ST公司自激式开关电源设计
1 Power Transformer Design Calculations
l The specifications:
– VAC = 85~265V
l Line frequency: 50~65Hz
– VO = 5V
– IO = 0.4A
Taking transient load into account, the maximum output current is set as
IO (m a x ) = 1.2IO= 4.8 A
1.1 Switching Frequency
The system is a variable switching frequency system (the RCC switching frequency varies with the input voltage and output load), so there is some degree of freedom in switching frequency selection. However, the frequency must be at least 25kHz to minimize audible noise.
Higher switching frequencies will decrease the transformer noise, but will also increase the level of switching power dissipated by the power devices.
The minimum switching frequency and maximum duty cycle at full load is expressed as
fS (m i n ) = 50 kHz
Dma x = 0.5
where the minimum input voltage is 50kHz and 0.5, respectively.
1.2 STD1LNK60Z MOSFET Turn Ratio
The maximum MOSFET drain voltage must be below its breakdown voltage. The maximum drain voltage is the sum of:
l input bus voltage,
l secondary reflected voltage, and
voltage spike (caused by the primary parasitic inductance at maximum input voltage).
The maximum input bus voltage is 375V and the STD1LNK60Z MOSFET breakdown voltage is
600V. Assuming that the voltage drop of output diode is 0.7V, the voltage spike is 95V, and the margin is at least 50V, the reflected voltage is given as:
Vfl = V( B R) DS S – Vm arg i n – VDC( ma x ) – Vsp k = 600 – 50 – 375 – 95 = 80 V
The Turn Ratio is given as
where,
Vfl = Secondary reflected voltage
V(BR)DSS = MOSFET breakdown voltage
Vmargin = Voltage margin
VDC(max) = Maximum input bus voltage
Vspk = Voltage spike
Vf = Voltage drop
N = Turn Ratio
Np = Primary Winding Turns
Ns = Secondary Winding Turns
1.3 Primary Current
l
l Primary Root Mean Square (RMS) Current is expressed as
where,
Ippk = Primary peak current
VO = Voltage output
IO(max) = Maximum current output
h = Efficiency, equal to 0.7
Dmax = Maximum duty cycle
VDC(min) = Minimum input bus voltage
Iprms = Primary RMS current
1.4 Primary Inductance
Primary Inductance is expressed as
where,
VDC (min) = Minimum
fs(min) = Minimum switching frequency
Ippk = Primary peak current
For example, if Primary Inductance is set to 5.2mH, the minimum switching frequency is:
1.5 Magnetic Core Size
One of the most common ways to choose a core size is based on Area Product (AP), which is the product of the effective core (magnetic) cross-section area times the window area available for the windings.
Using a EE16/8 core and standard horizontal bobbin for this particular application, the equation used to estimate the minimum AP (in cm4) is shown as
where,
Lp = Primary Inductance
Iprms = Primary RMS current
ku = Window utilization factor, equal to:
– 0.4 for margin wound construction, and
– 0.7 for triple insulated wire construction
Bmax = Saturation magnetic flux density
T = Temperature rise in the core
1.6 Primary Winding
1.6.1 Winding Turns
The effective area of an EE16 core is 20.1mm2 (in the core’s datasheet). The number of turns of primary winding is calculated as
where,
Np = Primary Winding Turns
VDC (min) = Minimum
Dmax = Maximum duty cycle
B = Flux density swing
Ae = Effective area of the core
1.6.2 Wire Diameter
The current density (AJ) allowed to flow through the chosen wire is 4A/mm2. The Copper diameter of primary wire is expressed as
where,
dp = Diameter of primary winding wire
Iprms = Primary RMS current
AJ = Current density
1.6.3 Number of Primary Winding Turns per Layer
The EE16 bobbin window is about 9mm, so if the enamel wiring chosen has a 0.21mm outer diameter and a 0.17mm Copper diameter, the number of turns per layer is expressed as
where,
Np1 = Layer 1 Primary Winding Turns
Np1 = 42 turns per layer, 4 layers needed
Np = 168 (total turns for all 4 layers)
1.6.4 Practical Flux Swing
Using the Np = 168 value, the practical flux swing is expressed as
where,
B = Flux density swing
VDC(min) = Minimum input bus voltage
Dmax = Maximum duty cycle
fs(min) = Minimum switching frequency
Ae = Effective area of the core
Np = Primary Winding Turns
1.7 Secondary Winding
Using triple insulation wire with a 0.21mm Copper diameter, the number of turns of secondary winding is expressed as
where,
Ns = Secondary Winding Turns
Np = 168 (total turns for all 4 primary winding layers) Np = Primary Winding Turns
N = Number of turns per primary winding layer
1.8 Auxiliary Winding
1.8.1 Winding Turns
The MOSFET gate voltage at minimum input voltage should be 10V to conduct the MOSFET completely. For this application, the optocoupler is powered by the fly-back method, so the number of auxiliary winding turns of auxiliary winding is calculated as
where,
Vg = Gate voltage
VDC(min) = Minimum input bus voltage
Na = Auxiliary Winding Turns Np = Primary Winding Turns Vo = Optocoupler voltage
VF = Fly-back voltage
Ns = Secondary Winding Turns
1.8.2 Wire Diameter
With the auxiliary winding turns set to 11 (Na =11), the enamel wire chosen has a 0.21mm outer diameter and a 0.17mm Copper diameter. The Copper diameter of primary wire is expressed as
1.9 Gap Length
The gap length setting is based on the number of primary winding turns and primary inductance during the manufacturing process.
Note: In practice, the saturation current value must be ensured. If it is not, then the design activity should be restarted.
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