Designing a 100kHz 32 watt Push-Pull Converter

Colonel Wm. T. McLyman

The push-pull converter, shown in Figure 1, is one of the oldest topologies. This topology is widely used and probably the best understood. The push-pull approach provides regulation dc isolation and conversion in one step. The push-pull converter transformer, size wise, is one of the most efficient per unit volume.

There are a multitude of converter topologies for the engineer to access and to make trade-offs on. No one converter circuit has it all. There are two outstanding drawbacks to the push-pull, center tapped converter. The action of the center tap transformer is such that each power MOSFET will see a voltage equal to twice the input voltage, plus the leakage inductance spikes. The other is flux imbalance in the power transformer. With careful design, the flux imbalance can be minimized. The push-pull transformer should not be designed with a magnetic material with a square loop, as shown in Figure 2. The normal resting point of the square loop material is at one end or the other, not in the center, also shown in Figure 2.

+ C1 V in Q1 PWM Q2 N1

T1 N2

CR1

L1 C2

5V@4A

CR2 CR3-6 + C3

L2

12V@1A

Figure 1. Push - Pull Center Tapped Converter. The shaded area of the hysteresis is the B. The operating flux density is B/2. Ferrite material has a much

more rounded hysteresis loop, as shown in Figure 3. The material shown here is Magnetics, P and R 1

material. The lower remanence, Br, gives a much more rounded hysteresis loop, as shown in Figure 3, and is more forgiving when there is a flux imbalance. This lower remanence, Br, requires more driving force (H) to reach saturation. B (tesla)

H (oersted)

Figure 2. Typical Square Loop Magnetic Material Operating Characteristic.

Bm, Tesla 0.45 0.4 25 C 100 C

P & R M aterial

0.3 0.2 0.1 H, oersted

2.5

2.0

1.5

1.0

0.5

0.5 0.1

1.0

1.5

2.0

2.5

25 C Bm = 0.500T @ 15 oersted 0.2 100 C Bm = 0.375T @ 15 oersted 0.3 0.4 0.45

Figure 3 Typical ferrite hysteresis loop operating at 25 and 100 degrees C. The following information is the design specification for a 38 watt push-pull transformer, operating at 100kHz, using the, Kg core geometry approach. Please refer to Wound Magnetics Journal , April -June 1998.

For this article, the magnetic core and wire data have been taken from the author's book, Magnetic Core Selection for Transformers and Inductors, Second Edition. The author will refer to chapters and page numbers in the book for a quick reference. Some of the design information has been described in past articles in the Wound Magnetics Journal .

For a typical design example, assume a push-pull, full wave, center tapped circuit, as shown in Figure 1, with the following specification: 1. 2. 3. 4. 5. 6. 7. 8. 9. Input voltage, Vin(min) = 24 volts Output voltage, Vo = 5 volts @ Io = 4 amps Output voltage, Vo = 12 volts @ Io = 1.0 amps Frequency, f = 100,000 hertz Temperature rise, 30 degrees C Efficiency, = 98 % Regulation, = 0.5 % Diode voltage drop, Vd = 1.0 volts Design operating flux density, Bac = 0.05 tesla

10. Notes: Using a center tapped winding, Pa = 1.41 Using a single winding, Pa = 1.0 At this point, select a wire so that the relationship between the ac resistance and the dc resistance is 1: Rac =1 Rdc The skin depth in centimeters is: = = 6.62 f 6.62 100,000 , [cm] , [cm]

= 0.0209, [cm] Then, the wire diameter is: Wire Diameter = 2 ( ) , [cm]

Wire Diameter = 2 ( 0.0209 ) , [cm] Wire Diameter = 0.0418, [cm] Then, the bare wire area A w is: Aw = Aw = D2 , [cm 2 ] 4

(3.1416 )(0.0418 )

4 Aw = 0.00137, [cm 2 ]

, [cm 2 ]

From the Wire Table, in Chapter 5 on Page 187, number 27 has a bare wire area of 0.001021 centimeters. This will be the minimum wire size used in this design. If the design requires more wire area to meet the specification, then, the design will use a multifilar of #26. Listed Below are #27 and #28, just in case #26 requires too much rounding off.

Wire AWG #26 #27 #28 Step No. 1.

Bare Area 0.001280 0.001021 0.0008046

Area Ins. 0.001603 0.001313 0.0010515

Bare/Ins. 0.798 0.778 0.765

/cm 1345 1687 2142

Calculate the transformer output power, Po. Po = Po1 + Po2 , [watts] Po1 = I o1 (Vo1 + Vd ) , [watts] Po1 = 4 ( 5 +1 ) , [watts] Po1 = 24, [watts] Po2 = I o2 ( V o 2 + V d ) , [watts] Po2 = 1 (1 2 + 2 ) , [watts] Po2 = 14, [watts] Po = ( 24 + 14 ), Po = 38, [watts] [watts]

Step No. 2.

Calculate the secondary apparent power, Pts. Pts = Ptso1 + Ptso2 , [watts] Ptso1 = Po1 ( Pa ) , [watts] Ptso1 = 24 (1.41 ), [watts] Ptso1 = 33.8, [watts] Ptso2 = Ptso2 ( Pa ) , [watts] Ptso2 = 14 (1 ), [watts] [watts] Ptso2 = 14, [watts] Pts = ( 33.8 + 14 ), Pts = 47.8, [watts]

Step No. 3.

Calculate the total apparent power, Pt. P Pin = o , [watts] Ptp = Pin Pa , [watts] Pt = P tp + P ts , [watts] 38 Pt = (1.41) + 47.8, [watts] 0.98 Pt = 1025, [watts]

Step No. 4.

Calculate the electrical conditions, Ke . Ke = 0.145 K f

( ) ( f ) ( B ) (10 )
2 2 2 4 m 2 2 2

K f = 4.0, [square wave] Ke = 0.145 ( 4.0 ) (100,000 ) ( 0.05 ) 10 4 Ke = 5800 Step No. 5. Calculate the core geometry, Kg. Kg = Kg = Pt , [cm 5 ] 2K e

(102.5 ) , 2 ( 5800 )( 0.5 )

[cm 5 ]

K g = 0.0177, [cm5 ]

When operating at high frequencies, the engineer has to review the window utilization factor, Ku. Please refer to the Wound Magnetics Journal , July - September 1998. When using a small bobbin, ferrites use the ratio of the bobbin winding area to the core window area. The area is only about 0.6. Operating at 100kHz and having to use a #26 wire, because of the skin effect, the ratio of the bare copper area to the total area is 0.78. Therefore, the overall window utilization Ku is reduced. To return the design back to the norm, the core geometry Kg is to be multiplied by 1.35, and then, the current density J is calculated, using a window utilization factor of 0.29. K g = 0.0177 (1.35 ) , [cm5 ] K g = 0.0239, [cm5 ]

Step No. 6.

Select from TDK Corp., page 354, a PQ core comparable in core geometry Kg.

Core number ................................................................................................................PQ-2020 Manufacturer ..............................................................................................................TDK Magnetic material ......................................................................................................PC44 Magnetic path length , MPL......................................................................................4.5 cm Window height ...........................................................................................................1.43 cm Core weight, W tfe ........................................................................................................15 grams Copper weight, W tcu ...................................................................................................10.2 grams Mean length turn, MLT .............................................................................................4.4 cm Iron area, A c ................................................................................................................0.62 cm2 Window area, W a .......................................................................................................0.658 cm2 Area product, A p ........................................................................................................0.408 cm4 Core geometry, Kg .......................................................................................................0.0232 cm5 Surface area, A t ...........................................................................................................19.7 cm2 Millihenrys per 1000 turns, AL .................................................................................3150

Step No. 7.

Calculate the number of primary turns, Np, using Faradays Law. Np = Vp 104

( )

K f Bac f Ac

, [turns]

( 24) (10 4 ) Np = , ( 4.0 )( 0.05 )(100000 )( 0.62 )

N p = 19, [turns]

[turns]

Step No. 8.

Calculate the current density J using a window utilization, Ku = 0.29. Pt 10 4

J = J =

( )

K f Ku Bac f Ap

, [amps/cm 2 ]

(102.5 ) (104 ) , ( 4.0)( 0.29)( 0.05)( 100000)( 0.408 )

2

[amps/cm 2 ]

J = 433, [amps/cm ]

Step No. 9.

Calculate the input current, Iin. I in = I in = Po Vin , [amps]

38 , [amps] ( 24)( 0.98)

I in = 1.61, [amps] Step No. 10. Calculate the primary bare wire area, A wp(B) . Awp( B) = Awp( B) = I in D max J , [cm 2 ] , [cm 2 ]

(1.61)

0.5

433 Awp( B) = 0.00263, [cm 2 ] Step No. 11.

Calculate the required number of primary strands, Snp. S np = S np S np Awp( B)

#26 0.00263 = 0.00128 = 2.05, [use 2] per centimeter.

Step No. 12.

Calculate the primary new

cm ( new) = cm S np 1345 = cm 2 ( new ) = 673 cm

( new)

Step No. 13.

Calculate the primary resistance, Rp. 6 R p = MLT N p 10 , [ohms] cm

( )

R p = ( 4.4 )(19 )( 673 ) 10 6 , [ohms] R p = 0.0563, [ohms]

Step No. 14.

Calculate the primary copper loss, Pp. Pp = I 2 p R p , [watts] Pp = (1.61) ( 0.0563, ) [watts]
2

Pp = 0.146, [watts] Step No. 15. Calculate the secondary turns, Ns1. N pV s1 1 + , [turns] Vin 100 Vs1 =Vo + Vd , [volts] N s1 = Vs1 = 5 + 1, [volts] Vs1 = 6, [volts] N s1 =

(19)(6 ) 0.5 1+ , (24) 100

[turns]

N s1 = 4.77 use 5, [turns] Step No. 16. Calculate the secondary turns, Ns2. N s2 = Vs 2 N pVs 2 1+ , [turns] Vin 100 = Vo + 2Vd , [volts]

Vs 2 = 12 + 2, [volts] Vs 2 = 14, [volts] N s2 =

(19)(14) 0.5 1+ , (24) 100

[turns]

N s 2 = 11.1 use 11, [turns] Step No. 17. Calculate the secondary bare wire area, A ws1. Aws1( B) = Aws1( B) = Aws1( B) Step No. 18. I o1 Dmax J , [cm 2 ]

, [cm 2 ] 433 = 0.00653, [cm 2 ]

(4 )

0.5

Calculate the required number of secondary strands, Sns1. S ns1 = S ns1 S ns1 Aws1( B)

#26 0.00653 = 0.00128 = 5.1, [use 5]

Step No. 19.

Calculate the secondary, S1 new

per centimeter.

cm ( new) = cm S ns1 1345 = cm 5 ( new ) = 269 cm

( new)

Step No. 20.

Calculate the secondary S1 resistance, Rs1. 6 Rs1 = MLT ( N s1 ) 10 , [ohms] cm

Rs1 = ( 4.4 )( 5 )( 369 ) 10 6 , [ohms] Rs1 = 0.0059, [ohms]

Step No. 21.

Calculate the secondary copper loss, Ps1. Ps1 = I s21 Rs1 , [watts] Ps1 = ( 4.0 ) ( 0.0059 ) , [watts]
2

Ps1 = 0.0944, [watts]

Step No. 22.

Calculate the secondary bare wire area, A ws1(B) . Aws 2(B) = Aws 2(B) Aws 2(B) Io 2 , [cm 2 ] J (1) = , [cm 2 ] 433 = 0.00231, [cm 2 ]

Step No. 23.

Calculate the required number of secondary strands, Sns2. S ns2 = S ns2 S ns2 Aws 2(B )

#26 0.00231 = 0.00128 = 1.8, [use 2]

Step No. 24.

Calculate the secondary, S2 new

per centimeter.

cm ( new) = cm S ns1 1345 = cm 2 ( new ) = 673 cm

( new)

Step No. 25.

Calculate the secondary, S2 resistance, Rs2. 6 Rs 2 = MLT ( N s 2 ) 10 , [ohms] cm

Rs 2 = ( 4.4 )(11)( 673 ) 10 6 , [ohms] Rs 2 = 0.0326, [ohms] Step No. 26. Calculate the secondary, S2 copper loss, Ps2. Ps 2 = I s22 Rs 2 , [watts] Ps 2 = (1.0 ) ( 0.0326 ) , [watts]
2

Ps 2 = 0.0326, [watts] Step No. 27. Calculate the total secondary copper loss, Ps. Ps = Ps1 + Ps2 , [watts] Ps = 0.0944 + 0.0326, [watts] Ps = 0.127, [watts] Step No. 28. Calculate the total primary and secondary copper loss, Pcu. Pcu = Pp + Ps , [watts] Pcu = 0.146 + 0.127, [watts] Step No. 29. Pcu = 0.273, [watts] Calculate the transformer regulation, . = = Pcu (100 ), Po [%] [%]

( 0.273 ) (100), (38)

= 0.718, [%]

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Step No. 30.

Calculate the milliwatts per gram, mW/g. mW = 0.000318 ( f gram

)(1.51) ( Bac )(2.747 )

mW 2.747 (1.51) = 0.000318 (100000 ) (0.05)( ) gram mW = 3.01 gram

Step No. 31.

Calculate the core loss, Pfe . mW 3 Pfe = Wtfe 10 , [watts] gram

( )( (

Pfe = ( 3.01)(15 ) 10 3 , [watts] Pfe = 0.045, [watts]

Step No. 32.

Calculate the total loss, P. P = Pcu + Pfe , [watts] P = ( 0.273 ) + ( 0.045 ) , [watts] P = 0.318, [watts] Calculate the watts per unit area, . = = P , [watts per cm 2 ] At

Step No. 33.

( 0.318 ) , (19.7)

[watts per cm2 ]

= 0.0161, [watts per cm 2 ]

Step No. 34.

Calculate the temperature rise, Tr. Tr = 450 ( )

(0.826 )

, [ o C]
(0.826 )

Tr = 450 (0.0161 ) Tr = 14.9, [ o C ]

, [ o C]

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Step No. 35.

Calculate the total window utilization, Ku. Ku = Kup + Kus Kus = Kus 1 + Kus 2 Kus1 = Kus1 = Ns1 Sn1 Aws1 Wa

(10)( 5.0)( 0.001603 ) = 0.122 ( 0.658 ) (11)(2.0)(0.001603) = 0.0536 Kus 2 = ( 0.658 )

Kup = Kup = N p Snp Awp Wa

( 38)( 2.0)( 0.001603 ) = 0.184 (0.658 ) Ku = ( 0.185 ) + ( 0.122 + 0.0536)

Ku = 0.361

Summary:

The above transformer was built, and tested. It meets the intent of the specification. The copper and core loss could be brought more in line (could be equal) by increasing the flux density. This increase would have made a more efficient transformer, but would have an impact on the volts per turn, which is, again, another tradeoff. The author hopes that this article with its step by step approach helps the readers understand the design of a push-pull converter transformer. The Author would like to thank Sherwood Associates for providing the TDK core, and Shafer Magnetic Components for building the transformer to prove form, fit and function. I would like to thank Bob Yahiro who has been reviewing the math in all of my articles. Shafer Magnetic Components 4773-H Brooks Street Montclair, Ca. 91763 Ph (909) 626 2722 The information in the book, Magnetic Core Selection for Transformers and Inductors ,.Second Edition , is an invaluable reference enabling engineers to quickly compare components and select the one best-suited to their needs in a minimum amount of time.

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The author is now serving as a consultant for the Reliability Engineering Office at the Jet Propulsion Laboratory, in Pasadena, California. He is working on reliability and robust issues for Wound Magnetics design.

BIBLIOGRAPHY Colonel William T. McLyman, Transformer and Inductor Design Handbook, Second Edition, Marcel Dekker Inc., New York, 1988. Colonel William T. McLyman, Magnetic Core Selection for Transformers and Inductors, Second Edition, Marcel Dekker Inc., 1997. Colonel William T. McLyman, Designing Magnetic Components for High Frequency, dc-dc Converters, Kg Magnetics, Inc., 1993. Software For information regarding the above Books and Companion Software in Windows 95', 98', NT, or to order the books and software, contact: Kg Magnetics, Inc. 38 West Sierra Madre Blvd. Suite J Sierra Madre, Ca. 91024 Phone (626) 836-7233 or Fax (626) 836-7263 See the Web Page for a pictorial software demonstration. Web Page: www.kgmagnetics.com Email:sheassoc@pacbel.net

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