ON time, OFF time Primary and secondary number of turns Output voltage Output diode drop off voltage NS (5 + 0.5)(1 - 0.45) = = 0.187 36 · 0.45 NP VDS = VIN + NP * · VOUT +VLEAKAGE NS VLEAKAGE is the voltage spike resulting from leakage inductance (Typically add 20-30% of VIN depending if a snubber is used or not) V*OUT = VOUT + VD output voltage including diode voltage drop Design Tip 2: Use a MOSFET with a sufficient safety margin in breakdown voltage, as the voltage spike from discharge of leakage inductance can destroy the MOSFET. 14 www.we-online.com/midcom more than you expect 4 4th Step Selection of the core For frequencies between 25 and 500kHz, the best choices for core material are so called power ferrites, MnZn ferrites with a permeability of 2400. The saturation flux density Bs of this material is 390mT at 100°C. Fig. 4 shows the specific losses for given frequencies and flux densities. Pcv - Bm 5588.4492 1E+4 200kHz 14.465505 1035.2894 100˚C Core loss Pcv (kW/m3) 100kHz 4.677008 1E+3 1056.6629 64kHz 2.306808 594.96247 The package type depends on the power to be transformed. A starting point is transformer indexes. Tab. 3 shows a power table in the Custom Capabilities Catalog. 500kHz 200kHz 32kHz 1E+2 1.053128 222.66027 100kHz 25kHz 1.030651 154.6565 1E+1 25kHz 64kHz 32kHz 1E+0 1E+1 1E+2 1E+3 Flux Density (mT) Fig. 4: Specific losses against the change in flux density Power DC/DC Flyback Power Level (W) at 100kHz 1 2 2 3 3 3 4 5 6 6 8 8 8 8 8 10 10 10 10 10 14 14 14 Offline Power Level (W) at 100kHz 5 7 Package Size Mount Pins EP5 ER9.5 ER11.5 EP7 EP7 EP7 EPX7 ER14.5 EPX9 RM4 EP10 EP10 EP10 EPC13 EPC13 EE13/7/4 (EF12.6) EE13/7/4 (EF12.6) EE13/7/4 (EF12.6) EE13/7/4 (EF12.6) RM5 EFD15 EE13/7/6 EFD15 SMD-H SMD-V SMD-V SMD-H TH-H SMD-H SMD-H SMD-V SMD-H TH-V SMD-H TH-H SMD-H TH-H SMD-H TH-H SMD-H TH-H SMD-H TH-V SMD-H TH-H TH-H 6 8 12 6 6 8 8 12 8 6 8 8 8 10 10 8 9 9 10 6 12 8 8 NEW Safety Length (mm) Width (mm) Height (mm) Bobbin Page Number 6.6 10.0 13.0 10.2 10.2 9.8 10.2 16.0 10.2 11.4 13.3 13.3 13.3 14.6 14.6 14.7 13.8 13.7 13.7 14.0 17.2 15.0 16.8 8.3 12.1 12.7 13.4 8.3 9.1 9.1 16.8 10.2 11.4 15.2 11.7 15.2 14.7 20.9 16.8 23.7 20.5 19.7 14.0 22.2 15.8 16.8 5.6 6.0 6.4 8.6 9.8 10.5 12.3 7.6 12.7 11.2 11.4 12.6 11.6 8.5 8.3 12.7 11.0 10.2 10.5 11.2 8.9 18.5 8.9 070-4426 070-6051 070-6058 070-5801 070-2150 070-4436 070-4434 070-4477 070-5103 070-5754 070-6052 070-2365 070-4410 070-5483 070-4887 070-4849 070-6258 070-5662 070-4820 070-2250 070-4265 070-5449 070-2745 51 73 74 52 53 54 64 75 65 88 55 57 56 66 67 22 24 23 25 89 41 26 39 Tab. 3: Core geometries and typical transformable power at 100kHz DC/DC For the total needed power of 12.22W, in our example we choose EFD15 core size, with SMD-H, 10-pin bobbin, as the estimated power level for this package (100KHz DC/DC Flyback) is 14W. 15 5 5th Step Define the number of turns and calculate core losses The minimum number of turns is defined by the saturation flux density for a given core. The ferrite material 1P2400 has a saturation flux density of 312mT (BMAX derated to 80%). Thus, the minimum number of turns is: NP > LPRI · IPK,PRI 91µH · 1.64A = = 31.88, choose 32 BSAT · AE 0.312T · 15mm2 NS = NP · n = 32 · 0.187 = 5.98 As we need a complete number of turns, and to have a little safety margin, we choose NS = 6: NP = NS ∕n = 6∕0.187 = 32.08 NP = 33 Calculate the core loss due to change of the flux density as following: The flux variation is: ∆B = LPRI · IPK,PRI 91µH · 1.64A = = 301mT NP · AE 33 · 15mm2 Divide ΔB by 2 for a unipolar waveform to calculate Bpk from which we will determine the core loss. Out of Fig. 4 we can determine the specific loss, and together with effective volume of Tab. 4, we can calculate the core losses. Please use only half of ΔB to calculate the specific core loss. Bpk = ∆B / 2 = 301mT / 2 = 150.5mT 16 www.we-online.com/midcom more than you expect Core geometries and parameters Core geometry AE (mm2) LE (mm) VE (mm3) RTH (K/W) ER11/5 ER14.5 EFD15 EFD20 EE13/7/4 (EF12.6) EE16/8/5 (EF16) EE20/10/6 (EF20) EE25/13/7 (EF25) 11.00 17.30 15.00 31.00 12.40 20.10 32.00 51.40 14.70 19.00 34.00 47.00 29.60 37.60 46.00 57.80 161.70 328.70 510.00 1457.00 367.04 755.76 1472.00 2970.92 134 99 75 45 94 76 46 40 winding window height (mm) 1.60 2.74 1.80 2.25 1.80 2.51 3.15 4.01 Tab. 4 Calculating core loss (using Fig. 4 and Tab. 4): From Fig. 4, PV = 120kW/m3 (at 100kHz and 100˚C) Core loss = VE x PV = 510mm3 x 120kW/m3 = 62mW Thermal resistance of an EFD15 SMD-H 10 pin, Rth = 75K/W If we set a temperature rise limit of 40°C then the maximum power loss (PMAX) of the transformer is: PMAX = ˚CRISE/RTH = 40/75 = 533mW Dividing half of the losses to the core and half to the coil that is 533mW/2 = 266mW. The calculated core loss of 62mW is well below 266mW which suggests that our core is too large for this application but we’re not done yet. 17 6 6th Step Define wire thickness and calculate copper losses Select the wire cross section that the total power loss and the resulting temperature rise remain within reasonable bounds. Design Tip 3: For small parts the temperature rise should be less than 40°C. Design Tip 4: A good starting point is to select a current density of 4A/mm². The copper losses are calculated by Ohm´s law. For the thin wires, it is reasonable to disregard eddy current losses in the first step. Check if the selected wire fits into the winding build of the bobbin. By using Fig. 5 you can determine the number of layers you need. Note that this figure is only valid if you don´t need creepage and clearance distances. Fig. 5: Number of turns per layer for different packages and wires By multiplying the number of layers with the outer wire diameter (Tab. 5) we calculate the winding build. Calculate the total winding build by adding the winding heights of all windings. Check if the total winding build is less than the build of the winding window (Tab. 4) 18 www.we-online.com/midcom more than you expect Winding wires and parameters Wire diameter (mm) AWG 0.1 0.15 0.2 0.28 0.3 0.35 0.4 0.5 38 34 32 29 28 27 26 24 Outer diameter ER11.5 ER14.5 (mm) 0.125 0.177 0.239 0.329 0.337 0.387 0.459 0.566 57.18 24.00 13.10 6.55 5.68 4.13 3.14 1.97 71.47 30.00 16.38 8.19 7.10 5.16 3.92 2.47 DCR/Turn (mΩ/Turn) EFD15 EFD20 EE13/7/4 EE16/8/5 69.62 29.22 15.96 7.98 6.91 5.03 3.82 2.40 90.26 37.89 20.69 10.34 8.96 6.52 4.95 3.12 63.53 26.66 14.56 7.28 6.31 4.59 3.49 2.19 92.65 38.89 21.23 10.62 9.20 6.69 5.09 3.20 EE20/10/6 EE25/13/7 103.23 43.33 23.66 11.83 10.25 7.46 5.67 3.57 139.76 58.66 32.03 16.01 13.88 10.10 7.67 4.83 Tab. 5 As with storage chokes, first the currents have to be calculated. The effective current, the average current and the peak current can be distinguished by examining the current curves. The effective or RMS current is that with which the copper losses are calculated. It is the current averaged over the period. For the secondary side we calculate: IRMS, SEC = IPK, SEC 1-DMAX 3 ( NN ) we know, LSEC = IPK, SEC = s p 2 IRMS,SEC effective current on secondary winding where IPK, SEC = 2 · POUT LSEC · ƒ · LPRI = (0.187)2 · 91µH = 3.182µH 2 · 11 = 8.31A 3.182 x 10-6 x 100000 Hence, IRMS, SEC = 8.31 · 1-0.45 = 3.56A 3 19 For the effective current on the primary winding we calculate: IRMS, PRI = IPK, PRI DMAX = 1.64 3 0.45 = 0.635 3 In our example, we have an RMS current of 0.635A on primary and 3.56A on secondary side. At 4A/mm², we need cross sections of 0.158mm² and 0.89mm² on primary and secondary, the corresponding diameters of which are 0.44mm and 1.06mm respectively. We choose a wire diameter of 2 strands of 0.28mm on primary side and 2 strands of 0.5mm wire on secondary side. These results in a resistance of 132mΩ for primary winding and about 7mΩ maximum for the secondary side (see Tab 5). According to Ohm´s law, we calculate winding losses of 53mW and 88mW on primary of secondary windings respectively. Now we have fixed the design and can start with the winding of the transformer: 1. Core and bobbin: EFD15 2. Primary 2 * 33 turns ø 0.28mm wire 3. Insulation tape between primary and secondary 4. Secondary: 2 * 6 turns ø 0.5mm wire 20 www.we-online.com/midcom more than you expect Transformer construction Now that the steps are completed, you can begin the construction of the transformer. Review the following questions 1-9 to see if anything was missed in the steps leading up to the construction process. Q1: Is the transformer required to meet safety agency standards that are intended to reduce risks of fire, electric shock or injury to personnel? What Material Group/CTI rating is required for the materials? What are the creepage/ clearance distances? Q2: Is the transformer required to meet an insulation system? Q3: In what environment will the transformer operate? Q4: What power supply and trans former topology will be used? Q5: How much space is allowed for the transformer on the printed circuit board? Q6: What is the lowest and highest frequency of operation? Q7: What is the wattage rating of the transformer? Q8: What are the input and output voltages and currents of the transformer, and how many windings are needed? Q9: Are the materials suitable for a lead-free solder reflow process? Here are some basic guidelines to follow when building a transformer. By following these guidelines, you will minimize the manufacturing costs, while optimizing the electrical performance. Note these guidelines are not intended to show all possible methods of construction. The accompanying photographs show an example of a surface mount construction. 21 General example of step-by-step construction of a transformer 22 Step 1 – Bare Bobbin Step 2 – Shelf Tape Step 3 – Wind 1 Step 4 – Wrapper Tape 1 Step 5 – Wind 2 Step 6 – Wrapper Tape 2 Step 7 – Wind 3 Step 8 – Finish Tape Step 9 – Solder Step 10 – Core Step 11 – Core Tape www.we-online.com/midcom more than you expect Glossary Margin (Shelf) Tape – Determine if a safety isolation barrier is required and where that barrier will be located. In the example, margin (shelf) tape is applied to one side of the bobbin (coil former). The number and placement of margin tape will affect magnetic coupling and leakage inductance. An alternative to margin tape is double or triple insulated wire. This wire may be cost prohibitive on high turn windings. Wire Strands/Wire Gauge – Choose the type of wire, number of strands, and wire gauge based on the frequency of operation and current carrying ability. Be aware that heavy gauge or multi-stranded wire may solder bridge together on adjacent terminals. Turns Per Layer (TPL) – Pick a turns per layer of wire that fills the winding area of the bobbin. On low turns per layer windings, it may be necessary to space the turns of wire evenly across the bobbin. This also applies to high turn, multilayered windings where the last layer does not entirely fill the bobbin. Minimize the number of layers of wire to reduce leakage inductance and eddy current losses. Pinout – A number of factors will affect the bobbin pinout, including safety agency requirements and circuit board layout. Typically, the primary windings are terminated on one side of the bobbin, and the secondary windings are terminated on the other. Ideally, the pinout for a particular winding will be dictated by the number of layers of wire, whether odd or even, although other factors will also affect it. If the winding ends on the side of the bobbin that is opposite from the intended finish terminal, bring the wire across the coil at a 90˚ angle. Place the wire in an area where it will be the least disruptive to subsequent windings and the ferrite core set. Tape can be used to hold the wire down at the bend. It may be necessary to place a piece of tape under this wire to insulate it from its own winding to prevent cut-through and subsequent shorted turns. Pulling this wire across the coil at an angle other than 90˚ will cause the subsequent windings to not lay uniformily and evenly. Interlayer Insulation – Interlayer tape may be required if there is a high voltage potential between each layer of wire within the same winding. Wrapper Tape/Finish Tape – Select a wrapper tape that is slightly wider than the distance between the bobbin flanges. This extra width allows the tape to lap up the sides of the flanges without folding over. This ensures isolation between the windings, minimizing the risk of wire-to-wire contact and potential dielectric breakdown. The higher temperatures associated with a lead-free solder reflow process may cause the standard polyester tapes to shrink. Also, smaller transformer packages will absorb more heat, causing more tape shrinkage. This tape shrinkage will have a direct affect on dielectric breakdown strength and the integrity of the safety isolation barrier. High temperature polyamide tapes are available, but their comparative tracking index (CTI) is lower with a resulting change in the material group. This results in a greater creepage/clearance distance requirement. Core Set/Core Tape/Insulation Tape – Choose the appropriate core set and AL inductance factor. Secure the core set to the coil with 2 layers of tape. Do not stretch the tape during the application process. It may be necessary to apply insulation tape to one or both sides of the core set to insulate the core from the terminals. Additionally the core set may be bonded to the coil (bobbin) with an adhesive or varnish coating. 23 more than you expect n Fast Time-to-Market n Smart Transformer n Innovative Selector Designs n Logistic Solutions n Reliable Quality n Global Account Management n Reference Designs of Leading IC Manufacturers n Direct Support through Solution Oriented Employees www.we-online.com/midcom INSIGHT DESIGN 9999062 • Revised MARCH 2015 Added value for you. More than you expect!