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Old 3rd September 2014, 09:18 PM   #1
rcbuck is offline rcbuck  United States
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Default Best Flyback Design Tool?

Anyone have a suggestion for the best offline flyback design tool? I see ones from Power Integrations, Infineon, TI, ON Semiconductor, and others.

Has anyone designed a power supply using one of these tools? I'm mainly interested in the transformer design since I will determine which devices to use for the switching circuit.

For example, the BVdss rating for the Power Integration devices is 700 volts. So if I use their tool to design the transformer, in some cases I would have to use an external device such as an NCP2117 driving an external Mosfet.

The designs I would be creating would be 100 watts or less with a maximum output voltage of 35 volts. Input VAC range would be 85-135.
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Old 3rd September 2014, 10:35 PM   #2
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I never used these tools but relied on my own spreadsheets.
I hope this one is useful for you.
Attached Files
File Type: zip flyback-calc-xfr-pub-en.xls.zip (3.7 KB, 29 views)
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Old 4th September 2014, 04:02 AM   #3
rcbuck is offline rcbuck  United States
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Voltwide, very interesting. I played with your spread sheet. The calculations are very close to what the Power Intergrations tool calculates.

I just finished a 45 volt, 2 amp supply based on PI tool calculator output values. I used a EFD30, N87 core gapped for 787 uH.

Output voltage varies from 46.7 volts at 93 ma load to 46.9 volts at 2.35 amp load. The only annomally I see is with a 1.2 amp load the output jumps to 48.1 volts.
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Old 4th September 2014, 01:23 PM   #4
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Nice to see that PI have adopted my calculations
Irregularities of output voltage often indicate a change of operating mode, from discontinuous to continuous or vice versa.

My calculations are strictly based on discontinuous "critical conduction mode" aka "boundary conduction mode", aka "quasi-resonant zero voltage switching" (QR-ZVS), aka "ringing choke" converter. There is no fixed frequency, operating cycle frequency drops with load, i.e. lowest frequency at max load.

Over the years I designed a series of such off-line converters. My favourite controllers are 8pin PFC-controllers like L6565 from ST, an off-the-shelf product that simply does the job. Others like FAN7527 may work as well.

Concerning the ferrite, you may have a look at ER28 cores, often seen in far east smps.
Center pole is round, and the bobbin is very wide enabling good coupling essential for flyback.

Last edited by voltwide; 4th September 2014 at 01:44 PM.
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Old 4th September 2014, 01:49 PM   #5
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Quote:
Originally Posted by rcbuck View Post
Output voltage varies from 46.7 volts at 93 ma load to 46.9 volts at 2.35 amp load. The only annomally I see is with a 1.2 amp load the output jumps to 48.1 volts.
Are these results of calculation, simulation or realistic measurements?
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Old 4th September 2014, 09:25 PM   #6
kees52 is offline kees52  Netherlands
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I have a short question about smps, I want to build a inverter this winter who is for welding, I need a constant voltage source.

Am I right when I say that I need a type with voltage feedback and a current limit protection (only for as it stick).

and a current source have no voltage feedback and only a adjustable current limiter, (voltage version a fixed current limit).

This is for a co2 welder it needs constant voltage.

It is the only question to be shure.

thanks
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Old 4th September 2014, 09:26 PM   #7
rcbuck is offline rcbuck  United States
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These are actual measurements using high power resistors as loads. Measurements were made with my DMM that is fairly accurate. I let each load run for 2 minutes before writing down the results.

The transformer runs warm but not too hot to touch.
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Old 4th September 2014, 10:33 PM   #8
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Obviously you did not complete the upload of your data
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Old 5th September 2014, 01:09 PM   #9
rcbuck is offline rcbuck  United States
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Quote:
Obviously you did not complete the upload of your data
I wasn't going to upload any data. I was just referring to the measurement values that I originally posted. Those figures were measurements I took from the running power supply.
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Old 5th September 2014, 05:47 PM   #10
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ok, I see. It would be interesting to know more details:
-is it fixed frequency pwm? or something else?
-schematics of your circuit
-How long ist ton, toff & tdt (deadtime) at max load?
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