5 - L-25 (DP) (Pe) ( (Ee) Nptel)

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For the given operating frequency (f) the product ‘Ac Aw’, known as area product is roughly

proportional to the VA rating of the transformer as other parameters have nearly fixed
magnitudes.

25.2 Derivation of Design Equations for SMPS Transformer


The nature of voltage and flux waveforms in SMPS transformers is different from that of utility
transformer. Moreover SMPS circuits of different topologies generate different kinds of winding
voltages (and hence the flux-linked waveforms) and need to be considered separately.

In this section some representative voltage and flux waveforms have been taken up and through
them the transformer design procedure has been illustrated.

25.2.1 Transformer with Square-Wave Voltage and Bipolar Flux


Fig. 25.2 shows the typical winding voltage and core-flux waveform produced by one of the
popular SMPS topologies that utilizes a H-bridge converter to get high frequency ac voltage
from the dc input. The primary side of the SMPS transformer is connected to the H-bridge output
and the secondary side voltage is rectified and filtered to get regulated dc output voltage of
desired magnitude. The transformer windings carry bi-direction current and the flux linking the
windings is also bipolar. The input dc bus voltage is unregulated and often varies over a large
range. The duty ratio ‘D’ of the switches is controlled within 0<D<0.5 to regulate the output
voltage. The mean of the rectified secondary side voltage, under steady state and after accounting
for voltage drops in the rectifier diode and filter inductor, equals the desired load voltage and can
be assumed fixed to the output voltage ‘Vo’. However under dynamic condition, which may arise
due to sudden change in load or supply voltage, the mean (dc) output voltage on the secondary
side may be significantly higher than its steady state magnitude. For calculation of peak flux in
the core, the worst-case condition will correspond to maximum duty ratio (D=0.5) and maximum
magnitude of input voltage. The worst-case current through the windings will correspond to
maximum duty ratio (D=0.5) and peak magnitude of output (load) current. Now the transformer
may be designed as per the design steps given below:

(i) Determination of primary to secondary turns ratio (NP/ NS):- This can be found from
the knowledge of operating range over which the input dc voltage may vary. Let the
input voltage vary from Vmin to Vmax. With minimum input voltage ‘Vmin’ and duty
ratio ‘D’ = 0.5, the magnitude of square-shaped secondary side voltage should equal
(Vo + VR), where VR is the estimated voltage drop in the transformer winding, output
rectifier and filter circuit under maximum load condition. The transformer turns ratio
can thus be estimated to NP/ NS = Vmin /(Vo + VR). The actual number of turns in the
windings will be found as shown below in step (v).
(ii) Determination of peak magnitude of flux in the transformer core: As per above
discussion, the maximum flux in the core will correspond to a square wave voltage of
magnitude Vmax across the primary winding (refer to Fig. 25.2 with D=0.5). The
frequency of voltage waveform ‘f’(=1/T) is same as the frequency at which the
converter switches are turned on and is fixed beforehand. Now by simple integration
of the square wave voltage waveform, the peak flux ‘ φm ’ is related to the input
voltage as, Vmax = 4.0 f φm NP = 4.0 f Bm Ac NP ---------------------------(25.5)

Version 2 EE IIT, Kharagpur 5

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