TECHNOLOGICAL INSTITUTE OF THE PHILIPPINES

938 Aurora Boulevard, Cubao, Quezon City

DESIGN OF A 20W +19V FLYBACK CONVERTER POWER SUPPLY

Ib n partial fulfillment of the requirements for the course ECE Elective III (ECE 113)

Submitted by:
BINOS, Kristel Camille C.
DE PAZ, Mark Timothy O.
DELA CRUZ, Cedric G.
ORTILLA, Ray Louie M.
TABO, Jacob Jewel C.
EC51FC2
Submitted to:
ENGR. SAMUEL MABANTA
Instructor

October 12, 2016

ABSTRACT
Flyback converter topology is a common configuration of converters in low power switched mode
power supplies. In this project, the flyback converter is used in the design of a 12 V power supply with 5 W
output. The target specifications for the project are discussed in the first part together with the theory of the
operation and the schematic diagram of the circuit to be used. The values of the components that was used
and the transformer specifications was computed based on the process of designing a flyback converter.
The project was tested to see if the target specifications were met. Waveforms and thermal data was
also included in the paper. After testing and re-testing, the project achieved an efficiency of 74.9%

DESCRIPTION OF THE PROJECT

The project is a design of a dual polarity power supply with a flyback converter configuration. The
output of the design is +19 V with 75% efficiency. It is operational at input voltages from 110 V to 240 V AC,
and is short circuit protected at the positive output. The heart of the circuit is the transformer, made up with
an EE 22 core. The design of the project utilizes the IC UC3842 as the PWM controller of the device.
The following table summarizes the specifications of the project.
Input Voltage

110 240 V AC

Output Voltage

+19 V 5%

Ripple Voltage

190 mV

Output Power

20 W

Efficiency

75 %

THEORY OF OPERATION
The flyback converter configuration that was used in this project is an example of a DC to DC
converter. It is similar to the buck boost converter with the inductor replaced by a transformer, hence its
operating principles are related to each other.

The flyback converter has three modes of operation. In the first mode of operation, the primary
winding of the transformer becomes connected to the input supply, with the dotted end connected to the
positive side. This happens when the switched is turn on. A voltage is induced in the secondary winding and
the diode in series with the secondary winding will be reverse biased. Thus, current is able to flow in the
primary winding but cannot flow in the secondary winding because the diode is reverse biased. In this mode
of operation, both the primary current and the input supply voltage across the primary winding inductance
rises linearly.
After conducting for some time, the switch gets turned off. This is the second mode of operation of
the flyback converter. In this mode of operation, the voltage polarities across the primary and the secondary
windings reverse. This correspondingly forward biases the diode in series with the secondary winding and

the current flows and also charges the output capacitor. During this time, the secondary winding is trasferring
energy from the magnetic field of the transformer to the output.
When the transfer of the energy is complete, the secondary voltage and current becomes zero and
the diode stops conducting. However, the output capacitor, being charged, continues to supply voltage to
the load. This is the third mode of operation.
When the switch is turned on once again, the third mode ends and the first mode begins again and
the sequence repeats.

DESIGN COMPUTATIONS FOR ALL COMPONENTS AND TRANSFORMER

=

=
= ()

=
=

=
= %
= %

20
=
= . ~

0.75
= (2.5 /)
= (27 )(2 )
=

= (2)( )2

(1 )
27(1 0.2)
= (2)(1102 )
(54 ) 60

= .
= 2402
= .

max

= 0.48

0.48
(132.41 )
=
1
1 0.48
= .

= + = 339.41 + 122.22
= .

ds

nom

=V

dc rating

dc rating

=V

nom

ds

* derating factor
/ derating factor
461.63

= 659V

dc rating

dc rating

0.7

K =1

RF

max

= 0.48

f = 67 KHz
S

( )2
( (132.41 )(0.48))2
=
= .
2
(2)(27 )(67 )(1)

27
=
=
= .

(132.41 )(0.48)

(
)()
(132.41 ) (0.48)
=
=
= .
(35.13 )(67 )

849.64
= +
= 424.81 + (
) = .
2
2

= 3 ()2 + (

2
849.63 2 0.48
2

) ](
) = [3(424.82 ) + (
) ](
) = 339.86
2
3
2
3
= + (0.12)
= 849.63 (1 + 0.12)
= .

106

1.12
951.66
=
106
(0.35) (41 2 )
= (EE 22)
=

122.22
=
=

+
19 + 0.7

= 6.20

74
=
6
=
+
16 + 1.3
=
=

( + ) (19 + 0.7)
=

= = 849.63 mA
= ()() = (6.20)(849.63 ) = .
=

12
() =
(5.26) = . ( 22)

11

1
( )
() =

() + ()
1 0.48 126.79
() = 351.77 (
)[
] = .
0.48
19 + 0.7

339.86
= =
= 0.067972 2
5
5/^2

=

74
= 339.86 ( ) = .

12

.
= =
= .
5
/^
() = () +

(. )

(. )

(339.41 )(19 + 0.7)

(() + () )
= 19 +
= .

126.79

1
( )
1 0.48 126.79
() =

= 351.77 (
)[
] = .

() + ()
0.48
19 + 0.7
> 1.3 ()
> .
> 1.5 ()
> .
() = () 2 () 2 = (2.356)2 (1.05)2 = 2.110
=

1
= 1.02
984.66

TRANSFORMER SPECIFICATIONS
Primary Winding Inductance
Secondary Winding Inductance
Auxililiary Winding Inductance
Leakage Inductance
Primary Winding Resistance
Secondary Winding Resistance
Auxiliary Winding Resistance
Primary Winding Number of Turns
Secondary Winding Number of Turns
Auxiliary Winding Number of Turns
Core

VOLTAGE AND CURRENT REGULATION AND RIPPLE DATA

Ripple Data
1. Low Line (100 V input)

Positive Output Ripple

2. High Line (240 V input)

1.13 mH
172. 0 uH
127.8 uH
124. 0 uH
4.78
0.64
0.66
74 turns
12 turns
11 turns
EE 30

WAVEFORM REFERENCES
High Line

Vds

Rectifier Diode

Auxiliary

Snubber Circuit

Secondary

Low Line

Secondary

Auxiliary

Snubber Circuit

Rectifier Diode

THERMAL PROFILE
Table Thermal Data
Critical Components
Bridge Rectifier Diodes
D1
D2
D3
D4
DC link Capacitor
Series Inductor
Transformer
PWM
Rsense
MOSFET
Snubber Capacitor
Snubber Diode
Snubber Resistor
Optocoupler
Output Diode
C12
C15
C11
C5
C8
C9
C10
R1
C14
C13
R5
R6
R12
R13
C2
C7
C4
R10
R18
R8

Value
1N4007
1N4007
1N4007
1N4007
68 uF 400V

Temperature at
low line (oC)

32.8
32.9
33
33.4
33.8
31.6
33.6
UC3842
37.9
1 Ohms
30.1
2N90
38
100uF
42.9
HER208
41.3
75kohm
39.8
Optocoupler
48.5
MRF10100
36.3
Miscellaneous Components
0.01uF
35.2
0.01uF
34.5
0.1nF
35.1
0.1uF
33.3
0.1uF
32.7
0.1uF
33.1
0.1uF
33.4
0.1uF KX2
34.2
1000uF
42.8
1000uF
37.2
100k
43.8
100k
42.7
100
38
10k
35.8
10pF
36.1
10pF
37.1
10pF
36.5
10
35.3
10
38.3
15
36.4

Temperature at
high line (oC)
34.3
35.9
36
36.7
34.6
31.5
35.9
39.4
29.9
38.3
45.2
41.5
42.4
40.5
30.3
33.5
32.5
34.1
33.3
32.4
31.6
32.7
34.1
39.7
37
41.8
42
46.5
33.4
37.5
37.2
37.4
35.4
42.1
37

R15
R16
R21
R22
R23
R24
VR1
C3
CY1
R11
R25
R19
C1
R14
R17
R20
R4
R7
R3
IC2
R9
ZD1
ZD2
CY4
D2
L2
TH1
Q2
Q3

1k
1k
1k
1k
1k
1k
1k
1nF
1nF
2k
330
390
47uF
5.1k
5.1k
5.1k
5.1k
5.6k
75k
817C
820
C18
C24
CD222M
FR107
Inductor
NTC 5D-11
TL431A
TL431A

34
33.6
35.4
33.8
33.9
34.7
36.5
36.6
36.9
34.2
34.9
34.6
36.1
34.2
36.1
35.4
34.8
34.7
35.5
38.3
35.5
30.7
31.1
37.6
40.3
37.7
32.1
35
30.9

34.6
32.7
35.5
33.2
34.1
34
34.8
34.4
34.7
34.8
37.7
34.1
34.3
34.2
33.7
33.8
33.4
33.5
35.1
37
38
38.6
38.6
37.7
40.7
40
31.5
34.5
31.5

DEVIATION FROM ORIGINAL POWER SUPPLY SPECIFICATIONS

New Specifications

Original Specifications

Rating

20 W

36 W

MOSFET
Rsense
R2
DC Link Capacitor

2N90 (2A, 900V)

1 Ohm
1.5 kOhm
68 uF 650V

5N60 (5A, 600V)

0.56 Ohm
2 kOhm
47uF 400V

ACTION TO COMPLY TO POWER SUPPLY SPECIFICATIONS

To arrive at the required power rating, the proponents assured that the transformer yields the
required specifications since the output power depends on this component. In order to come up with the
desired transformer output, the first thing to do is to follow the design computations. Another thing is to utilize
the wire gauge which could support the current rating of the design.
For the charging current, we set the output power to the required specification which is 10% more
than the rated current. We do this by varying the current sense resistor used on UC3842.
The ripple voltage depends on the output capacitor. With that, we assure that the output capacitor
used is capable of limiting the ripple voltage up to the desired specification.
After encountering some problems with the circuit, we decided to do the following:

Replace the start-up resistor because our prototype didnt power up with our first start-up resistor.

Replace the current sense resistor because it didnt allow our prototype to operate at full load.

Replace the current limit resistor so as to achieve the required specification which is 10% above the
rated current.

Replace the RC (resistor-capacitor) to increase the duty cycle

DESIGN NOTES
In designing the project, we took note of the following:

It is imperative for us to follow the computations because the components and its values that we
used were based on the computations.

It is important to know the specifications of the IC that we used because the start-up current will
depend on that. Not all IC will result to the same start-up current, and so the IC that we chose has
a start-up current that is relative to our design.

We set the duty cycle of the PWM controller slightly above the computed value to ensure its
functionality in the circuit.

The transformers winding must be neat and fine because if the winding is otherwise, it will have an
effect to its output.

Another thing about the transformer is the core. It has to be aligned when glued together. The
impedance of the windings of the transformer will be affected if it is not aligned when glued.

In powering up the project, it is advisable to start it in low line (110 V) and gradually increase the
voltage until it reaches high line (240 V).

The equipment that we used in testing the prototype are the electronic load, variac and oscilloscope.
The oscilloscope must be floating because if it is grounded, there will be no isolation between the
primary and secondary windings of the transformer.

FINAL DEBUGGING RESULTS AND SOLUTIONS

ISSUES ENCOUNTERED
Transformer is not rated at 20W
Current sense is inaccurate to desired
specifications
Output voltage at no load test was about
12V which is out of specifications of the
project
MOSFET rating is high for 20W and can be
replaced with a lower rating for decreased
economic value yet still within specifications
Power dissipating resistors at primary side
(100k and 100 ohm resistors) heat up as
observed in thermal profile
Power supply output changes from 19 V to
17 V in high line
The current that the transformer is supplying
in the controller is insufficient
The fuse exploded

SOLUTIONS
Wounded new transformer using EE22 core
based on design computations
Replace current sense resistor to 1.5
Change output voltage divider network
replacing one resistor with 1.5k based on
computations
Replace MOSFET from 5N60C to 2N90
Replace 47uF dc link capacitor to 68uF
400V for longer discharge time to avoid
stressing power dissipating resistors
Replace transformer from EE22 core to
EE30 core
Wounded another transformer
Replace fuse, check critical components

LESSONS LEARNED
After doing the project, we learned the following:

Making a transformer is not an easy task. Since the output specifications of the circuit depend on the
transformer, it is very important that it possesses the desired specifications needed in order to come
up with the required output. We can arrive at a good transformer through computations. First, the
size of the wire gauge to be used depends on the computed value. Also, this should be wind properly
so as to improve the efficiency of the design.

In testing the circuit, it is necessary that the oscilloscope is not grounded in order to isolate the
primary from secondary.

Always observe safety precautions since we are dealing with high voltage.

RECOMMENDATION TO FUTURE POWER ELECTRONICS STUDENTS

For the future students of Power Electronics III who are to make the same project, the proponents
recommend the following:
Make sure to complete all the computations first to arrive at the desired specifications.
Start making your project as early as possible to finish the whole prototype on time.
Be careful in testing the prototype because it deals with a high amount of voltage.
Since the target efficiency of the project was not met, it is recommended to increase the duty
cycle of the PWM controller to increase the efficiency






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MBR20100CTP
SWITCHMODE
Power Rectifier
. . . using the Schottky Barrier principle with a platinum barrier
metal. These stateoftheart devices have the following features:

20 Amps Total (10 Amps per Diode Leg)

Guardring for Stress Protection
Low Forward Voltage
150C Operating Junction Temperature
Epoxy Meets UL94, VO at 1/8
Low Power Loss/High Efficiency
High Surge Capacity
Low Stored Charge Majority Carrier Conduction

http://onsemi.com

SCHOTTKY BARRIER
RECTIFIER
20 AMPERES
100 VOLTS
1

Mechanical Characteristics:

2, 4

Case: Epoxy, Molded

Weight: 1.9 grams (approximately)
Finish: All External Surfaces Corrosion Resistant and Terminal

3
4

Leads are Readily Solderable

Lead Temperature for Soldering Purposes:
260C Max. for 10 Seconds
Shipped 50 units per plastic tube
Marking: B20100P

MAXIMUM RATINGS (Per Diode Leg)

1
Symbol

Value

Unit

Peak Repetitive Reverse Voltage

Working Peak Reverse Voltage
DC Blocking Voltage

VRRM
VRWM
VR

100

Average Rectified Forward Current

(Rated VR, TC = 133C)

IF(AV)

10

Peak Repetitive Forward Current

(Rated VR, Square Wave, 20 kHz,
TC = 133C)

IFRM

20

NonRepetitive Peak Surge Current

(Surge Applied at Rated Load
Conditions Halfwave, Single
Phase, 60 Hz)

IFSM

150

Peak Repetitive Reverse Surge

Current (2.0
s, 1.0 kHz)

IRRM

0.5

Storage Temperature Range

Tstg

65 to +175

Operating Junction Temperature

TJ

65 to +150

dv/dt

10,000

V/
s

Rating

Voltage Rate of Change (Rated VR)

CASE 221A
TO220AB
PLASTIC

MARKING DIAGRAM

YY WW
B20100P
AKA

YY
= Year
WW
= Work Week
B20100P= Device Code
AKA
= Diode Polarity

ORDERING INFORMATION

Semiconductor Components Industries, LLC, 2001

May, 2001 Rev. 1

Device

Package

Shipping

MBR20100CTP

TO220

50 Units/Rail

Publication Order Number:

MBR20100CTP/D

MBR20100CTP
THERMAL CHARACTERISTICS
Characteristic

Symbol

Value

Unit

Maximum Thermal Resistance, Junction to Case

RJC

2.0

C/W

Maximum Thermal Resistance, Junction to Ambient

RJA

60

C/W

ELECTRICAL CHARACTERISTICS (Per Diode Leg)

Maximum Instantaneous Forward Voltage (Note 1.)
(iF = 10 Amps, TC = 125C)
(iF = 10 Amps, TC = 25C)
(iF = 20 Amps, TC = 125C)
(iF = 20 Amps, TC = 25C)

vF

Maximum Instantaneous Reverse Current (Note 1.)

(Rated dc Voltage, TC = 125C)
(Rated dc Voltage, TC = 25C)

iR

Volts
0.75
0.85
0.85
0.95
mA
6.0
0.1

iF, INSTANTANEOUS FORWARD CURRENT (A)

iF, INSTANTANEOUS FORWARD CURRENT (A)

1. Pulse Test: Pulse Width = 300 s, Duty Cycle 2.0%

100
75C
125C

25C

10

0.1

1
1.1 1.2
0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
VF, INSTANTANEOUS FORWARD VOLTAGE (VOLTS)

100
75C
125C
25C
10

0.1

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

1 1.1 1.2
VF, INSTANTANEOUS FORWARD VOLTAGE (VOLTS)

Figure 1. Maximum Forward Voltage

Figure 2. Typical Forward Voltage

700
125C
600

0.0001

C, CAPACITANCE (pF)

IR, REVERSE CURRENT (A)

0.001

75C

0.00001

0.000001

0.0000001
0.00000001

25C

10

500
400
300
200
100

40 50 60 70 80
20 30
VR, REVERSE VOLTAGE (VOLTS)

90 100

Figure 3. Typical Reverse Current

20

40
60
80
100
VR, REVERSE VOLTAGE (VOLTS)

Figure 4. Typical Capacitance

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2

120

14

18
16

dc

RATED
VOLTAGE
APPLIED

14
12

PF(AV), AVERAGE FORWARD

POWER DISSIPATION (W)

IF(AV), AVERAGE FORWARD CURRENT (A)

MBR20100CTP

SQUARE WAVE

10
8
6
4
2
0

115

120

125
130
140 145
135
TC, CASE TEMPERATURE (C)

150

10
SQUARE WAVE
8
6
4
2
0

155

Figure 5. Current Derating, Case, Per Diode

dc

12

14
16
12
2
4
6
8
10
IF(AV), AVERAGE FORWARD CURRENT (AMPS)

18

Figure 6. Forward Power Dissipation, Per Diode

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MBR20100CTP
PACKAGE DIMENSIONS
TO220 THREELEAD
TO220AB
CASE 221A09
ISSUE AA

T
B

SEATING
PLANE

F
T

DIM
A
B
C
D
F
G
H
J
K
L
N
Q
R
S
T
U
V
Z

Q
1 2 3

H
K
Z
L

NOTES:
1. DIMENSIONING AND TOLERANCING PER ANSI
Y14.5M, 1982.
2. CONTROLLING DIMENSION: INCH.
3. DIMENSION Z DEFINES A ZONE WHERE ALL
BODY AND LEAD IRREGULARITIES ARE
ALLOWED.

G
D
N

INCHES
MIN
MAX
0.570
0.620
0.380
0.405
0.160
0.190
0.025
0.035
0.142
0.147
0.095
0.105
0.110
0.155
0.018
0.025
0.500
0.562
0.045
0.060
0.190
0.210
0.100
0.120
0.080
0.110
0.045
0.055
0.235
0.255
0.000
0.050
0.045
----0.080

MILLIMETERS
MIN
MAX
14.48
15.75
9.66
10.28
4.07
4.82
0.64
0.88
3.61
3.73
2.42
2.66
2.80
3.93
0.46
0.64
12.70
14.27
1.15
1.52
4.83
5.33
2.54
3.04
2.04
2.79
1.15
1.39
5.97
6.47
0.00
1.27
1.15
----2.04

SWITCHMODE is a trademark of Semiconductor Components Industries, LLC.

ON Semiconductor and
are trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC reserves the right to make changes
without further notice to any products herein. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any particular
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including without limitation special, consequential or incidental damages. Typical parameters which may be provided in SCILLC data sheets and/or
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MBR20100CTP/D