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TIDA-00367: TIDA-00367 flyback transformer design

Genius 3055 points

Replies: 17

Views: 1086

Part Number: TIDA-00367

Hi,

Related to the TIDA-00367, is the flyback transformer (T1) design available ?

Thanks,

Manu

  • Hi,

    The transformer details are available in Wurth Electrik (WE) website. Please search for the WE part number: 750342946 in https://www.we-online.com/

    The same can be seen at the page:
    katalog.we-online.de/.../UCC28630-DB-TIDA-00367-Rev-E2_Flyback_1

    Thanks,
    Manu Balakrishnan
  • In reply to Manu Balakrishnan:

    Hi Manu,

    Ah this is quite confusing. :-)

    I did notice that Wurth has the transformer with them. Actually, we have a transformer manufacturer doing work for us, located here and hence the query related to the transformer design.

    Thanks,

    Manu

  • In reply to Manu Abraham:

    Any thoughts on the transformer design ? At least any thoughts on where to start with the design of the transformer ?

    Thanks,
    Manu
  • In reply to Manu Abraham:

    Hi Manu,

    The transformer design is done by Wurth, specifically for this design. The part datasheet from Wurth has the basic details like size (from that, the core size can be found out), turns ratios, isolation requirement between windings, primary inductance, dc resistance and leakage inductance. I think the missing parameter is the number of turns, which you may have to calculate using the standard flyback transformer design. I will not be able to share more details on the transformer, as the transformer design is owned by Wurth.

    Please note that, for this design, the most challenging and important part is to minimize the leakage inductance. The leakage inductance is very crucial as the power level is as high as 150W. Higher leakage inductance will cause challenge in taking care of the snubber losses.

    Please use the design calculator of UCC28630 for detailed design:
    www.ti.com/.../getliterature.tsp

    Please use the below training material to understand more on the transformer design.
    training.ti.com/transformer-designer-isolated-high-voltage-power-design

    Hope this will help you to find the missing parameters like number of turns. Please validate the designed values with the Wurth transformer parameters.

    Please let us know if you need further support.

    Thanks & Regards,
    Manu Balakrishnan
  • In reply to Manu Balakrishnan:

    Hi Manu,

    Thanks for your reply, but without knowing the core material, vendor etc, it would be quite hard to continue, unless the design is started from scratch, I guess! :-( Looking through past posts on the forum, I feel that many others also feel the same. The whole point of a reference design is to have a reference to something. If someone is holding that hostage, then that doesn't make any sense. How I wish TI would provide the transformer design like how Power Integrations does for their reference designs!

    Thanks,
    Manu
  • In reply to Manu Abraham:

    Hi Manu,

    We do provide transformer design for many of our designs. Below are some designs where we have transformer design available for a 65W converter using the same part family UCC28630.
    www.ti.com/.../ucc28630evm-572
    http://www.ti.com/tool/PMP9643

    For some reference designs, we directly take the custom transformer parts from Wurth, so that it is easy to support worldwide customer requirements. This will help the worldwide designers to directly get the sample from Wurth for quick prototyping.

    Let me direct this E2E thread to my colleague Ramkumar, he will be able to help you with the specs for the transformer.

    Thanks,
    Manu Balakrishnan
  • In reply to Manu Balakrishnan:

    Hi Manu,

    I had a look at PMP9643, but that has a slightly lower power than I required, everything else is great. If I can simply increase the output power of PMP9643 from 65W to about 100W, that would exactly fit the requirement.

    I follow very much what you are saying.

    Since we have transformers being manufactured here, importing the same transformer, the levies are much higher. For prototyping/testing sourcing from Wurth might work, but in reality for production when volumes are the intent, then the Wurth road does not seem to work in addition to their their very high price quotes for the transformer.

    It's their product they can determine it's price, but in the end to be sold in the market, it's price should be justified. I could've taken the samples from them and asked manufacturers to simply copy that design, but that's not a comfortable thing for me to do.

    Hence looked towards a design that TI provided.

    Thanks,
    Manu
  • In reply to Manu Abraham:

    TIDA-00367 Transformer spec.docxHi Manu,

    Please find atached a spec sheet for the transformer. This should work for the 100W output you are looiking for. Please take care of minimizing leakage inductance to <4.5uH.

    Best Regards,

    Ram

  • In reply to Ramkumar S:

    Hi Ram,

    Thanks for the help. In the construction, W3 seems to be missing ?
    What needs be done to minimize the leakage inductance, as per your suggestion ?


    Thanks,
    Manu
  • In reply to Manu Abraham:

    Also, have 3 queries on the topic.

    1. W4 is the winding for the Aux power for the UCC28630. But that winding seems to have triple insulation, rather than output that would need that isolation.

    2. W2 and W3 the outputs that require isolation uses standard 26AWG ?

    I guess that's by accident ?

    3. If I need to reduce the output voltage to about 21V instead of the calculated 24V, can I simply assume that 24/(5+4) = 2.66V/turn and thus deduct 1 turn from W2, thus making it 4 turns ?

    Thanks,
    Manu

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