An algorithm for designing an inductor-transformer of a flyback converter with optimal copper core loss ratio

Abstract EN

Flyback converters are becoming more and more popular due to their simplicity and the few number of components that they require.

One of the main challenges that face the design of flyback converters is the design of the transformer which is vital to the operation of the converter.

The transformer stores energy when the electronic switch is ON and transfers this energy through the secondary side when the switch is OFF.

Hence it's more a case of two coupled inductors rather than the conventional transformer action.

This research presents an algorithm to design the inductor-transformer of a flyback converter.

The essential equations for inductor-transformer are presented, calculations of primary and secondary winding specifications is also carried out.

The algorithm adopts a method of optimizing the design by considering an optimal copper/core loss ratio.

Several common cores configuration are considered and results for each type is presented.

Numerical values such as optimum CU and core losses, efficiency, air gap length, number of turns on both sides for each type of core is illustrated .

Change of switching frequency and its effect on optimal efficiency and air gap length is carried out using two configurations only.

Results show that some of the proposed cores have high optimal efficiency, reasonable weight and satisfactory performance.

The proposed algorithm can be utilized for continuous and discontinuous modes of operation for a flyback converter.