analysis and design of a high voltage flyback converter...

8
Analysis and Design of a High Voltage Flyback Converter with Resonant Elements 107 JPE 10-2-1 Analysis and Design of a High Voltage Flyback Converter with Resonant Elements Sung-Soo Hong * , Sang-Keun Ji * , Young-Jin Jung * , and Chung-Wook Roh †* Dept. of Electrical Engineering, Kookmin University, Seoul, Korea Abstract This paper presents the operational characteristics of a high voltage flyback converter with resonant elements. In high voltage low power applications, the effect of a transformer’s stray capacitance might be the most important factor that influences the overall performance of the circuit. A detailed mode analysis and the design procedure are presented in designing the high voltage flyback converter. To verify and confirm the validities of the presented analysis and design procedure, a computer simulation and experiments have been performed. Key Words: Flyback converter, High voltage power supply, Resonant elements, Stray capacitance I. I NTRODUCTION Flyback converters have been widely used because of their relative simplicity and their excellent performance for mult- output applications. They can save cost and volume compared with the other converters, especially in low power applications. In a flyback converter, a transformer is adopted to achieve galvanic isolation and energy storage. Research is mainly focused on the leakage inductance of the transformer [1]–[3], since voltage spikes caused by the series resonance between the transformer leakage inductance and the parasitic capac- itance of the switch are the dominant factors in determining the power conversion efficiency and the switching noise in low output voltage and high output current applications. On the other hand, in high output voltage and low output current applications such as the high output voltage power supply (HVPS) in printers, the horizontal deflection circuit in cathode-ray tubes (CRT) displays, etc., the aforementioned res- onance is not the main factor which degrades the performance of a flyback converter. Instead, the parallel resonance between the transformer’s magnetizing inductance and the parasitic capacitance of the transformer are the dominant factors, since the large number of turns of the secondary windings generate a large parasitic capacitance. The duty cycle loss due to this resonance is a severe problem in such high output voltage applications. Beside the problem of low power conversion efficiency, the expected output voltage in the kilo voltage range cannot be obtained in the first prototype based on the conventional design method. A redesign of the transformer based on the trial and error process is inevitable in this case. This results in a lengthy Manuscript received Nov. 4, 2009; revised Jan. 6, 2010 Corresponding Author: [email protected] Tel: +82-2-910-4947, Fax: +82-2-910-4449, Kookmin University * Dept. of Electrical Engineering, Kookmin University, Korea process for developing a high output voltage flyback converter [4]–[6]. Therefore, it is very important for the optimum design of a high voltage flyback converter to take into consideration the resonance between the magnetizing inductance and the parasitic capacitance of the high voltage transformer which has large secondary winding turns [7], [8]. In this paper, the operational characteristics and an analysis considering the resonance effect is provided in details. A design example of a high voltage flyback converter with resonant elements is also presented. Finally, an experimental prototype circuit with an output of 1200V is provided to demonstrate the performance characteristics and design procedure of a high voltage flyback converter with resonant elements. II. THE OPERATIONAL CHARACTERISTICS A. Circuit Configuration Fig. 1 shows the flyback converter with a high voltage flyback transformer, having high turns ratio between the primary and secondary windings considered in this paper. This flyback converter with resonant elements is composed of resonant tank networks including the parasitic capacitor of the switch (C p ), the transformer magnetizing inductance (L m ), the parasitic capacitor of the diode (C s ) and the winding capacitance (C ws ). Since the capacitance on the secondary side is reflected to the primary side with the value of n 2 times, where n is the turn ratio of the transformer and the winding capacitance (C ws ) is sufficiently large compared with that of a conventional transformer. Thus, the resonance between the parasitic capacitance C ws and the magnetizing inductance which arise during the turn-on and turn-off transitions of the semiconductor elements is the dominant factor which affect the duty cycle loss [9]. This circuit can be transformed to an equivalent circuit on the primary side, as shown in Fig. 2. A process to determine

Upload: phungliem

Post on 25-Mar-2018

229 views

Category:

Documents


3 download

TRANSCRIPT

Page 1: Analysis and Design of a High Voltage Flyback Converter ...4hv.org/e107_files/public/1311406499_2431_FT1630_flybackscope.pdf · Analysis and Design of a High Voltage Flyback Converter

Analysis and Design of a High Voltage Flyback Converter with Resonant Elements 107

JPE 10-2-1

Analysis and Design of a High Voltage FlybackConverter with Resonant ElementsSung-Soo Hong∗, Sang-Keun Ji∗, Young-Jin Jung∗, and Chung-Wook Roh†

†∗Dept. of Electrical Engineering, Kookmin University, Seoul, Korea

Abstract

This paper presents the operational characteristics of a high voltage flyback converter with resonant elements. In high voltagelow power applications, the effect of a transformer’s stray capacitance might be the most important factor that influences theoverall performance of the circuit. A detailed mode analysis and the design procedure are presented in designing the high voltageflyback converter. To verify and confirm the validities of the presented analysis and design procedure, a computer simulation andexperiments have been performed.

Key Words: Flyback converter, High voltage power supply, Resonant elements, Stray capacitance

I. INTRODUCTION

Flyback converters have been widely used because of theirrelative simplicity and their excellent performance for mult-output applications. They can save cost and volume comparedwith the other converters, especially in low power applications.

In a flyback converter, a transformer is adopted to achievegalvanic isolation and energy storage. Research is mainlyfocused on the leakage inductance of the transformer [1]–[3],since voltage spikes caused by the series resonance betweenthe transformer leakage inductance and the parasitic capac-itance of the switch are the dominant factors in determiningthe power conversion efficiency and the switching noise in lowoutput voltage and high output current applications.

On the other hand, in high output voltage and low outputcurrent applications such as the high output voltage powersupply (HVPS) in printers, the horizontal deflection circuit incathode-ray tubes (CRT) displays, etc., the aforementioned res-onance is not the main factor which degrades the performanceof a flyback converter. Instead, the parallel resonance betweenthe transformer’s magnetizing inductance and the parasiticcapacitance of the transformer are the dominant factors, sincethe large number of turns of the secondary windings generatea large parasitic capacitance.

The duty cycle loss due to this resonance is a severeproblem in such high output voltage applications. Beside theproblem of low power conversion efficiency, the expectedoutput voltage in the kilo voltage range cannot be obtained inthe first prototype based on the conventional design method.A redesign of the transformer based on the trial and errorprocess is inevitable in this case. This results in a lengthy

Manuscript received Nov. 4, 2009; revised Jan. 6, 2010†Corresponding Author: [email protected]

Tel: +82-2-910-4947, Fax: +82-2-910-4449, Kookmin University∗Dept. of Electrical Engineering, Kookmin University, Korea

process for developing a high output voltage flyback converter[4]–[6]. Therefore, it is very important for the optimum designof a high voltage flyback converter to take into considerationthe resonance between the magnetizing inductance and theparasitic capacitance of the high voltage transformer whichhas large secondary winding turns [7], [8]. In this paper,the operational characteristics and an analysis considering theresonance effect is provided in details. A design example of ahigh voltage flyback converter with resonant elements is alsopresented. Finally, an experimental prototype circuit with anoutput of 1200V is provided to demonstrate the performancecharacteristics and design procedure of a high voltage flybackconverter with resonant elements.

II. THE OPERATIONAL CHARACTERISTICS

A. Circuit Configuration

Fig. 1 shows the flyback converter with a high voltageflyback transformer, having high turns ratio between theprimary and secondary windings considered in this paper.This flyback converter with resonant elements is composedof resonant tank networks including the parasitic capacitorof the switch (Cp), the transformer magnetizing inductance(Lm), the parasitic capacitor of the diode (Cs) and the windingcapacitance (Cws). Since the capacitance on the secondary sideis reflected to the primary side with the value of n2 times,where n is the turn ratio of the transformer and the windingcapacitance (Cws) is sufficiently large compared with thatof a conventional transformer. Thus, the resonance betweenthe parasitic capacitance Cws and the magnetizing inductancewhich arise during the turn-on and turn-off transitions of thesemiconductor elements is the dominant factor which affectthe duty cycle loss [9].

This circuit can be transformed to an equivalent circuit onthe primary side, as shown in Fig. 2. A process to determine

Page 2: Analysis and Design of a High Voltage Flyback Converter ...4hv.org/e107_files/public/1311406499_2431_FT1630_flybackscope.pdf · Analysis and Design of a High Voltage Flyback Converter

108 Journal of Power Electronics, Vol. 10, No. 2, March 2010

Fig. 1. Flyback Converter with Resonant Elements.

(a) Short circuit cell (b) ZVS quasi-resonantnetwork

(c) Equivalent circuit

Fig. 2. Equivalent Circuit of high voltage Flyback Converter withResonant Elements.

the topology of a resonant switch network is to replace allthe low-frequency filter inductors with open circuits, and toreplace all the dc sources and low-frequency filter capacitorswith short circuits [10]. The elements of the resonant switchcell remain in Fig. 2(a). The parasitic capacitance of the diode(Cs) and the winding capacitance (Cws) on the secondary sideare reflected to the primary side with the value of n2 times. Inthe case of the zero-voltage-switching (ZVS) quasi-resonantswitch, the network of Fig. 2(b) is always obtained, where theparasitic capacitances referred to the primary side are givenas follows:

Cr = Cp//Cwsn2

//Csn2. (1)

So this simplified flyback equivalent circuit which consistsof magnetizing inductance (Lm) and stray capacitance (Cr) isshown in Fig. 2(c).

B. Operational Principles

For the convenience of the mode analysis in the steady state,several assumptions are made as follows:• The semiconductor devices are ideal, i.e., there is no

forward voltage drop in the on-state, no leakage currentin the off-state, and no time delay at both turn-on andturn-off.

(a) Mode 1 [t0 ∼ t1] (b) Mode 2 [t1 ∼ t2]

(c) Mode 3 [t2 ∼ t3] (d) Mode 4 [t3 ∼ t4]

Fig. 3. Four operating modes of high voltage flyback converter withresonant elements.

• The converter is operated in the boundary conductionmode (BCM) [11], [12].

• The output capacitors Co is sufficiently large. Thereforethe output voltage can be assumed to be a constant DCvoltage during the switching period Ts.

• The following variables are defined as follows:– Characteristic impedance Zo =

√Lm/Cr.

– Resonant frequency fo = 1/2π√LmCr.

– Characteristic impedance ratio Qp =√n2RL/Zo.

– Normalized switching frequency ratio fns = fs/fo,where fs is the switching frequency of the converter.

The steady-state voltage and current waveforms for eachoperating mode of the circuit shown in Fig. 2(c) are illustratedin Fig. 3. There are four stages during one switching period.The corresponding key waveforms are given in Fig. 4. Everycycle of the converter’s operation can be divided into thefollowing intervals, depicted in Fig. 4: (t0, t1), the resonanceof Lm and Cr; (t1, t2), the linear discharging of Lm; (t2, t3),the resonance of Lm and Cr; (t3, t4), the conduction of Q.

Mode 1 [t0 ∼ t1]: Resonant IntervalPrior to t0, the switch Q is conducting and Vg is applied

to the primary winding. When Q is turned off at t=t0, theformer operational mode, where the magnetizing current iLmis linearly ramped up, ends. Because of the resonance betweenLm and Cr, the magnetizing energy in Lm is not immediatelytransferred to the secondary side. The energy transfer to thesecondary side is delayed until the parasitic capacitor Cr ischarged to VCr(t)=−nVo · Vdc. Vdc increases from 0 to Vg +nVo. In mode 1, the current and voltage can be represented asfollows:

vCr(t) =Vg cosω0t− i(0)Z0 sinω0t (2)

iLm(t) =VgZ0

sinω0t+ i(0) cosω0t (3)

where ωo = 1/√LmCr, Zo = ωoLm.

This mode ends when VCr(t) = −nVo at t=t1. At t=t1, thediode D on the secondary side is turned on. From equation(2), the stray capacitance voltage VCr(t1) can be obtained as:

−nVo = Vg cos θ1 − i(0)Zo sin θ1 (4)

Page 3: Analysis and Design of a High Voltage Flyback Converter ...4hv.org/e107_files/public/1311406499_2431_FT1630_flybackscope.pdf · Analysis and Design of a High Voltage Flyback Converter

Analysis and Design of a High Voltage Flyback Converter with Resonant Elements 109

Fig. 4. Key waveforms of high voltage flyback converter with resonantelements.

where θn = ω0(tn − tn−1). Hence, θ1 = ω0(t1 − t0).The switch conversion ratio M reflected to the primary side

is given by nV o/Vg and can be represented as follows:

M + cos θ1 −i(0)ZoVg

sin θ1 = 0. (5)

Mode 2 [t1 ∼ t2]: Discharging IntervalWhen VCr(t) reaches −nV o at time t=t1, the diode in the

secondary side is turned on and the magnetizing current in Lmflows to the secondary side. The magnetizing inductor currentiLm, flowing through the path Lm − d−Co, is expressed as:

iLm(t) = −nVOLm

(t− t1) + i(t1). (6)

It is noted that VCr remains at −nV o. The voltage across theprimary switch is given during this mode by Vdc = Vg +nV owhich is the same as that of an ideal flyback converter. Theenergy stored in the primary inductance of the transformer istransferred to the load. At t=t2, the stored energy is completelytransferred, and i(t2) becomes zero.

This state can be approximately described by the followingequation:

−nVOLm

(t− t1) + i(t1) = 0→ θ2 =Z0i(t1)

nVO. (7)

Substituting (7) into (3) leads to

θ2M = sin θ1 +i(0)ZoVg

cos θ1. (8)

Mode 3 [t2 ∼ t3]: Resonant IntervalAfter the energy stored in Lm is completely transferred

to the output capacitor and the load on the secondary side,resonant occurs between Cr and Lm. When the current inLm is zero, the diode on the secondary side is turned off.

However, the drain-source voltage of the switch Vdc doesnot immediately go to zero but a quasi resonant occurs. Theresonant action of Lm and Cr causes Vdc to decrease to zeroat t3. Therefore the body diode of switch Q is turned on andit ensures the zero voltage switching (ZVS) operation. Theinductor current iLm, flowing through the path Lm − d−Co,is negative. The resonant voltage VCr and the resonant currentiLr on the primary side can be expressed as:

vCr(t) =−nVO cosωot (9)

iLm(t) =−nVoZo

sinωot. (10)

This stage ends when VCr(t) reaches Vg at t=t3 and thefollowing equations can be obtained from equation (9):

cos θ3 = − 1

M. (11)

From the equation (11), it can be seen that the switchconversion ratio M should be at least larger than 1. The switchQ can operate with ZVS for M > 1.

Mode 4 [t3 ∼ t4]: Charging IntervalIn this mode the switch Q is turned on and Vdc=0. Before

the polarity of the current iLm changes, the main switch shouldbe turned on to ensure ZVS operation. The input energyis stored in the magnetizing inductance Lm, via the pathVg−Lm−Q. The voltage VCr(t) remains Vg . The primary sidecurrent iLm increases linearly, and is expressed as:

iLm(t) =VgLm

(t− t3) + i(t3). (12)

This mode ends when the switch Q is turned off. Sincei(t4) = i(0), equation (12) can be written as:

i(0) =VgZo

[θ4 −M sin θ3]. (13)

The output current Io can be found by averaging the outputdiode current id(t) over one switching period as:

IO =1

TS

∫ t4

0

id(t)dt =θ2

θ

ni(t1)

2(14)

where θ = ωoTS . Substitution of (14) into (7) leads to:

θ22 =

Qp(15)

where Qp = n2VoZoIo

. Combining (5) and (8) gives:

θ2 sin θ1 = cos θ1 +1

M. (16)

Substitution of (5) into (13) leads to:

cos θ1 +M

sin θ1= −M sin θ3 + θ4. (17)

Page 4: Analysis and Design of a High Voltage Flyback Converter ...4hv.org/e107_files/public/1311406499_2431_FT1630_flybackscope.pdf · Analysis and Design of a High Voltage Flyback Converter

110 Journal of Power Electronics, Vol. 10, No. 2, March 2010

Based on (11), and (15)∼(17) the expressions can beobtained as:

θ3 = cos−1

− 1

M

(18a)

θ2 =

√2θ

Qp(18b)

θ1 = cos−1− 1M + θ2

√θ2 + 1− 1

M2

θ22 + 1

(18c)

θ = θ1 + θ2 + θ3 + θ4 (18d)

θ4 =cos θ1 +M

sin θ1+M sin θ3. (18e)

Expressions (18a)-(18e) will be used later to design the ZVShigh voltage flyback converter with resonant elements.

C. Voltage Conversion RatioThe magnetizing current iLm during the entire mode of

operation is expressed as:

i(t1) =VgZO

sin θ1 + i(0) cos θ1 (19a)

i(t2) = 0 = −nVOZO

θ2 + i(t1) (19b)

i(t3) = −nVOZO

sin θ3 (19c)

i(t4) = i(0) =VgZO

θ4 + i(t3). (19d)

From (19b), the magnetizing current at t=t1 can be ex-pressed as:

i(t1) =nVOZO

θ2. (20)

Substitution of (20) into (19a) leads to:

i(0) =

nVOZO

θ2 −VgZO

sin θ1

cos θ1. (21)

From (21), (19d) can be expressed as:

i(t3) =

nVOZO

θ2 −VgZO

sin θ1

cos θ1− VgZO

θ4. (22)

The voltage conversion ratio can be calculated from thesubstitution of (22) into (19c) as follows:VOVg

=1

n

θ4 cos θ1 + sin θ1

θ2 + cos θ1 sin θ3

=1

n

(t4 − t3) cos(t1 − t0)√LmCr

+√LmCr sin

(t1 − t0)√LmCr

(t2 − t1) +√LmCr cos

(t1 − t0)√LmCr

sin(t3 − t2)√LmCr

. (23)

It is noted that if the time intervals at mode 1 and mode 3 areshort, the voltage conversion ratio of equation (23) becomesas:

VoVg

=1

n

(t4 − t3)

(t2 − t1)=

1

n

D

1−D(24)

where D is the duty cycle, D = t4 − t3 and 1−D = t2 − t1.It is also noted that equation (24) is the same as the voltageconversion ratio of a conventional flyback converter.

Fig. 5. Waveforms for the switch power loss as a function of Qp and fns.

III. DESIGN CONSIDERATIONS

A. Switch Power Losses

The characteristic impedance ratio Qp and the normalizedswitching frequency ratio fns are the most important pa-rameters for a high voltage flyback converter with resonantelements because they determine the power loss. Since theload current is small in low power level high output voltageapplications, the power loss of the switch is the dominantfactor. For example, in a HVPS in a laser jet printer, whosepower level is about 1Watt with an output voltage of 1,500volt, the size and volume of the converter is determined mainlyby the switch due to its large sized heatsink element.

The energy dissipated by the switch during the resonantperiods, such as Mode 1 and Mode 3, is given by the currentthough the parasitic capacitance of the switch Cp multiplied bythe drain-source voltage Vds. During these resonant periods,the drain-source voltage of the switch Vdc can be expressedas:

Mode1 : vds(t) = Vg(1− cos θ) + i(0)Zo sin θMode3 : vds(t) = Vg + nVo cos θ

. (25)

The power loss of the switch during the resonant periodis defined as an integral of the drain-source voltage of theswitch multiplied by magnetizing inductance current and di-vided by the period T . In addition, because the magnetizinginductance current divides into the parasitic capacitance Cpand the resonant capacitance Cr, the impedance ratio shouldbe multiplied. The power loss of the switch, Psw loss, can beobtained as follows:

Psw loss=

Vg

2

Z0(− cos θ1+1)+Vg i(0) sin θ1

+ 12

i(0)2Z0−Vg

2

Z0

sin2 θ1−Vgi(0)

2 sin2 θ1

+nVOZ0

∣∣∣Vg cos θ3−Vg−nVO

2 sin2 θ3

∣∣∣

×1θ×

CpCr. (26)

The characteristics of the switch power loss during theresonant period are depicted in Fig. 5. These characteristicsdescribes how, at a given fns, the power loss magnitude varieswith the characteristic impedance ratio Qp. We can minimizethe power loss of the switch by optimal choices of Qp and fns.The power loss decreases as Qp decreases and fns increases.However, the switch conversion ratio M is less than 1 as Qp

Page 5: Analysis and Design of a High Voltage Flyback Converter ...4hv.org/e107_files/public/1311406499_2431_FT1630_flybackscope.pdf · Analysis and Design of a High Voltage Flyback Converter

Analysis and Design of a High Voltage Flyback Converter with Resonant Elements 111

decreases and fns increases. Therefore to obtain the minimumpower loss of the switch Qp, it is recommended to select alow value of fns and a high value of M , which determinesthe turns ratio of the transformer.

B. Boundary Condition of the Resonant Capacitor

When designing a high voltage flyback converter withresonant elements, there exist a minimum value of the resonantcapacitor Cr. The parasitic capacitances of the switch anddiode are obtained from the available datasheet. There alsoexists a minimum winding capacitance on the large numberof turns of the secondary windings. The parasitic capacitanceof the diode (Cs) and the winding capacitance (Cws) on thesecondary side are reflected to the primary side with the valueof n2 times. When selecting Qp and fns it should be notedthat there exists a minimum resonant capacitance Cr.

IV. DESIGN PROCEDURE

From the operational analysis described above, the designprocess of a high voltage flyback converter with resonantelements is considered in this section and a design example isgiven based on a 150mW prototype converter.

Step 1 Define the system specifications: The input voltageVin, output voltage Vo, output power Po, switching frequencyfs, parasitic capacitance of the switch Cp, parasitic capaci-tance of the diode Cs and the winding capacitance Cws.

Step 2 Select the characteristic impedance ratio Qp andthe normalized switching frequency ratio fns: The key de-sign parameter is the power loss of the switch. Mechanismsthat cause power loss are discussed in Chapter 3, includingswitching loss.

Step 3 Determine M and θ1 ∼ θ4: With Qp and fnsselected, the switch conversion ratio M is reflected to theprimary side and the phase variables of each mode θ1 ∼ θ4

can be found from (18a∼e). If M < 1, other values of Qpand fns should be selected.

Step 4 Determine the turns ratio n and the resonant elementssuch as Lm and Cr: The turns ratio n of the high voltagetransformer can be found from M specified in Step 3.

n = MVgVo. (27)

The characteristic impedance Zo and the resonant frequencyfo can be determined, using Qp, fns and equation (27).

Zo =n2RLQp

, fo =fsfns

. (28)

From equation (28), the resonant elements are obtained as:

Lm =Zo

2πfo, Cr =

1

2πZofo. (29)

Check to see if the resonant capacitor Cr is larger thanCrmin equals Cs + Cws. If not, return to Step 2, i.e. selectother values of Qp and fns.

Fig. 6. Circuit topology design for high output voltage application :Vg = 24V , Vo = −1220V , Vc1 = 610V , Q = KSD526− Y , D1,D2 = 718, Lm = 100.8µH , Cr = 50.58nF , Co, C1 = 470pF ,

RL = 10MΩ.

Step 5 Determine the maximum voltage and current stresson the switch: From equation (3), the peak current of themagnetizing inductance can be expressed as:

iLm,pk =

√VgZo

2

+(i(0)

)2. (30)

The voltage stress of the switch and the output diode areexpressed as:

Vds,max = Vg + nVO, Vd,max = VO +1

nVg. (31)

A. Design ExampleLow input voltage, high output voltage and low power level

applications, are the areas where high voltage flyback con-verters can be particularly advantageous. As an example, weconsider the design of a 150mW flyback DC-to-DC converteraccording to the following specifications:

• range of input voltage: Vg,min=24V , Vg,max=27V• output voltage: Vo=−1.22kV (using voltage doubler:Vc1=610V )

• load range: 12.2µA ≤ Io ≤ 122µA• switching frequency: fs=70kHz• minimum capacitance: Cp=90pF , Cs=10pF , Cws=20pF

The high output voltage flyback power circuit in this exam-ple is shown in Fig. 6. Using Step 2, Qp and fns are selected asQp=84 and fns=0.933 respectively. It is noted that this designexample features a low input voltage, an extremely high outputvoltage and a small load range in a real printer application.Thus, Qp and fns are selected to be large values. Fromequation (19), the switch conversion ratio M and θ1 ∼ θ4

are obtained as M=1.0163, θ1=2.362, θ2=0.338, θ3=3.321 andθ4=0.253 respectively. Since M > 1, we can proceed to thenext step. From equation (27), the turns ratio n of the highvoltage transformer is obtained as n=0.04. From equation (28),the characteristic impedance Zo and the resonant frequencyfo are Zo=44.66Ω and fo=70.45kHz. Finally, from equation(29), the resonant elements are obtained as Lm=100.8µHand Cr=50.58nF . We observe that Cr satisfies the desiredconstraint on the minimum Cr, where Crmin=18.86nF . From(30), the peak current is iLm,pk=586mA. From (31), thepeak drain-to-source and diode voltage are Vds,max=48.4V andVd,max=1210V , respectively. The key components include: theswitch Q: KSD526-Y and the output diode D: 718.

Page 6: Analysis and Design of a High Voltage Flyback Converter ...4hv.org/e107_files/public/1311406499_2431_FT1630_flybackscope.pdf · Analysis and Design of a High Voltage Flyback Converter

112 Journal of Power Electronics, Vol. 10, No. 2, March 2010

V. SIMULATION AND EXPERIMENT

To verify the analysis and design procedure presented inthis paper a PSIM simulation and an experiment were carriedout on an actual high voltage flyback converter with resonantelements using the specifications and parameters listed inTable 1. A schematic representation of the flyback convertermodeled in the simulation program is shown in Fig. 6.

The high voltage flyback converter with resonant elementsconsists of an ideal transformer, a magnetizing inductance anda resonant capacitor. In order to make the design process moreefficient, the PSIM simulation data contains key waveformssuch as the voltage stress on the switch, the magnetizing in-ductor current and the resonant capacitor voltage. This flybackdesign example is included to demonstrate an application ofthe procedure, and the results are supported by a simulation.The simulation and theoretical results are compared in Table 2,which shows the design parameters and the simulated valuesof the key voltage and the current waveforms during thewhole switching period. Fig. 7 shows the results of the PSIMsimulation, which contains the key voltage and the currentwaveforms of the high voltage flyback converter. It can beseen that the PSIM simulation results coincide well with thepredicted results shown in Fig. 4 and Table 2.

TABLE IPARAMETERS OF EXPERIMENTAL CIRCUIT

Part Value TypeSwitch Q Vce : 80V KSD526-Y

Diode (D1, D2) Vr : 6kV 718Transformer (Lm) 100.8µH Ferrite CoreCapacitor (C1, Co) 470pF C1 : ceramics / Co : ALLoad Resistor (RL) 10MΩ Non-Inductive Resistor

TABLE IIDATA OF DESIGN VALUE AND IMULATION RESULT

Design SimulationParameter

value ResultDeviation

Vc −1220[V ] −1205[V ] 1.23[%]

i(0) 233.2[mA] 218.3[mA] 6.39[%]

i(t1) 211.0[mA] 210.1[mA] 0.85[%]

t1 ∼ t0 5.338[µs] 5.35[µs] 0.26[%]

t2 ∼ t1 0.877[µs] 0.89[µs] 1.48[%]

t3 ∼ t2 7.502[µs] 7.49[µs] 0.16[%]

t4 ∼ t3 0.571[µs] 0.56[µs] 1.93[%]

TABLE IIIDATA OF MEASURED RESULT AND SIMULATION RESULT

Measured DesignParameter

result resultDeviation

Vo −1226[V ] −1205[V ] 1.71[%]

Vce,max 50.3[V ] 48.5[V ] 3.58[%]

Vcr,max 24.7[V ] 24.0[V ] 2.83[%]

Vcr,min −26.0[V ] −24.0[V ] 5.80[%]

Vscc,max 637[V ] 600[V ] 5.81[%]

Vscc,min −655[V ] −613[V ] 6.41[%]

Fig. 7. PSIM simulation results for the design circuit operating at−1205Vdc output.

(a) Simulation results

(b) Experimental results

Fig. 8. Key waveforms of high voltage flyback converter.

Fig. 8 shows the experimental waveforms of Fig. 6, Vo,VCr, Vsec and Vds, respectively. Each waveform shows goodagreement with the simulation and the experimental results inTABLE III. As can be seen, the output voltage (Vo) is about -1226V. The designed value and the simulated value are -1220Vand -1205V, respectively. In addition, the measured outputvoltage was within 1.23% of the calculated value, verifyingthe accuracy of the equations given here. The other measuredparameters are also similar to the calculated and simulatedvalues.

The measured power loss of the switch is shown in Fig.9 and TABLE IV, which shows the waveforms of Vce, Ic

Page 7: Analysis and Design of a High Voltage Flyback Converter ...4hv.org/e107_files/public/1311406499_2431_FT1630_flybackscope.pdf · Analysis and Design of a High Voltage Flyback Converter

Analysis and Design of a High Voltage Flyback Converter with Resonant Elements 113

Fig. 9. Switch power loss of experimental measurements.

TABLE IVDATA OF MEASURED RESULT

Parameter Measured resultVce,max 51.0[V ]

Vce,min −0.4[V ]

Ic,max 145[mA]

Psw Loss 0.159[W ]

and Psw Loss , respectively. As can be seen, the power lossis negligible. The temperature of the switch is about 30.4Cat an ambient temperature of 24.1C. It is verified that byconsidering the parasitic capacitance of transformer, the outputvoltage of the actual low power high voltage output flybackconverter can be precisely predicted.

VI. CONCLUSIONS

The effect of the resonant elements in a dc/dc converter witha transformer can be very important and must be consideredwhen designing a high voltage flyback converter. The firstrequirement of a flyback converter used in low power levelhigh output voltage applications is that the output voltageshould be obtained at the expected value. Unlike an idealflyback converter, the output voltage of a real converter isrestricted by the parasitic properties of the high voltageflyback transformer. The influence of the transformer’s straycapacitance is dominant.

In this paper, to analyze the effects of these resonant ele-ments, an equivalent circuit was derived. The design considera-tions and a design example of a high voltage flyback converterwith 150mW have been presented. The design, simulation andexperimental results were also given and the results agree wellwith the analytical results. This design procedure is expectedto be well suitable for high output voltage applications.

ACKNOWLEDGMENT

This work was supported by the research program 2010of Kookmin University, Korea and also by the Ministry ofKnowledge Economy (MKE), Korea, under the InformationTechnology Research Center (ITRC) support program super-vised by the Institute of Information Technology Advancement(IITA) under Grant IITA–2009-C1090–0904-0002.

REFERENCES

[1] Shelton Gunewardena, Wendel E. Archer, Robert O. Sanchez, “Highvoltage miniature transformer design,” Electrical Insulation Conferenceand Electrical Manufacturing & Coil Winding Conference, 2001 Pro-ceedings, pp.141-147, 2001.

[2] M. J. Prieto, A. Fernandez, J. M. Diaz, J. M. Lopera, J. Sebastian,“Influence of transformer parasitics in low-power applications,” AppliedPower Electronics Conference and Exposition, 1999 APEC’99 Four-teenth Annual, Vol.2, pp.1175-1180, Mar. 1999.

[3] MIT, Staff of Dept of EE, Magnetic circuit and transformer, MIT Press,1965

[4] McArdle, J., Wilson, T.G. Jr., and Wong, R.C., “Effects of power–train parasitic capacitance on the dynamic performance of DC–to-DCconverters operating in the discontinuous MMF mode,” IEEE Trans. onPower Electron., Vol. 2, No. 1, pp.2–19, Jan. 1987.

[5] Lu, H.Y., Zhu, J.G., Ramsden, V.S., and Hui, S.Y.R., “Measurementand modeling of stray capacitance in high frequency transformer,” IEEEPower Electronics Specialist Conf. Rec., pp.763–768, Jun. 1999.

[6] Lu, H.Y., Zhu, J.G., and Hui, S.Y.R., “Experimental determination ofstray capacitances in high frequency transformers,” IEEE Trans. onPower Electron., Vol. 18, No. 5, pp.1105–111, Jun. 2003.

[7] S.-K. Chung, “Transient characteristics of high-voltage flyback trans-former operating,” Applied IEE Proceedings Electric Power Applica-tions, Vol. 151,No. 5, pp.628-634, Sep. 2004.

[8] Huang Kewei, Li Jie, Hu Xiaolin, Fan Ningjun, “Analysis and simulationof the influence of transformer parasitics to low power high voltageoutput flyback converter,” IEEE Industrial Electronics InternationalSymposium, pp. 305-310, Jun. 2008.

[9] Ramsden, V.S., Lu, H.Y., and Zhu, J.G., “Dynamic circuit modeling ofa high frequency transformer,” IEEE Power Electronics Specialist Conf.Rec., Vol. 2, pp.1479–14857, May 1998.

[10] Robert W, Dragan M, Fundamentals of Power Electronics, BoulderColorado, 2002.

[11] Tabisz, W.A.; Gradzki, P.M.; Lee, F.C.Y., “Zero-voltage-switched quasi-resonant buck and flyback converters- experimental results,” IEEE Trans.on Power Electron., Vol. 4, No. 2, pp.194-204, Apr. 1989.

[12] Vorperian, V., “Quasi-square-wave converters: topologies and analysis,”IEEE Trans. on Power Electron., Vol. 3, No. 2, pp. 183-191, Apr. 1988.

Sung-Soo Hong received his B.E. degree in ElectricalEngineering from Seoul National University, Seoul,Korea, in 1980, and his M.S. and Ph.D. in Electricaland Electronics Engineering from the Korea AdvancedInstitute of Science and Technology, Seoul, Korea, in1986 and 1992, respectively. From 1984 to 1998, hewas an Electronics Engineer with Hyundai ElectronicsCompany. In 1993, he was with the Virginia PolytechnicInstitute and State University, Blacksburg, as a Research

Scientist. Since 1999, he has been an Assistant Professor in the ElectronicsEngineering Department, Kookmin University, Seoul, Korea. His researchinterests are in the areas of modeling and control techniques for powerconverters, EMI analysis and reduction techniques for power electronicscircuits.

Sang-Keun Ji was born in Seoul, Korea in 1981. Hereceived his B.S. and M.S. in Electronics Engineeringfrom Kookmin University, Seoul, Korea, in 2007 and2009, respectively, where he is currently working towardhis Ph.D. in the School of Electronics Engineering. Hisresearch interests are in the areas of high-efficiencypower converters and renewable energy applications.Mr. Ji is a member of KIPE (Korean Institute of PowerElectronics).

Young-Jin Jung was born in Seoul, Korea in 1978.He received his B.S. in Electronics Engineering fromSuwon University, Suwon, Korea, in 2004. He receivedhis M.S. in Electronics Engineering from KoookminUniversity, Seoul, Korea, in 2008. Since 2006, he hasbeen with Department of Power Electronics, KookminUniversity, where he is currently a doctoral student.His research interests are in the areas of modelingand control of converters and inverters. Mr. Jung is a

member of KIPE (Korean Institute of Power Electronics).

Page 8: Analysis and Design of a High Voltage Flyback Converter ...4hv.org/e107_files/public/1311406499_2431_FT1630_flybackscope.pdf · Analysis and Design of a High Voltage Flyback Converter

114 Journal of Power Electronics, Vol. 10, No. 2, March 2010

Chung-Wook Roh was born in Korea in 1971. Hereceived his B.S., M.S., and Ph.D. in Electrical En-gineering and Computer Science from the Korea Ad-vanced Institute of Science and Technology (KAIST),Taejon, Korea, in 1993, 1995, and 2000, respectively.In 2000, he joined the Digital Media Network Division,Samsung Electronics Company, Suwon, Korea, wherehe was a Project Leader of the Plasma Display DriverDevelopment Team. Since 2004, he has been with the

department of Electrical Engineering, Kookmin University, Seoul, Koreawhere he is currently an Associate Professor. His research interests includedriver circuits of displays such as light emitting diodes, plasma display panels,

low-power circuits for flat panel displays, as well as the modeling, design, andcontrol of power conversion circuits, soft-switching power converters, resonantinverters, and electric drive systems. He is the author or coauthor of more than100 technical papers published in journals and conference proceedings andhas more than 50 patents. Dr. Roh has received several awards including aBest Presentation Award from the annual conference of the IEEE IndustrialElectronics Society in 2002, a Best Paper Award from the Korean Institute ofPower Electronics in 2003 and a Best Paper Award from the Korean Instituteof Power Electronics in 2009, respectively. He is currently a journal editorfor the Korean Institute of Power Electronics.