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UCC24624: Transformer Design

Muhammad Arsalan Athar
Intellectual 390 points
Part Number: UCC24624

Tool/software:

Hi TI members,

I need to design a Center-tapped Transformer similar to the one in the document: "UCC24624 Dual-Channel Synchronous Rectifier Controller for LLC Resonant Converters"  from TI. Please advise how I can design this transformer according to my specifications.

The spec values are:

Input Voltage: 60V

Output Voltage: 30V

Turns ratio = 2 : 1

Switching Freq range: 0-160Khz

Resonant Frequency: 55 / 60Khz LLC Converter

Output Power:  150Watt (30V output x Max Cuurent 5A).

Is there any online tool or simulator through which i can put those above values and then get the result like transformer core size, wire gauge of the windings, core and wire cross-section area and other parameters for designing the Center tapped transformer?

Please Suggest accordingly

Kind Regards

Arsalan

  • 0
    TI__Guru* 75995 points

    Hello,

    Your inquiry has been received and is under review.

    Regards,

  • 0 in reply to Mike O'
    TI__Guru* 75995 points

    Hello,

    Could you send me a link to the document you mentioned?

    Regards,

  • 0 in reply to Mike O'
    Intellectual 390 points

    Hi Mike,

    Thanks for your reply.

    https://www.ti.com/product/UCC24624

    "UCC24624 Dual-Channel Synchronous Rectifier Controller for LLC Resonant Converters"

    Thanks

    Kind Regards

    Arsalan

  • 0 in reply to Muhammad Arsalan Athar
    TI__Guru* 75995 points

    Hello,

    Are you looking for help with the design of an LLC transformer?

    Have you selected an LLC controller for your design?

    Regards,

  • 0 in reply to Mike O'
    Intellectual 390 points

    Hi Mike,

    Thanks for your message.

    Mike O' said:
    Are you looking for help with the design of an LLC transformer?

    Yes. 

    Mike O' said:
    Have you selected an LLC controller for your design?

    I have already selected the UCC24624 Rectifier controller for SR1 and SR2 for my LLC design. The other controller for switches Q1 & Q2 for LLC have also been chosen.

    The problem is the design of a Center-tapped Transformer for LLC design.

    Thanks 

    Regards

    Arsalan

  • 0 in reply to Muhammad Arsalan Athar
    TI__Guru* 75995 points

    Hello,

    Could you tell me which TI LLC controller you are using for your LLC design?

    Regards,

  • 0 in reply to Mike O'
    Intellectual 390 points

    Hi Mike,

    Thanks for your reply.

    Mike O' said:
    Could you tell me which TI LLC controller you are using for your LLC design?

    I use an external controller like F28335 DSP for switches Q1 & Q2.

    Muhammad Arsalan Athar said:
    The problem is the design of a Center-tapped Transformer for LLC design.
    Muhammad Arsalan Athar said:

    I need to design a Center-tapped Transformer similar to the one in the document: "UCC24624 Dual-Channel Synchronous Rectifier Controller for LLC Resonant Converters"  from TI. Please advise how I can design this transformer according to my specifications.

    The spec values are:

    Input Voltage: 60V

    Output Voltage: 30V

    Turns ratio = 2 : 1

    Switching Freq range: 0-160Khz

    Resonant Frequency: 55 / 60Khz LLC Converter

    Output Power:  150Watt (30V output x Max Cuurent 5A).

    Is there any online tool or simulator through which i can put those above values and then get the result like transformer core size, wire gauge of the windings, core and wire cross-section area and other parameters for designing the Center tapped transformer?

    Pease suggest accordingly for the center-tapped transformer design.

    Thanks

    Arsalan

  • 0 in reply to Muhammad Arsalan Athar
    TI__Guru* 75995 points

    Hello,

    Your inquiry is under review and I will get back to you shortly.

    Regards,

  • 0 in reply to Mike O'
    TI__Guru* 75995 points

    Hello,

    Your question is really in regards to designing an LLC transformer and not designing with the UCC24624.

    The F28335 is a C2000 digital controller.  Going forwarded when you have questions relating to the power stage using the C2000 controller please repost in the e2e with C2000 in the thread title.

    In regards to having transformers and other magnetics designed for our reference designs and evaluation modules.  We typically give our turns ratio, magnetizing inductance, peak and RMS currents to a magnetic design house to design the magnetics for us.

     

    You could use the UCC25640x excel design tool to calculate the turns ratio, magnetizing inductance and transformer currents.  The following link will get you to this excel tool.  

    https://dr-download.ti.com/design-tools-simulation/calculation-tool/MD-4q9segeylW/01.00.00.0C/sluc675c.zip

     

    Once you have the transformer turns ratio, magnetizing, inductance and RMS currents; along with, any isolation requirements you may have.  You can use this information  to have a Magnetic design house such as Wurth, GCI or Renco design a transformer for your application. 

    If you want to design the transformer yourself.  Mag-Inc has many application notes that can help you in the design process.

    https://www.mag-inc.com/

    Thank you for interest in Texas Instruments (TI) products.  If you have a related question, please click the "Ask a related question" button in the top right corner. The newly created question will be automatically linked to this question.

    Regards,