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LM5022: PMP20676

Part Number: LM5022
Other Parts Discussed in Thread: TPS40210, LM3481, , PMP20676

Hello, I would like to use as a starting design for a flyback DC-DC converter, one with one of your products LM5022, LM3481 or TPS40210.

The input parameters are: 

Vin = 9 - 60V;

Vo1=12V/2A (isolated);

Vo2=5V/4A (non isolated, FB controlled, power supply for RPi 4);

Selected transformer: PA0769NL (forward, 36-75V, 5V/9A, 12V/4.2A);

Selected start design: PMP20676 (for now);

Please for a detailed design calculation guide and a tips for the cheapest implementation.

Tsvetan

  • Hi Tsvetan,

    Thank you for asking this question. 

    For your design, you could do a primary-side regulated (PSR), multiple-output flyback. You can use this reference design as a start with the TPS40210: 

    http://www.ti.com/tool/PMP7024

    In this design, you would want to have a transformer with 4 windings. I would not recommend utilizing the forward transformer, since the forward transformer is meant to only transfer energy from the input to the output during the on-time. For a flyback transformer, energy is stored during the on-time and delivered during the off-time, so the operations of the transformers are different. If you use a forward transformer, I'm afraid that you will end up saturating the core. A flyback transformer is better here. 

    In designing the power-stage of a flyback converter, I would recommend this guide: 

    http://www.ti.com/lit/an/snva761a/snva761a.pdf 

    In particular, I would focus especially on the selection of the flyback transformer, input and output capacitor, MOSFET and diode selection- since the selection for those are constant for any flyback converter.

    As for the compensation, you can follow section 5.1 here to get the power stage poles and zeros for a flyback converter: 

    http://www.ti.com/lit/an/snva866/snva866.pdf

    Once you do this, you will need to determine your crossover frequency, which should be lower than your right-half plane zero (RHPZ).

    However, if you are using the TPS40210, you will need to implement a Type-III compensation network instead of a type-II, which you can find the transfer function for here: 

    http://www.ti.com/lit/an/slva662/slva662.pdf

    If the calculations become too heavy, I would recommend to simply populate the values you see in the design, and take a closed-loop response with a Bode plot in order to assess your cross-over frequency and phase margin. You can see that this has been done via TP10 and TP11 in the above reference design. 

    I hope this helps,

    Richard. 

  • Hi Richard,

    Thanks for the quick and complete reply. I want to ask some more questions:
    - Since I did not find the flybak transformer with the specified parameters, is it possible without deterioration of the output parameters to use the specified forward transformer (PA0769NL), taking care of the calculations in the datasheet in the 3rd and 4th notes:
    "...
    3. For flyback topology applications, it is necessary to ensure that the transformer will not saturate in the application. The peak flux density (Bpk) should remain below 2700Gauss. To calculate the peak density, use the following formula:
    Bpk (Gauss) = K1_Factor * Ipk (A)

    4. In high volt-sec applications, it is important to calculate the core loss of the transformer. Approximate transformer core loss can be calculated as:
    CoreLoss (W) = 1.32E-13 * (Freq_kHz) * (ΔB_Gauss)

    where ΔB can be calculated as:

    For Flyback Topology: ΔB = K1_Factor * (A)
    For Forward Topology: ΔB = K1_Factor * Volt-µsec
    ... "

    - Is it better to use a DCM to avoid more difficult compensation due to RHPZ, although it will give me more ripples and switching currents?

    I would also like to remove the chip limit I mentioned in my previous post, only the price remains decisive.

    Regards,
    Tsvetan

  • Hi Tsvetan,

    For the first question - I would strongly recommend against using the forward transformer. It may be possible to use a transformer meant for a forward converter topology, but you may have to oversize and may end up being more expensive in the long run in terms of cost, design and test time.

    The transformer for this design is shown in the design report: http://www.ti.com/lit/ug/sluu899/sluu899.pdf 

    You can check other flyback transformer vendors to see if there are specifications similar to the one seen in the schematic and test report. 

    For the second question- the RHPZ still exists, but it is pushed beyond half of the switching frequency, so you can neglect it in your compensation. I would recommend utilizing CCM because it has better cross regulation as seen in this paper: https://www.ti.com/seclit/ml/slup261/slup261.pdf 

    Thanks,

    Richard

  • Thanks Richard for the tip on the transformer - I'll do it.

    I would be glad if you had a proposal for it.

    Regards,
    Tsvetan