Professional Documents
Culture Documents
Cookbook
for do-it-yourself transformer design
Content
02
Introduction
04
Transformer Design
06
Step-by-step
to flyback converter design
07
1st step:
Definition of the turns ratio and the duty cycle
10
2nd step:
Definition of inductance
11
3rd step:
Selection of the core
12
4th step:
Calculating primary turns
13
5th step:
Defining the wire cross section
15
Transformer Construction
17
Step-by-step-construction
18
Glossary
19
20
Product Overview
22
23
03
Introduction
The Speedy Design Kits are made for engineers to wind
04
PLEASE NOTE:
Althought 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 or alleyed to be
caused by this book.
All appropriate material is only valid for
low power applications. For applications
with 60 VDC / 48 VAC or more, please refer
to relating safety regulations.
Bobbins
Wires ()
0.1 mm (AWG38)
0.15 mm (AWG34)
0.2 mm (AWG32)
0.28 mm (AWG29)
0.3 mm (AWG28)
0.1 mm (AWG38)
0.3 mm (AWG28)
0.35 mm (AWG27)
0.4 mm (AWG26)
0.5 mm (AWG24)
0.1 mm (AWG38)
0.15 mm (AWG34)
0.2 mm (AWG32)
0.28 mm (AWG29)
0.3 mm (AWG28)
0.35 mm (AWG27)
0.4 mm (AWG26)
0.5 mm (AWG24)
Wrapper
tape
Cores
Gapping
Material
Mylar
0.05 mm, 0.1 mm,
0.15 mm, 0.19 mm
Mylar
0.05 mm, 0.1 mm,
0.15 mm, 0.19 mm
Mylar
0.05 mm, 0.1 mm,
0.15 mm, 0.19 mm
Extras
Design Guide
Abc of transformers and
Software for Flyback Design
WE-FLEX-DESIGNER
Order
Code
750 102
750 101
on request
05
Transformer Design
The following example gives you an idea how to design a
transformer for a flyback converter.
Compile specifications
Calculate inductance
Decide on core
no
Step-by-step
to flyback converter design
Fig. 2 shows the basic schematics of a flyback converter.
1. Switch closed:
1. Continuous mode:
the gap.
2. Switch open:
With the switch open the current is interrupted on primary
2. Discontinuous mode:
will be zero at the end of the cycle. There are current gaps
07
transformer requires a larger package if these requirements are considered. Special care should be taken for
Off-line applications.
Operating
voltage
RMS-voltage
or DC
50
100
125
150
200
250
300
400
600
800
1000
Basic insulation
400<CTI<600
0.9
1.0
1.1
1.1
1.4
1.8
2.2
2.8
4.5
5.6
7.1
CTI<400
1.2
1.4
1.5
1.6
2.0
2.5
3.2
4.0
6.3
8.0
10.0
CTI>600
1.2
1.4
1.6
1.6
2.0
2.6
3.2
4.0
6.4
8.0
10.0
Reinforced insulation
400<CTI<600
CTI<400
1.8
2.4
2.0
2.8
2.2
3.0
2.2
3.2
2.8
4.0
3.6
5.0
4.4
6.4
5.6
8.0
9.0
12.6
11.2
16.0
14.2
20.0
Tab. 2: Creepage distances for different operating voltages according to EN60950 for Polution degree 2*
* Pollution degree 2 (P2): Only non-conductible pollution can occur. Temporary conductibility can occur due to bedewing.
Remark: Transformers with almost closed housing belong typically to pollution degree P2. It has not to be air tight.
08
Operating voltage
peak value or DC
50
100
125
150
200
250
300
400
600
800
1000
Reinforced insulation
2000
2000
2000
2000
3000
3000
3000
3000
3000
3000
3000
We now want to show the step-by-step design process for a flyback converter.
The following example should help to understand the design steps:
36-57 V
5V
1.5 A
50%
300 kHz
Functional operation*
09
N1
The maximum duty cycle and the highest currents do
occur at the minimum input voltage. This is the worst case.
N2
0.4
36 V
1-0.4
5 V + 0.7 V
= 4.2
a short time.
DESIGN TIP 1:
Keep a little safety margin to the
maximum allowed duty cycle of the IC.
4+
= 0.39
5 V + 0.7 V
N1
N2
vTmax
1-vTmax
Ui, min
U o*
vTmax =
N1
N2
Uo* + UL
N2
N1
N2
Ui, min
U o*
UDS = Ui +
UL = input voltage
N1
10
4
36 V
vTmax =
DESIGN TIP 2:
Use a MOSFET with a sufficient safety
margin in breakdown voltage as the
voltage spike from the discharge of
the leakage inductance can destroy
the MOSFET.
2nd step:
Definition of inductance
As with storage chokes, first the currents have to be
calculated. The RMS current, the average current and
Po
Iavg, prim =
Ui vT
7.5 W
36 V 0.8 0.39
= 0.67 A
inductance.
IRMS, sek =
1
1-vT
1.5 A
1-0.39
= 1.92 A
IRMS, prim =
Po
Ui
7.5 W
36 V 0.8 0.39
vT
= 0.42 A
DESIGN TIP 3:
Usually inductance is defined by the
ripple current on secondary side
which is a certain percentage of the
average current. For continuous
mode designs choose a ripple of
20% to 50% of the average current.
We calculate the following secondary inductance with a
ripple of 25%:
U*o (1-vT)
Lsek =
5.7 V 0.39
0,25 2.45 A 300 kHz
= 12.1 H
on primary side:
Iavg, sek =
Io
1-vT
1.5
1-0.39
= 2.45 A
Lprim = Lsek (
N1
N2
)2 = 12.1 H 16 = 193.6 H
11
3rd step:
Selection of the core
For frequencies between 100 and 500 kHz, the best choice
for core material are so called power ferrites, MnZn ferrite
with a permeability of 2000-2500 e.g. 1P2400. The
saturation flux density Bs of 1P24000 is 360 mT at 100C.
Fig. 4 shows the specific losses for given frequencies and
flux densities. The package type depends on the power to
be transformed. A starting point is provided in Tab. 4.
Core geometry
ER 11/5
ER14.5/6
EFD15
EFD20
EE12.6
EE16
EE20
EE25
Flyback converter
8.5
20
26
50
17
41
73
135
Push-Pull Converter
14
32
42
80
28
67
118
218
4th step:
Calculating primary turns
The minimum number of turns is defined by the saturation
Nprim >
Lprim Iprim
Bsat Ae
193.6 H 0.75 A
0.36 T 15 mm2
=
= 27
Fig. 5: Maximum magnetic flux against the number of turns for different package styles. Note: For flyback converters
magnetic flux is calculated by inductance*peak current.
13
B =
193.6 H 0.17 A
32 15 mm2
= 68 mT
Core
geometry
Ae (mm2)
Le (mm)
Ve (mm3)
Rth (K/W)
winding window
height (mm)
ER 11/5
ER14.5/6
EFD15
EFD20
EE 12.6
EE 16
EE 20
EE 25
11.9
17.6
15
31
12.4
20.1
32
52.5
14.7
19
34
47
29.7
37.6
46
57.5
174
333
510
1460
369
750
1490
3020
134
99
75
45
94
76
46
40
1.6
2.75
1.8
1.8
2.1
2.5
3.15
3.95
14
5th step:
Defining the wire cross section
Select the wire cross section that the total power loss and
bounds.
DESIGN TIP 4:
For small parts the temperature rise
should be less than 40 K.
DESIGN TIP 5:
A good starting point is to select a
current density of 4 A/mm.
Fig. 6: Number of turns per layer for different packages and wires
15
Wire
diameter
(mm)
AWG
Outer
diameter
(mm)
0.1
0.15
0.2
0.28
0.3
0.35
0.4
0.5
38
34
32
29
28
27
26
24
0.125
0.177
0.239
0.329
0.337
0.387
0.459
0.566
DCR/Turn (m/Turn)
ER11
ER14.5
EFD15
EFD20
EE12.6
EE16
EE20
EE25
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
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
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
Now we have fixed the design and can start with the
Transformer Construction
Now that the steps in figure 3-5 are completed you
can begin the construction of the transformer.
Step-by-step-construction
18
Step 3 Wind 1
Step 5 Wind 2
Step 7 Wind 3
Step 9 Solder
Step 10 Core
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 tapes 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 degree angle. Place the wire in
an area where it will be the least disruptive to subsequent
windings and the ferrite core set.
Price in
Price in US$
300
400
Ship in 3 days*
200
300
Ship in 7 days*
100
150
FREE
FREE
* Shipped with FedEx Priority
20
on www.we-online.com/speedy
Midcom:
+1 (0) 605-886-4486 or
email: speedy@we-online.com or
www.we-online.com/speedy
salesmen
1 10 customized pieces
2 Specification Sheet,
Test Data & Deviation Report
3 Shipped within
selected service time
Design-In support
- Flyback
Worldwide availability
- Forward
Rapid prototyping
- Push-Pull
- Coupled Inductors
Telecom Applications:
package styles
- xDSL
21
Product Overview
EMC Ferrites
EMC Ferrites for cable assembly
SMD Ferrites
Inductors
Filter & RF Chokes
Power Inductors
Common Mode Chokes
Transformers
LAN Transformers
Telecom Transformers
Power Transformers
RF Components
RF Inductors
LTCC Components
Varistors
Disk Varistors
SMD Varistors
ESD Suppressors
D-SUB Filter Connectors &
EMC Shielding Material
D-SUB Filter Connectors
EMC Shielding Materials
Assembly
Spacer
Cable Assembly
Shrinkle Tube
Connectors
Wire-to-Board
Board-to-Board
Wire-to-Wire
22
Wrth Elektronik differs in several aspects from all other component manufacturers:
We deliver all catalogue products ex stock and our technical sales
force can support your designs with market experience.
Worldwide Technical
Sales Force
TECHNICAL
SALES FORCE
REFERENCE
DESIGNS
Design Kits
DESIGN
KITS
24 h E-Mail Hotline
E-MAIL HOTLINE
23
www.we-online.com