A Guide to Flyback Transformers
What are Flyback Transformers? Educational
A flyback transformer is a coupled inductor with a gapped core. During Courses
each cycle, when the input voltage is applied to the primary winding,
A Guide to AEC-Q200
energy is stored in the gap of the core. It is then transferred to the Qualified Components
secondary winding to provide energy to the load. Flyback transformers
A Guide to Coupled
are used to provide voltage transformation and circuit isolation in flyback
Inductors
converters.
A Guide to Flyback
Flyback transformers are the most popular choice for cost-effective, Transformers
high-efficiency isolated power supply designs up to approximately A Guide to Forward-mode
120 Watts. They provide circuit isolation, the potential for multiple Transformers
outputs and the possibility of positive or negative output voltages. They A Guide to Gate Drive
can also be regulated over a wide range of input voltage and load Transformers
conditions. Because energy is stored in the transformer, the flyback A Guide to Understanding
topology does not require a separate output filter inductor like the other Common Mode Chokes
isolated topologies. This reduces the component count and simplifies the Magnetics for Power over
circuit requirements. This article discusses flyback transformers and Ethernet (PoE)
applications for which they are best suited.
Understanding and
Selecting Isolation
What is a flyback? Transformers
What is a Conical Inductor?
In the flyback topology, energy is stored in the magnetic field of the
transformer during the first half of the switching cycle and then released What is an Inductor?
to the secondary winding(s) connected to the load in the second half of What is an LC Filter?
the cycle. Flyback transformers feature a gapped-core construction, Wirewound Ferrite Beads:
which allows high energy storage without saturating the core. This energy Outperforming Traditional
storage aspect distinguishes flybacks from other topologies such as Chip Ferrite Beads
forward-mode where energy transfers immediately from primary to
secondary. Flyback transformers are also known as coupled inductors,
because they have a gapped core construction and store energy in the
core.
How does a flyback controller
work?
Figure 1
The flyback topology is based on a buck-boost topology, with the
transformer providing isolation and, if needed, voltage transformation by
turns ratio. The schematic shown in Figure 1 represents a typical flyback
circuit.
The most commonly used switch (SW) in a flyback converter is a MOSFET
(Metal Oxide Semiconductor Field Effect Transistor), but occasionally a
bipolar transistor and sometimes GaN (gallium nitride) or SiC (silicon
carbide) are used. The flyback controller opens and closes the switch with
the appropriate duty cycle to achieve the required output voltage. The
duty cycle of flyback transformers typically does not exceed 0.5. Various
combinations of turns ratios and duty cycles can be used to achieve the
required output voltage according to this equation:
Vout = Vin*(Ns/Np)*(D/(1-D)) where:
Vout is the output voltage
Vin is the input voltage
Ns = secondary turns
Np = primary turns
D = duty cycle = ton/(ton + toff)
The basic flyback cycle includes the following portions:
1. When the FET (Field Effect Transistor) SW is closed (ON), current is
conducted through the transformer primary. This sets up a magnetic
field in which energy is stored in the core. The combination of winding
polarity (identified by the polarity dots) reverse biases the output
diode to ensure that no energy is transferred to the secondary (load)
when the switch is closed. During this portion of the cycle, current in
the primary is ramping up over time to store energy (= ½LI2).
2. When the FET is opened (OFF) the magnetic field collapses,
transferring the stored energy to the secondary winding and,
ultimately the load. At the close of the switch, current in the
secondary is at its peak and ramps downward as the stored energy is
transferred to the load.
Figure 2
Figure 3
If the FET is turned back on before all of the flyback energy is transferred
to the secondary, the secondary current never reaches zero. This is
referred to as continuous conduction mode (CCM). An example of a CCM
waveform is shown in the Figure 2. If the stored flyback energy is
completely emptied to the secondary before the FET is turned back on,
the secondary current reaches zero before the end of the period, creating
an "idle time" (tidle) during the cycle. This is called discontinuous
conduction mode (DCM). An example of a DCM waveform is shown in the
Figure 3. Transformers may be designed for CCM, DCM, or both. Flyback
transformers may operate in both CCM and DCM modes, depending on
the input voltage and load conditions.
When designing a flyback transformer, the worst-case condition of
maximum load at the minimum input voltage creates the highest (peak)
primary current requirement. Select a transformer that has a peak
primary current (Ipk) or primary saturation current (Isat) that is well above
the expected primary current peak for your application. If the application's
peak primary current draw exceeds the transformer rating, core
saturation will cause the primary inductance to drop. If the load requires
more energy at this point, the energy storage capability of the
transformer will be exceeded and the load will not receive the required
energy. This will lead to loss of regulation, therefore the peak primary
current (Ipk) or primary saturation current (Isat) of a flyback transformer is
a critical parameter.
What are typical flyback
transformer applications?
You can use Flyback transformers in many applications, including:
DC-DC power supplies
Telecom
LED Lighting
Power over Ethernet (PoE)
Capacitor charging
Battery charging
Solar Microinverters
AC-DC power supplies
Off-the shelf flyback transformers are available for many applications
where low cost, small size, and high-efficiency are required. They are
typically used in DC-DC controllers in the telecommunications (telecom)
voltage range of 37 – 72Vdc, sometimes at extended voltages ranging
from 2 – 400 Vdc, and also within the universal AC line input voltage range
(85 – 265 Vac ).
Flyback transformers are commonly used for output current below about
10 Amps and output power below about 100 Watts. Coilcraft offers
standard, off-the-shelf flyback transformers with power capabilities
ranging from a few Watts to up to around 120 Watts. When higher current
and power is required, forward-mode, push-pull, or half-bridge / full-bridge
topologies become more efficient alternatives.
How do I select the Coilcraft
flyback transformer that best fits
my application requirements?
As with any electronic component, selecting flyback transformers
involves a multitude of competing trade-offs in performance, size,
efficiency, cost, and weight. Careful selection of core size is required to
achieve high energy storage without core saturation. Wire size (diameter)
must be chosen carefully to provide high output current without
overheating the wire insulation. Core shape and bobbin selection must be
optimized to minimize the winding length and achieve the lowest possible
DCR. High switching frequency can be used to reduce transformer size,
but care must be taken to avoid increased AC losses from core loss,
proximity effect, and skin effect.
Coilcraft offers a helpful selection guide PDF for finding the right off-the-
shelf flyback transformer based on:
Whether you power your application by a DC source or by an AC line
input source
The required transformer input voltage range (Vmin is worst case)
The required output voltage(s)
The required output rms current or power. Approximate output
power: Pout = Vout * Iout
Coilcraft displays its flyback transformers by input voltage range, and
sorts within that category by output power.
References
Mammano, Robert A., 2017. Fundamentals of Power Supply Design. Texas
Instruments.
Colonel Wm. T. McLyman, 1988. Transformer and Inductor design
Handbook. 2nd ed., Marcel Dekker.
What's Next?
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