DCM Flyback Converter Design

Po 35.55 W Dmin 0.13333333 OUTPUTS

Vdc_min 100 V Ip_rms 0.72566134 A
Vdc_max 375 V Ts 0.00001 s Output1 :-
Ef 0.8 I_Density 5 A/sqmm Vo_1
Fsw 100000 Hz Aw_pri 0.14513227 sqmm Io_1
Vor 100 V a_1
Dmax 0.5 Ns_1
Core Calculations Ls_1
Pin_max 44.4375 W Kp 0.35 tof_1
Ap_Calc 1658.65448 mm^4 Dof_1
Iavg_min 0.1185 A Ipk_sec_1
Iavg_max 0.444375 A Awin_Core 87 sqmm Irms_sec_1
Ipk_pri 1.7775 A Ap_Core 4524 mm^4 Ns_1_new
Aw_sec_1
L_pri 281.2939522 uH lg 0.34845289 mm Vo_1_new
Vripple_Per 5 %
Bmax 0.25 T P_loss 4.44375 W
Ae_Core 52 sqmm Vripple 5 V

Np 39 Turns
Al required 0.18494014 uH/sqTurCmin 1451.32267 uF Po_1
Bmax_new 0.246548323 T Po_1_new
 Output2 :- Output3 :- Output4 :-
15.5 V Vo_2 12.7 V Vo_3 7.5 V Vo_4
0.1 A Io_2 2A Io_3 1A Io_4
6.451612903 a_2 7.874015748 a_3 13.33333333 a_4
6.045 Turns Ns_2 4.953 Turns Ns_3 2.925 Turns Ns_4
6.657845022 uH Ls_2 4.623503488 uH Ls_3 1.664461256 uH Ls_4
9.268639E-07 s tof_2 0.000003816 s tof_3 2.10679E-06 s tof_4
0.092686395 Dof_2 0.381604713 Dof_3 0.210678982 Dof_4
2.157813998 A Ipk_sec_2 10.48205083 A Ipk_sec_3 9.493115927 A Ipk_sec_4
0.37928125 A Irms_sec_2 3.738457941 A Irms_sec_3 2.515699495 A Irms_sec_4
6 Turns Ns_2_new 5 Turns Ns_3_new 3 Turns Ns_4_new
0.07585625 sqmm Aw_sec_2 0.679719626 sqmm Aw_sec_3 0.503139899 sqmm Aw_sec_4
15.38461538 V Vo_2_new 12.82051282 V Vo_3_new 7.692307692 V Vo_4_new
Cout_2_min 1495.383176 uF Cout_3_min 1006.279798 uF Cout_4_min

1.55 W Po_2 25.4 W Po_3 7.5 W Po_4

1.538461538 Po_2_new 25.64102564 Po_3_new 7.692307692 Po_4_new
 5.5 V
0.2 A
18.18181818
2.145 Turns
0.739760558 uH
1.720187E-06 s
0.172018669
2.325329009 A
0.556815829 A
2 Turns
0.111363166 sqmm
5.128205128 V
222.7263318 uF

1.1 W
1.025641026
Current Controller Design

PSIM Reference PADS Reference Value

Ra R1 2160 Ω
Rt R2 15000 Ω
Ct C1 1.1466666667E-09 F
Rb R3 1100.625 Ω
Rf_2 R4 2500 Ω
Rf_1 R5 9500 Ω
Rcs
Transformer Design

Core Type :- E25/13/7

Core Material:- N87 (MnZn)

Wire Selection
Coils Area required Units A.W.G Area Units Diameter Units A.W.G Used
Primary 1 0.1451322673 sqmm #25 0.1624 sqmm 0.45 mm #25
Primary 2 (Aux) 0.07585625 sqmm #27 0.1 sqmm 0.32 mm #27
Secondary 1 (+12V) 0.6797196256 sqmm #20*2 0.82 sqmm 0.41 mm #20*2
Secondary 2 (+5V) 0.5031398991 sqmm #20 0.52 sqmm 0.41 mm #20
Secondary 3 (-5V) 0.1113631659 sqmm #27 0.1 sqmm 0.41 mm #27
#19 0.65 sqmm 0.91 mm
Winding #21 0.41 sqmm 0.72 mm
Coils No. of Turns Units
Primary 1 39 Turns
Primary 2 (Aux) 6 Turns
Secondary 1 (+12V) 5 Turns
Secondary 2 (+5V) 3 Turns
Secondary 3 (-5V) 2 Turns

Winding Width (Ww) 15.3 mm

Winding Height (Hw) 3.85 mm
 Core Loss
Current Density Units Conditions: 100kHz, 100C, 0.2T
4.4683579821 A/sqmm
3.7928124991 A/sqmm Core Loss/m^3 375 kW/m^3
3.6651548437 A/sqmm V_core 3020 mm^3
4.9327441086 A/sqmm Core Loss 1.1325 W
5.5681582939 A/sqmm
Bill Of Material for DCM Flyback

S.No. PSIM Reference PADS Reference Component

1 U1 U1 UC3845AN
2 U2 U2 PC817A
3 U3 U3 TL431
4 U4 U4 GBU4J-BP
5 MOS1 MOS1 SPP04N80C3
6 TR1 TR1 E25 Bobbin
7 Z1 Z1 1N4728A
8 Z2 Z2 1N4740A
9 Cin_f C12 Capacitor
10 Cin_bulk C2, C11 Capacitor
11 Rst R14, R15, R16, R17 Resistor
12 Rclamp R12, R13 Resistor
13 Cclamp C6 Capacitor
14 Dclamp D7 Diode
15 C1 C13 Capacitor
16 R1 R18 Resistor
17 C2 C14 Capacitor
18 Cvcc1 C7 Capacitor
19 Cvcc2 C4 Capacitor
20 Ra R1 Resistor
21 Rt R2 Resistor
22 Ct C1 Capacitor
23 Rcr R9 Resistor
24 Ccr C3 Capacitor
25 Rcs R7, R8 Resistor
26 Rb R3 Resistor
27 Ri R10 Resistor
28 Rf1 R5 Resistor
29 Rf2 R4 Resistor
30 Rz R11 Resistor
31 Cz C5 Capacitor
32 Cf5, Cf5n, Cf12 C8, C9, C10 Capacitor
33 Cb5 C20, C21, C22 Capacitor
34 Cb5n C23, C24 Capacitor
35 Cb12 C15, C16, C17, C18,C19 Capacitor
36 D1, D2, D3 D1, D2, D3 Diode
37 U5 U5 LM7805
38 D4, D5, D6 D4, D5, D6 Diode
39 Rg R6 Resistor
 Description / Value Package
Current-Mode PWM Controller TH
5kV Isolation Optocoupler TH
2.49V Voltage Reference TH
600V, 4A, 1-Phase Bridge Rectifier TH
800V, 4A, N-Channel MOSFET TH
E25 Transformer TH
3.3V Zener Diode TH
10V Zener Diode TH
1uF/630 Ceramic Capacitor TH
100uF/450vdc Electrolytic Capacitor/ 2 Parallel TH
27kΩ Resistor / 4 series 1206
100kΩ Resistor/ 3 parallel 2512
3.3nF/600v ceramic Capacitor 1206
1A/1200V SMD
22uF/25v TH
1KΩ 1206
22uF/25v TH
100uF/25v TH
1uF/50v 1206
2.2kΩ 1206
15kΩ 1206
1nF 805
1kΩ 1206
560pF 1206
1.2Ω/2 parallel/.75W 2010
1kΩ 1206
1kΩ 1206
9.6kΩ 1206
2.5kΩ 1206
100kΩ 1206
10pF 1206
0.1u 1206
470uF/16V / 2parallel slot 3 TH
220uF/16V only 1no slot 2 TH
470uF/25V / 4parallel slot 5 TH
M7 Diode (DO-214) SMD
5V Linear Voltage Regulator TH
80A, 3A SK38A Schottky Diode SMD
1Ω Gate Resistor 1206