THE DC-DC FLYBACK CONVERTER WITH PWM CONTROLLER

NURUL FATIHAH BINTI ABD AZIZ

UNIVERSITI TEKNOLOGI MALAYSIA

PSZ 19:16 (Pind. 1/07)

UNIVERSITI TEKNOLOGI MALAYSIA

DECLARATION OF THESIS/UNDERGRADUATE PROJECT PAPER AND
COPYRIGHT
Authors full name

NURUL FATIHAH BINTI ABD AZIZ

Date of birth

20th SEPTEMBER 1990

Title

THE DC-DC FLYBACK CONVERTER WITH PWM

CONTROLLER

Academic Session

2012/2013

I declare that this thesis is classified as:

CONFIDENTIAL (Contained confidential information under the Official Seceret Act
1972)*

RESTRICTED

OPEN ACCESS

(Contains restricted information as specified by the organization

where research was done)

I agree that my thesis to be published as online open access (full

text).

I acknowledge that UniversitiTeknologi Malaysia reserves the right as follows:

1.
2.
3.

The thesis is property of University Teknologi Malaysia

The Library of UniversitiTeknologi Malaysia has right to make copies for the purpose of
research only.
The Library has the right to make copies of the thesis for academic exchange.
Certified by:

____________________________________
SIGNATURE
900920-06-5442
(NEW IC NO./PASSPORT NO.)
DATE: 14 JUNE 2013

_______________________________
SIGNATURE OF SUPERVISOR
MR ABD JAAFAR BIN SHAFIE
NAME OF SUPERVISOR
DATE: 14 JUNE 2013

NOTES: *If the thesis is CONFIDENTAL or RESTRICTED, please attach with the
letter from the organization with period and reasons for confidentiality or
restriction.

I hereby declare that I have read this thesis and in my opinion this thesis is
sufficient in terms of scope and quality for the award of the degree of Bachelor of
Electrical Engineering

Signature

Name

Mr.Abd Jaafar Bin Shafie

Date

14TH JUNE 2013

THE DC-DC FLYBACK CONVERTER WITH PWM CONTROLLER

NURUL FATIHAH BINTI ABD AZIZ

This thesis is submitted in partial fulfilment of the requirement for the award of the
Degree of Bachelor in Electrical Engineering

Faculty of Electrical Engineering

Universiti Teknologi Malaysia

JUNE 2013

ii

Hereby, I declare that this thesis entitled The DC-DC Flyback Converter with
PWM Controller is the result of my own research except the cited in the references.
The thesis has not been accepted for any degree and is not concurrently submitted in
candidature of any other degree.

Signature

...............................................................

Name

Nurul Fatihah Binti Abd Aziz

Date

14 JUNE 2013

iii

To my father & mother,

Mr.Abd Aziz Bin Yusof & Mrs.Jamilah Binti Ali

My sibling,

Hartini
Chairil Anuar
Zaity Akhtar
Mardiana
Mohamed Izahad
Muhammad Firdaus
Nur Azilah

All my friends and relatives,

All the beloved supervisor,

Thousand thanks and appreciation for your support, encouragement and

iv

ACKNOWLEDGEMENT

Praise be to Allah S.W.T., the Most Enamoured and the Most Mighty. Peace
be upon him, Nabi Muhammad S.A.W., the messenger of God.
First of all, I most likely to convey my heartily thankfulness to my supervisor,
Mr. Abd Jaafar Bin Shafie for kind-hearted, give the comment, sharing the idea and
guide me in order to finish this project.
My second appreciated to my big family who had been supported and give a
lot of motivate in all year that I has been in my study. Thankfulness also regarding to
the loving, understanding, kindness and spend their time to me.
Furthermore, I would like to said thank for technician of Power Electronic
Laboratory, Mr. Yusuf Bin Jamil and PCB Laboratory for guidance and giving their
kindness and helping me to complete this project.
Last appreciation to my friends, Arinah, Afiqah, Razman, Syukri, and also big
applause to all my friends including ENCONs member that give a lot of support, idea
and helping in sharing their knowledge,

ABSTRACT

According to the DC-DC converter, there are two kind of types which is linear
power supply and switched mode power supply (SMPS). The differences of this
converter is switch mode power supply (SMPS) had an isolated transformer and nonisolated transformer. The examples of isolated transformer DC-DC converter such as
this project, namely as Flyback, Push Pull, Forward and many more. This thesis was
related in applying the design of isolated transformer, executed through hardware
circuit and designing the PWM controlled to functioning the converter. The
transformer for this project is set up in step down transformer, which mean the input
voltage is greater than the output voltage. And this output also can be variety when
changing the duty cycle of PWM controlled. The SG3525A was used in designing the
PWM controlled, which the duty cycle can be set to the desired value. For the signal
to the switch, driver circuit is applied and HCPL3120 is used to conduct the output.
The analysis of result had been taken, and troubleshoot will be conducted if the
objective in this project not achieve.

vi

ABSTRAK

Terdapat dua jenis penukar DC-DC iaitu pembekal kuasa lelurus dan pembekal
kuasa boleh ubah. Perbezaan di antara dua jenis penukar ini ialah, pembekal kuasa
boleh ubah mempunyai pengubah memencil manakala pembekal kuasa lelurus tidak
mempunyai pengubah memencil. Contoh pengubah memencil di dalam penukar DCDC yang terdapat didalam projek ini dikenali sebagai penukar flyback, dan sama jenis
dengan push pull, forward dan berbagai jenis lagi. Tesis ini berkaitan dalam
mengaplikasikan reka bentuk pengubah memencil, dihasilkan menjadi perkakas litar
dan mereka bentuk pengawal PWM untuk menghidupkan penukar tersebut. Pengubah
yang digunakan didalam projek ini ialah pengubah langkah turun, yakni voltan yang
masuk lebih tinggi dari voltan keluar. Dan voltan ini boleh diubah-ubah semasa
menukar kitaran tugas pengawal PWM. SG3525A digunakan dalam mereka bentuk
pengawal PWM, di mana kitaran tugas boleh ditetapkan pada nilai yang dikehendaki.
Bagi isyarat ke suis, litar kawalan diaplikasikan dan HCPL3120 diguna bagi
mengawal keluarannya. Analisis keputusan telah diambil dan kajian kesilapan akan
dijalan jika objektif projek ini gagal dicapai.

vii

TABLE OF CONTENTS

CHAPTER

TITLE

PAGE

DECLARATION OF THESIS

ii

DEDICATION

iii

ACKNOWLEDGEMENTS

iv

ABSTRACT

ABSTRAK

vi

TABLE OF CONTENTS

vii

LIST OF TABLES

ix

LIST OF FIGURES

LIST OF SYMBOLS

xii

LIST OF APPENDICES

xiii

1 INTRODUCTION
1.1 Overview

1.2 Problem Statement

1.3 Objective

1.4 Scope of Work

1.5 Thesis Outline

2 LITERATURE REVIEW
2.1 Derivation of Flyback Converter

2.2 Analysis of Flyback Converter

2.2.1 Analysis when the Switch Turns ON

2.2.2 Analysis when the Switch Turns OFF

10

viii

2.3 Switching Part

12

2.4 Transformer

14

2.5 Pulse Width Modulation (PWM)

16

3 METHODOLOGY
3.1 Introduction

19

3.2 Analysis of the Flyback Converter

20

3.2.1 Switch in ON Condition

21

3.2.2 Switch in OFF Condition

22

3.3 Transformer

23

3.4 Pspice Simulation

26

3.5 Driver Cicuit

29

3.6 Flyback Converter Circuit

30

3.7 Testing on Photoboard

30

3.8 Express PCB

31

4 RESULT AND DISCUSSION

4.1 Pulse Width Modulation (PWM) Output

34

4.2 Driver Circuit Output

35

4.3Drain-Source Voltage Output

36

4.4Voltage Flyback Converter and Driver Output

37

5 CONCLUSION AND RECOMMENDATION

5.1 Conclusion

41

5.2 Recommendation

42

5.2.1Turn-off Snubber Circuit

43

5.2.2Designing the Transformer

43

REFERENCES

44

APPENDICES

45

ix

LIST OF TABLES

TABLE

TITLE

PAGE

2.1

Description of SG3525A

17

3.1

Design Parameter Specification

21

3.2

Core Geometries and Typical Transformer

25

Power

4.1

Comparison between Experimental and

38

Calculation
4.2

Comparison between Experimental and

Simulation

38

LIST OF FIGURES

FIGURE TITLE

PAGE

2.1

The Flyback Converter Circuit

2.2

The Buck Boost Converter Circuit

2.3

The Circuit of Buck Boost with Inductors

2.4

The Primary and Secondary Winding Isolated

2.5

The Circuit of Flyback during Switch Closed

2.6

The Flyback during Switch Open

10

2.7

Theoretical Graphs for Flyback Converter

12

2.8

Symbol oF MOSFET

13

2.9

Rating of Switching Devices

13

2.10

B-H Loop for Core

15

2.11

Power Transformer Circuit

15

2.12

Flyback Transformer Circuit

16

2.13

Pin Connection of SG3525A

17

2.14

Oscillator Discharge

18

3.1

Flow Chart onProject

20

3.2

LCR Databridge

24

3.3

Simulation Profile

26

3.4

Table for Create Pspice

27

3.5

Circuit Design in Pspice

27

3.6

Output Voltage

28

3.7

Output Power

28

3.8

Get Driver Circuit

29

3.9

Power Stage of Flyback Converter

30

xi

3.10

Circuit at Bread Broad

31

3.11

PWM in PCB

32

3.12

Driver in PCB

32

3.13

Converter in PCB

33

4.1

PWM Output

35

4.2

Driver Output

36

4.3

Drain-Source Voltage Output

36

4.4

Converter Voltage Output

37

4.5

Experimental vs Calculation

39

4.6

Experimental vs Simulation

39

xii

LIST OF SYMBOLS

SMPS

Switch Mode Power Supply

DC

Direct Current

PWM

Pulse Width Modulation

Duty Cycle

Inductance

LM

Magnetizing Inductance

Efficiency

Capacitance

Frequency

IC

Integrated Circuit

Voltage

Ampere

Watt

Temperature

Hz

Hertz

Ohm

Micro Farad

Resistance

diode

VDS

Drain Source Voltage

VO

Output Voltage

VS

Input Voltage

PCB

Printed Circuit Board

xiii

LIST OF APPENDICES

APPENDIX TITLE

PAGE

Datasheet SG3525A from

46

Datasheet HCPL3120 from

51

Datasheet IRF510

56

Datasheet ETD Core

59

Datasheet MUR860

62

CHAPTER 1

INTRODUCTION

1.1

Overview

DC DC converters are power electronic circuits that convert a dc voltage to

a different dc voltage at different level, often providing a regulated output [1].Variety
of the application can be obtained by the conversion of DC-DC converter such as
power supplies for the computer, telecommunication system and uninterrupted power
supply (UPS). One of the converters that had been popular nowadays is Flyback
converter that also categorized in the Switch Mode Power Supply (SMPS), the
advantages of this kind of SMPS regulator compare to the linear regular due to the
high efficiency that had been produced.

Moreover, the Switch Mode Power Supply (SMPS) also had function to fully
open (the switch is OFF) and fully close mean the switch is ON with the low power
losses. This SMPS is divided into two parts which is non-isolated transformer and
isolated transformer. The example of the DC-DC converter with non-isolated
transformer is buck converter, boost converter, the combination of buck and boost that
called as buck-boost converter.

The Flyback converter has been categorized in the DC-DC converter with
isolated transformer same goes to the forward converter, push-pull converter and
more. The operation of the Fly back converter is non-directly power conversion which
means the power of input does not combine with the power of output, and the isolated
transformer will use.

Flyback converter was imitative of the buck-boost converter with the isolated
transformer in it circuit. Additionally, Flyback converter commonly used for output
powers from about 5watt until 150watt. This output power shown that, Fly back
converter is suitable for the high power application such as television, DC welder and
another application.

1.2

Problem Statement

The main functioning of the converter is to convert DC input voltage level to

the DC output voltage level. This application for this types of converter was suitable
at DC welder, DC motor and many else. But when converting from input power to the
output power process, there are many power losses occur. The linear regulator that
conducted with transistor was operated in the linear mode. Due to the high current
transfer to the load the higher power losses will produce.

Based on the problem, the switch mode power supply (SMPS) is better to
overcome the low power losses during the converting from input to the output. The
transistor in SMPS is operated in switched mode mean that when the switch is ON, it
is fully saturated and when the switch is OFF the switch is in cut-off situation. Fly
back converter is suitable for the high power application, due to this matter, it need to
find the converter that produce higher duty cycle.

Furthermore, higher duty cycle mean that need to conduct the pulse width
modulation (PWM) with the period when time ON is much higher compared to the
period when the time is OFF. It mean that, the duty cycle must be greater or equal to
the 50%, and the Fly back converter can beat this matter weigh against to the forward
converter that only can conduct with the duty cycle less than 50%

1.3

Objectives

The objectives of this project are:

I.

To study the principle of power electronic converter on Fly back converter.

II.

To implement this converter using Pspice software.

III.

To study the isolation of the transformer.

IV.

To design the Flyback converter.

V.

To understanding the pulse width modulation (PWM) controller.

VI.

To identify the voltage output for the Flyback Converter.

1.4

Scope of the project

In order to meet achieve the goal of this project, first of all we need to study
and understand the operation and construction of the Flyback power electronic
converter. The operation of the Flyback converter when the switch is ON mean that
the switch closed and when the switch is OFF or another thoughtful when the switch
open. Kindly the derivate the formulae of the Flyback converter based on this
operation of switch.

Secondly, we must discover the understanding on the isolated transformer. As

we know, the main function of the transformer is to step-up and step-down the voltage
and it also can store the energy when the operating of the switching Flyback converter
is ON and conducting the energy to the secondary winding when the switch is OFF.

Next, study on the pulse width modulating (PWM) as the control circuits to
implementation the controlling of the output voltage. Furthermore, we need to design
the control circuit that produce the higher duty cycle for the high power application.
After reviews all the information and knowledge, next stage is to design the Flyback
converter and the isolated transformer. And we calculate the parameter using the
theoretical formulae and the design will be simulating to gain the waveform and value
same as the calculated value.

1.5

Thesis outline

Chapter 1: Introduction

This chapter will discover the fundamental of the Flyback converter including
examples of power switching DC-DC converter, the advantages of Flyback converter,
application for this type of converter. A review of the isolating transformer for the
DC-DC converter. Furthermore, the problem statement of this project mainly in the
transformer and pulse width modulation (PWM) aspect also described as well. It also
obtains the objective and the scope for this project.

Chapter 2: Literature Review

The contents of this chapter included all basics principle of operation and construction
of the Flyback converter, the operation of the switch in the Flyback converter, design
the transformer. It also will analyse the pulse width modulation (PWM), the advantage
of the PWM, and the design of pulse width modulation (PWM).

Chapter 3: Methodology

The technique that has been used for this project will discuss in the chapter. The flow
chart was provided as the guideline for this project and need to be accurate to flow, as
the result will produce the successful project. This chapter also indicated the some
computer software appliance.

Chapter 4: Preliminary Result

After calculated the value with theoretical formulae, simulation work that had been
running will provided and from this two of works, the combination will be done to
make sure that the value and waveform for simulation is same as the theoretical
knowledge.

Chapter 5: Conclusion

The summary of PSM 1 report will be shown.

CHAPTER 2

LITERATURE REVIEW

2.1

Derivation of Flyback Converter

Figure 2.1 show the Flyback converter circuit that is basically dc-dc converter
based on the buck-boost converter with the different of added factor of n for the duty
cycle, D. Figure 2.2 illustrate the buck-boost converter is the kind of converter that
can generate a higher or lower of the output voltage [1]. This kind of converter
normally used in televisions and computer monitors according to the comfortable with
the high-voltage power.

Figure 2.1

The Flyback Converter Circuit.

Figure 2.2

The Buck-Boost Converter Circuit.

The comparison between buck and boost will transform to the buck-boost
converter. The adding of the inductor with two parallel of wires into buck-boost
converter circuit producing the isolated at the inductor winding that has same
component symbol of the Flyback transformer as show in figure 2.3 and figure 2.4.
The switching Flyback will place at the primary winding that represented by MOSFET
according to the power rating and the frequency switching that view at figure 2.5.

Figure 2.3

The Circuit of Buck-Boost with Inductors.

Figure 2.4

2.2

Primary and Secondary Winding is Isolated.

Analysis of the Flyback Converter

For this kind of dc-dc converter, there are two parts of analysis which is when
the switch is on, mean the switch closed and when the switch is off, which descriptions
of switch when open.

2.2.1 Analysis when the switch turns ON

The reverse biased at the diode occur during this situation of the opening the
switch. According to this matter, the current does not flow from primary winding to
the secondary winding. And the energy will store at the magnetizing inductance, Lm
and for the load current, the filter of the capacitor will flow up the current though it

[2]. The circuit for the Flyback converter during the switch is ON is illustrated at the
figure 2.6.

Figure 2.5

Circuit of Flyback During the Switch Closed.

The analysis is started at primary winding of transformer side,

(2.1)
(2.2)

When the switch closed, the change for the current at the magnetizing inductance
transformer,

(2.3)

The analysis at the secondary winding of transformer side,

(2.4)

(2.5)

(2.6)
(2.7)

10

(2.8)

2.2.2 Analysis when the switch turns OFF

When the switch is OFF, the diode automatically will in forward biased
condition. The circuit when the switch open is shown in figure 2.7, the current at the
magnetizing inductance transformer will flow to the secondary winding of the
transformer. These conditions happen when the current in the magnetizing inductance
Lm, cannot change instantaneously when the switch is OFF, so the current will flow
between the magnetizing and the primary winding. The current from magnetizing will
through undotted primary winding to transfer the current by entering the undotted
secondary winding.

Figure 2.6

Illustration of Flyback Converter when Switch Open

The voltage across magnetizing inductance, Lm that approach from the secondary
terminal winding that transfer to the primary winding of transformer,

(2.9)
Voltages and currents for an open switch [3].

11

(2.10)
(2.11)

(2.12)

When the switch is OFF, the change for the current at the magnetizing inductance
transformer,

(2.13)

At the steady-state conditions, the net change in magnetizing inductance current must
equal to the zero,

(2.14)
(2.15)

12

Figure 2.7

2.3

Theoretical Graphs for Flyback Converter

Switching Part

To control the circuit there are many types of power semiconductor switches
that was introduced today. To achieve the successful for this project, the Metal Oxide
Semiconductor Field Effect (MOSFET) had been choose. This power semiconductor
switches have three terminal voltage-controlled switch that is differ from bipolar
transistor which is the three terminal current-controlled switch.

13

The three terminals know as drain (D), source (S) and gate (G) which have
their own function. MOSFET function as the switch to control the ON and OFF state.
The power rating for this category of power semiconductor switches is from 10kWatt
drop to the 100Watt. While for the frequency of switches is in range 100 kHz until
10MHz. MOSFET have the fast switching speeds high impedance gate required a
small voltage and charge to facilitate ON and OFF state [4]. The symbol of MOSFET
was illustrated in figure 2.13.

Figure 2.8

Figure 2.9

Symbol of MOSFET

The Graph of The Power Rating of The Switching Devices.

14

2.4

Transformer

There are two main functions of power transformer which is to step-up and
step-down time varying current and voltage and second function to provide the
electrical isolated. Electrical isolation by mean the transformers is needed in switches
mode power supply for three main reason, first for safety, it means that it importance
for the low voltage DC output to be isolated from the supply power. Next, the
transformer isolated necessary for different reference potentials and for voltage
matching.

Furthermore, in order to avoiding large voltage and current ratings of

semiconductor device due to the DC-DC converter value if it is higher, we need
transformer isolation. For Flyback converter transformer, it has one more function
which is to store the energy when the switch is ON and transfer the current when the
switch is OFF. The basic power transformer and the Flyback transformer with addition
of magnetizing inductance, Lm as the storage of energy is shown in figure 2.14 and
figure 2.15.

In order to create the isolate transformer, there are many aspect need to be
consider, the number of turns, the value of magnetizing inductance, after know this
things, the rms current also need to calculate, and from that the circular mils (size of
winding in transformer) can defined [6]. The tape of core have two types which is tape
wound core or ferrite cores. This core is appropriate to the application that need low
frequency because high flux density will minimize the transformer size. The own core
types have finite gap, the function of gap is to minimise the flux hysteresis in the
transformer [7].

15

Figure 2.10

B-H Loop for Core (a) Ungapped (b) Gap Condition

Vp/Vs

Figure 2.11

Is/Ip

Np/Ns

Power Transformer Circuit

16

Figure 2.12

2.5

Flyback Transformer Equivalent Circuit

Pulse Width Modulation (PWM)

The regulating pulse width modulators (PWM) is commonly use in the circuit
to control the power switching system. For this project, the SG3525A will be used as
the pulse width modulation integrated circuit to control ON and OFF the MOSFET as
the switch, the figure 2.16 illustrated. The switch use is MOSFET because according
to the power rating of that switch, power rating for this switch is 100Watt to 10kWatt.
The power that can be drive by this switch less than 500 V and for the current must be
less than 300 Amp. For pulse width modulation as a leader to conduct the MOSFET
ON and OFF by provide the pulse signal according to the duty cycle and switching
frequency.

Otherwise, for the frequency, the range that this device can run is 100Hz to
500k Hz. The SG3525 was designed for offer the improvement of performance and
lowered external parts count when used in designing all types of switching power
supplies.

17

Figure 2.13

Pin no.

Name

Sync

Pin Connections of SG3525A

Description

Sync input to the oscillator allows multiple units

to be slaved.

A single unit to be synchronized to an external

system clock.

Ct

A single resistor between it.

Discharge

Provide a wide range of dead time adjustment.

10

Shutdown

Controls both the soft-start circuit and output

stage.

Provide instantaneous turn off through the PWM

latch with pulsed shut-down.

11

Output A

Will connected to the OR gate.

14

Output B

Will connected to the OR gate.

15

+Vi

Voltage supply is 12V

Table 2.1

The descriptions of SG3525A

18

According to the datasheet of SG3525A, the maximum output voltage is 5V,

and the maximum duty cycle for this control circuit is 49%. To get the desire
frequency, CT and RT should be set to the certain value. The usual switching frequency
for this converter is range 100 kHz. The CT and RT is set to be in value of 12k and
1nF in order to get the desired frequency 100 kHz.

Figure 2.14

Oscillator Discharge Time versus RT and CT

CHAPTER 3

METHODOLOGY

3.1

Introduction

This chapter describes the flow operation about the ways to conduct this
project. In this chapter, just concentrated on determination the Flyback converter
based on fundamental information and knowledge and last but not least, the
appropriated formula that was discussed in chapter 2. This chapter also show the guide
that must flow to fulfil this guide line in order to have achieved an excellent result.

This project get started with understanding the fundamental of basic condition
of switch in Flyback converter circuit, as already mention on Chapter 2, the energy
will stored in the magnetizing inductance when the condition of switch in open state,
while the transmitted of energy to the secondary winding occurrence when the switch
in close condition. This basic operation had been received through many sources such
as paper, journal paper, references books and so on.

After getting the basic knowledge, this journey was continue by understanding
the isolated transformer work out, through this understanding, the designer of
transformer was started with step by step. As knowledge, the basic function of

20

transformer is to step-up and step down the voltage, but in this Flyback, it had one
more additional function which is to stored energy in the situation when the switch is
open.

After that, understanding in pulse width modulation (PWM) circuitry, basic

function of pulse width modulation (PWM) is to control the circuit and also to set the
duty cycle and frequency with the desired value that we need.

Literature

Make the

review on

calculation

Flyback circuit

based on

and

theoretical

Hardware
Implementation

transformer

Writing

Record the

Testing and find out

thesis

data

the troubleshoot

Figure 3.1

3.2

Flow Chart Based on Project

Analysis of the Flyback Converter

Before begin this project, we must find the operation and construction
regarding to the topic which is Flyback converter. The understanding the operation of
this kind the converter, know the basic operation of switching, types of this converter
and important thing, must find out the benefits of this converter compare to other

21

converter that also have same function to convert from DC power supply to the DC
output.

Furthermore, to operate this types of converter, identify the switch that used to
control the fully ON and OFF for these converter. The power semiconductor switch
has power rating value, and for this project, know the application that want for this
converter operates for. From that, the power rating that be chosen will compare to the
all the power rating for these kind of power semiconductor switch.

PARAMETER SPECIFICATIONS

SYMBOL

VALUE

Input Voltage

VS

9V

Output Voltage

VO

4.5V

Primary Turn

N1

40

Secondary Turn

N2

20

Duty Cycle

50%= 0.5

Switching Frequency

fS

50kHz

Load Resistance

12

Capacitance

100F

Primary Inductance

L1

4822H

Secondary Inductance

L2

1176H

Table 3.1

Design Parameter Specifications

3.2.1 Switch in ON Condition

On primary side
The change of current in transformer magnetizing inductance,
From the equation 2.1,

22

On secondary side
The voltage at secondary winding,
From equation 2.16,

From equation 2.6,

3.2.2 Switch in OFF Condition

The voltage output,

From equation 2.9,

23

For the magnetizing inductance current,

From equation 2.12 and 2.13,

At the steady-state conditions, the net change in magnetizing inductance current must
equal to the zero,

To find output power,

3.3

Transformer

The core of transformer specification was used in this project is ETD34 and
the grade of core is 3C90. On this project, the value of primary inductance and

24

secondary inductance is 4822H and 1176H, this measurement achieve by using the
LCR data bridge as shown in figure 3.2.

Figure 3.2

Measurement of inductance of transformer using LCR Data

Bridge

Compile specification

Define duty cycle and

turn ratio

Calculate inductance

Decide on core

Calculate copper losses

Define wire thickness

Define the number of

turn

Calculate core losses

In order to build the transformer, there are some specification need to know,
such as rms current for both of winding in the transformer. Besides that, the size core
of winding also had been calculated by using formulae,

25

Maximum duty cycle,

(3.1)

Effective current on secondary winding,

(3.2)

Effective current on primary winding,

(3.3)

Table 3.2

Core Geometries and Typical Transformer Power

26

3.4

Pspice Simulation

Before through the hardware, understand the Pspice software first. There are
variety of software that will simulink the circuit. But to achieve my expected outcome,
Pspice is used to implement simulation circuit design and after get the same thing with
expected result, and proceed to hardware process. The Pspice was used ORCAD
Pspice release 16.5 Lite edition. Involved six steps that have to follow regarding a
basic circuit simulation. Firstly need to create the profile of my project as shown in
figure 3.1. Secondly, draw the circuit to represent the design in this simulation profile
as shown in figure 3.6, the component for this design have own code such as for the
transformer, the code is XFRM_LINEAR, for diode the code used for simulation is
dbreak and more.

Project
title
name

Location to store the project

Figure 3.3

The form of the simulation profile

27

Figure 3.4

The table for create Pspice project

According to the figure 3.4 above, after created project profile, must choose blank
project to implement the design. The dbreak is the simplest diode models, it notes the
fact that can break open these models and fiddle with the internal parameters [5]. The
result for output voltage and power is show in figure 3.6 and figure 3.7,

Figure 3.5

The circuit design at Pspice

28

Figure 3.6

Figure 3.7

The output voltage (Vo)

The waveform for output power

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3.5

Driver Circuit

Design three circuit which is the main and important circuit, Flyback converter,
then control circuit that functioning as the controller of the power semiconductor
switch, mean that this type of controller will control ON and OFF of the switching
power supply. And lastly, the driver circuit, according to the control circuit, the voltage
output that produce by the pulse width modulation (PWM) is only small value which
is only 5 volt.

Furthermore, the value of output is inadequate to conduct the gate terminal of

the switch. So the driver circuit will function that can amplifies control signal which
is voltage output of pulse width modulation (PWM) to level required to drive these
power switch. The circuit of get driver show in figure 3.8,

Figure 3.8

Get Driver Circuit

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3.6

Flyback Converter Circuit

This converter is called as Flyback because of the high efficient due to the
multiple energy that transfer to the secondary winding. This multiple energy happen
according to the stored energy in the magnetizing inductance when the switch is ON
state and the power energy in the capacitance forward the energy to the secondary
winding and when the switch is OFF state, energy in magnetizing will flow to the
secondary and from that, the energy became double energy. When the converter has
high efficient, it give advantage to the circuit because it help in order to minimize the
losses. Figure 3.9 show the circuit of Flyback converter,

Figure 3.9

3.7

Power Stage of Flyback Converter

Testing on Photoboard

As shown in Figure 3.10, the bread board is one of the testing board before
implement the design circuit on the printed circuit board (PCB). To complete this
project, there are three main circuit that needed to be tested, first is Pulse Width

31

Modulation circuit (PWM), it purpose as control circuit, second is driver circuit that
neede to help PWM circuit in order to produce and at the same provided to the switch
of converter circuit to flow the circuit.

Figure 3.10

3.8

Circuit of Converter in Bread Board

Express Printed Circuit Board (PCB)

The hardware process will be continue after successful get the result of Pspice
simulation same with theoretical. The printed circuit board (PCB) is the conductor
surface that forms a critical interface between the component and the interconnection
circuitry [6]. The printed circuit board (PCB) of control and driver and converter show
in figure 3.11, figure 3.12 and figure 3.13,

There are four ways to fabricate the printed board circuit (PCB) which is single
sided, double sided, multilayer and flexible.

32

Figure 3.11

PWM Control Circuit on PCB Board

Figure 3.12

Driver Circuit on PCB Board

33

Figure 3.13

Flyback Converter Circuit on PCB Board

CHAPTER 4

RESULT AND DISCUSSION

4.1

Pulse Width Modulation (PWM) Output

For this project, the output of Pulse Width Modulation (PWM) get from the
output of SG3525A. In order to change the duty cycle of integrated circuit (IC)
SG3525A, the output voltage also will be fixed and Pulse Width Modulation produce
pulse signal that will connected to the Flyback converter circuit. Figure 4.1 shows the
Pulse Width Modulation (PWM) output though hardware circuit.

Though Pulse Width Modulation (PWM), it been recorded the value pk-pk of
the circuit is 4.48V. This value does not support the exact value to operate the switch
in converter. By adding the driver circuit, the switch of Flyback converter will operate
the converter.

35

Figure 4.1

4.2

Pulse Width Modulation (PWM) output

Driver Circuit Output

The output of driver circuit is connected to the gate and source of IRF 510.
IRF510 is the metal oxide semiconductor field effect transistor (MOSFET) that
functioning to close and open the converter circuit. The driver react as the amplifier
connected to the Pulse Width Modulation (PWM) in order to the switch of converter
conducted. The output of driver circuit was verified in Figure 4.2.

36

Figure 4.2

4.3

Driver Circuit Output

Drain-Source Voltage Output

According to figure 4.3 show output voltage between drain and source of
MOSFET, this output come when the MOSFET connected parallel with high value of
resistor and the source connected to ground while the drain connected to the source
12V.

Figure 4.3

Drain Source Voltage Output

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4.4

Voltage Flyback Converter and Driver Output

When duty cycle, D = 20%

V0 from driver circuit = 16V
V0 from converter circuit = 1.8V

When duty cycle, D =50%

V0 from driver circuit = 16V
V0 from converter circuit = 1.88V

When duty cycle ,D = 80%

V0 from driver circuit = 16.4V
V0 from driver circuit = 1.80V

Figure 4.4

Voltage Output from Pulse Width and Driver Circuit

38

Experimental

Calculation

Duty Cycle, D

Output Voltage, Vo (V)

Output Voltage, Vo (V)

0.0986

1.34

0.49

0.203

1.80

1.15

0.508

1.96

4.65

0.607

1.96

6.95

0.714

1.80

11.23

0.768

1.88

14.89

0.801

1.80

18.11

Table 4.1

Comparison Between Experimental and Calculation

Experimental
Duty cycle, D

Output Voltage, Vo (V)

Simulation
Output Voltage, Vo (V)

0.0986

1.34

0.78

0.203

1.80

1.36

0.508

1.96

4.4

0.607

1.96

6.34

0.714

1.80

10.98

0.768

1.88

13.45

0.801

1.80

17.02

Table 4.2

Comparison Between Experimental and Simulation

39

Figure 4.5

Vo Experimental versus Vo Calculation

Figure 4.6

Vo Experimental versus Vo Simulation

40

According to Figure 4.5, the experimental output voltage is differed compare

to the calculation output voltage. This situation happen due to the component that used.
From calculation, we assume that, all components such as switch (MOSFET), and
diode is ideal case component. But after we implemented into hardware, we use differ
component that not in ideal case component or non-ideal component. Due to the nonideal component, there are voltage drop occur through the circuit. As we know, voltage
drop is the voltage loss at all the component in this circuit.

The component was used according to the datasheet that we get through
internet as references. Through datasheet, we can identify the voltage input that
suitable to supply from DC power supply to the circuit. Besides that, we also can
define the limited current that flow into the component, so from that, current flow to
the component can be adjusted. Other than that, the reason due to the result is
designing the isolated component. The size core of winding play the main role in order
to get the desired result for converter. If we choose the less dimension of winding, the
current that flow to the circuit will not supported by the component.

The Pulse Width Modulation (PWM) need to be consider, because the gains
need to insufficient to adjust the circuit and get the minimum power losses in switching
part [8]. The secondary winding of transformer give leakage to the primary winding
of the circuit according to the coupling between primary and secondary winding. So
leakage that happen at secondary winding effected to the primary winding also.

The switching losses occur in the switch mode power supply such as Flyback,
Forward and etc. According to the arrangement of transformer series with the load,
and from that, overlapping of the falling current and rising voltage across the power
load during the switch is OFF.

CHAPTER 5

CONCLUSION AND RECOMMENDATION

5.1

Conclusion

As stated in the objective, the project will assumed as fruitful if the output
voltage for the Flyback Converter achieve same value and same waveform based on
theoretical by calculation. But finished this project, the output voltage was differ from
the calculation, this condition happen due to the isolated transformer that have its own
detail specification and leakage flux and flux saturation also can happens if the number
of winding that we need not same with the design. If the flux saturation ensue happen
according to the high voltage and low frequency in the circuit.

As mention before, this project have three stages, PWM controller, driver
circuit, and lastly switch mode power supply (SMPS) which is Flyback converter.
During we the duty cycle increased, make sure that we need to consider the input
voltage not increase. If the voltage is increase, the current will be over current
situation, and from that will give effect to the circuit. In this project, the most tickle
part is designing the transformer, there are many step to ensure that the isolated
transformer will drive according to the essential. To encircle the core of transformer
with winding, we need to find out the exact value of turn, for Flyback circuit, need to

42

know turn winding in primary and turn winding in secondary part. While, the Flyback
is differ to the Forward, which is for the Forward circuit, its need to find turns winding
for tertiary also.

After calculate the number of turns, need to recognize the magnetizing

inductance. For Flyback, there are inductance circuit that functioning as place to stored
energy when the switch is open. Addition from that, we also need to find the rms
winding currents in both windings [6]. Addition for that, design should be tested in
the bread board first, then after get the output according to actual, transfer it to the
printed circuit board (PCB) to be tested. During the experimental, we adjust the duty
cycle and take a look on the value of converter, whether it changed or remain in the
same value. As the conclusion, this project was achieved the objective but there are
little things to be precise to preferred value as high efficiency if Flyback converter.

5.2

Recommendation

Basically in the field of engineering or other, the excellent performance always

prerequisite. There are some recommendations for refining of the project in the
incoming future.

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5.2.1 Turn-Off Snubber Circuit

In the turn-off snubber circuits, it functioning to minimize the overlap losses

at turn-off. While for the turn-on, the switching losses is considered as lower with the
topology of transformer. Switching losses are consideration less with the MOSFET,
when MOSFET is applying into the turn-off circuit, the prime function to minimize
the overlap dissipation is already decrease.

5.2.2 Designing the Transformer

The hardest part in the Flyback converter is the transformer. This isolated
transformer main the bad functioning according to the leakage inductance, power
losses, and core losses. This situation can be prediction with the limiting the losses by
choose the accurate size core winding that suitable with the rms current and after
wrapping the core with the winding, use cellophane tape (yellow in colour) in order to
reduce to leakage inductance.

44

REFERENCES

[1] Daniel, W. Hart (2011). Power Electronics. McGraw. Hill International Edition.

[2] Abraham, I. Pressman (2001). Switching Power Supply Design. McGraw. Hill
International Edition. Electronic Series

[3] Erickson, Robert W. (Author). Fundamentals of Power Electronics. 2nd edition.

Secaucus, N. J., USA: Kluwer Academic Publishers. 2000.

[4] Ned Mohan. First Course on Power Electronics and Drives. 2003 Edition.
Minneapolis, M.N. USA. Mnpere.

[5] Clyde F. Coombs, Jr.: Printed Circuits Handbook, Sixth Edition LIST OF
CONTRIBUTORS. PREFACE, Chapter (McGraw-Hill Professional, 2008),
AccessEngineering

[6] Practical Power Application Issues for Switch-Mode Power Supplies, Fairchild
Power Seminar 2006,
Fairchild. Semiconductor.

[7] Nihal Kularatha, Power Electronics Design Handbook (Low Power Components
and Applications), Newnes.

[8] Narain G. Hingorani, Laszlo Gyugyi, Understanding FACTS, Wiley- Interscience,

IEEE Press.