ZVS Flyback Operation

Ernest H. Wittenbreder Technical Witts, Inc. 3260 S. Gillenwater Drive, Flagstaff, AZ 86001 (928) 773-8673 etecwitt@npgcable.com

ZVS Active Clamp Flyback Operation

Simplified Circuit

+ VLINE PWM A

CRESET

LMAIN

DOUT + COUT

MAUX LZVS B

RLOAD

PWM

MMAIN

DCLAMP

U.S. Patent: 5,402,329

2 Confidential - Property of Technical Witts, Inc.

ZVS Active Clamp Flyback Converter Eliminates first order (drain circuit) switching losses for high efficiency and reliability. The different ZVS design optimization process enables use of a larger MOSFET die size for reduced conduction losses and higher efficiency. Diode reverse recovery effects are eliminated. Relatively simple power stage with low parts count compared to all other isolated ZVS topologies. Second order transfer function behaves like a standard CCM flyback converter but with improved damping and can accommodate wide line voltage ranges. Destined to become an industry standard topology as a higher efficiency and higher frequency alternative to conventional off line flyback converters. Simple synchronous rectifier implementation using timing signals from ZVS drive choke. ZVS drive choke can also provide drive power.

ZVS Active Clamp Flyback Operation

Main Switch On Time

IPRI LMAIN VLINE IPRI LZVS PWM MMAIN DCLAMP COUT + ISEC RLOAD

U.S. Patent: 5,402,329

MMAIN is on. Current (and energy) ramps up in LMAIN and LZVS.

4 Confidential - Property of Technical Witts, Inc.

ZVS Active Clamp Flyback Operation

Turn Off Transition 1
IPRI1 + VLINE MAUX A MMAIN U.S. Patent: 5,402,329 LZVS B IPRI4 IPRI3 DCLAMP

CRESET IPRI2

LMAIN E

DOUT + ISEC1 COUT ISEC2

RLOAD

All switches are off. Primary current has reached its peak value. During turn off transition voltage rises at nodes A, B, and E. Parasitic capacitance of MMAIN and DCLAMP are charged. Parasitic capacitance of MAUX and DOUT are discharged.
5 Confidential - Property of Technical Witts, Inc.

ZVS Active Clamp Flyback Operation

Off Time 1

CRESET IPRI MAUX

LMAIN E

DOUT + ISEC1 COUT ISEC2

RLOAD

A LZVS

U.S. Patent: 5,402,329

MAUX body diode and DOUT begin to conduct. Node voltages are clamped. Primary winding current is still near its peak. ISEC1 is small compared to ISEC2, in general.
6 Confidential - Property of Technical Witts, Inc.

ZVS Active Clamp Flyback Operation

Off Time 2

CRESET

+ IPRI LMAIN E

DOUT + ISEC2 COUT ISEC1

MAUX A LZVS U.S. Patent: 5,402,329 B

RLOAD

MAUX turns on immediately after MAUX body diode begins to conduct. VNODEA > VNODEB, (VNODEA - VNODEB) increases with peak current and MMAIN duty cycle. IPRI ramps down gradually to zero. ISEC2 ramps up with ramp down of IPRI. CRESET voltage rises and hits a peak when IPRI drops to zero volts.
Confidential - Property of Technical Witts, Inc.

ZVS Active Clamp Flyback Operation

Off Time 3

CRESET

IPRI

LMAIN E

DOUT + ISEC2 COUT ISEC1

MAUX A LZVS U.S. Patent: 5,402,329 B

RLOAD

IPRI has reversed direction and now ramps up to a negative peak value equal to its original positive peak value. VCRESET is falling. ISEC2 is now much larger than ISEC1 and continues to ramp up reaching its peak value at the end of off time 3. VNODEA > VNODEB
8 Confidential - Property of Technical Witts, Inc.

ZVS Active Clamp Flyback Operation

Turn On Transition 1
IPRI2 VLINE + MAUX A MMAIN U.S. Patent: 5,402,329 LZVS B IPRI1 LMAIN E

CRESET

DOUT + ISEC2 COUT ISEC1

RLOAD

IPRI3

IPRI1 had reached its negative peak value. MAUX is turned off. Energy stored in LZVS charges parasitic capacitance of MAUX and discharges parasitic capacitance of MMAIN. Current in LZVS begins to ramp down rapidly as node A voltage falls towards ground. Initially node B voltage does not change. ISEC2 ramps down as IPRI1 ramps down.
Confidential - Property of Technical Witts, Inc.

ZVS Active Clamp Flyback Operation

Turn On Transition 2

IPRI VLINE

LMAIN E

DOUT + ISEC2 COUT ISEC1

RLOAD

A LZVS MMAIN U.S. Patent: 5,402,329

MMAIN body diode begins to conduct. VNODEB >> VNODEA IPRI ramps down quickly to zero. ISEC2 ramps down rapidly, but does not reach zero yet.
10 Confidential - Property of Technical Witts, Inc.

ZVS Active Clamp Flyback Operation

Turn On Transition 3

IPRI VLINE

LMAIN E

DOUT + ISEC2 COUT ISEC1

RLOAD

A MMAIN U.S. Patent: 5,402,329 LZVS IPRI

MMAIN is turned on immediately as body diode begins to conduct. VNODEB >> VNODEA IPRI rapidly ramps down to zero amps then reverses direction. ISEC2 continues ramping down rapidly, but does not yet reach zero amps. This phase can be considered part of the on time of MMAIN.
11 Confidential - Property of Technical Witts, Inc.

ZVS Active Clamp Flyback Operation

Turn On Transition 4

IPRI

LMAIN E

DOUT + ISEC2 COUT ISEC1

VLINE A MMAIN U.S. Patent: 5,402,329 LZVS B

RLOAD

IPRI has reversed direction and is now ramping up in value. VNODEB >> VNODEA DOUT continues to conduct and ISEC2 rapidly ramps down to zero amps. This phase can also be considered part of the on time of MMAIN.
12 Confidential - Property of Technical Witts, Inc.

ZVS Active Clamp Flyback Operation

Turn On Transition 5

IPRI1

LMAIN E

DOUT + COUT ISEC1

VLINE A MMAIN U.S. Patent: 5,402,329 IPRI2 LZVS DCLAMP ISEC2 B

RLOAD

IPRI3

ISEC2 has dropped to zero and now reversed direction. DOUT is off and its parasitic capacitance is being charged. VNODEB and VNODEE are falling, VNODEA = 0 Parasitic capacitance of DCLAMP is being discharged. ILZVS > ILMAIN, IPRI2 = IPRI1 + IPRI3 IPRI1 contains a component that represents the reflected (through the LMAIN transformer) ISEC2 current. This phase can be considered a part of the MMAIN on time.
Confidential - Property of Technical Witts, Inc.

13

ZVS Active Clamp Flyback Operation

Turn On Transition 6

IPRI1

LMAIN E COUT LZVS IPRI3 IPRI2 B DCLAMP + ISEC RLOAD

VLINE A MMAIN U.S. Patent: 5,402,329

The node B has dropped to ground forward biasing DCLAMP. Without DCLAMP node B voltage would become negative, ring, and overshoot parasitic capacitance of DOUT. IPRI2 remains constant VLZVS ~ ~ 0 IPRI1 initially drops in value as DCLAMP turns on because reflected secondary current disappears. IPRI1 ramps up gradually due to LMAIN applied voltage, correspondingly IPRI3 ramps down. DCLAMP continues to conduct until IPRI1 rises to value of IPRI2, IPRI3 = IPRI2 - IPRI1 This phase of operation can be considered to be part of the MMAIN on time. 14
Confidential - Property of Technical Witts, Inc.

VB - VA VLZVS 0

ILZVS 0

- VDCLAMP VB 0

IDCLAMP 0 15 Confidential - Property of Technical Witts, Inc.

VLPRI 0

ILPRI 0

VLSEC 0

ILSEC IDOUT 0 Confidential - Property of Technical Witts, Inc. 16

VMMAIN VA 0 IMMAIN

VMAUX

0 IMAUX ICRESET 0

17 Confidential - Property of Technical Witts, Inc.

VDOUT 0

IRLOAD 0

VCRESET 0

ICOUT 0

18 Confidential - Property of Technical Witts, Inc.