FINAL PROJECT REPORT

WORKSHOP OF MAGNETIC COMPONENT AND POWER

ELECTRONIC

“Project Work Forward Converter B”

Arranged by:

Muhammad Fauzi (1310191002)

Abdul Hakim Azis (1310191009)

Auliya Dewi Ariviyani (1310191024)

3 D4 ELIN A

Lecturer:

Ir. Moh. Zaenal Efendi, M.T.

BACHELOR OF APPLIED IN INDUSTRIAL-ELECTRICAL

ENGINEERING STUDY PROGRAM

DEPARTMENT OF ELECTRICAL ENGINEERING

ELECTRONIC ENGINEERING POLYTECHNIC INSTITUTE OF

SURABAYA

2021/2022
 SECTION 1

FUNDAMENTAL THEORY

The forward converter, shown in Fig. 1, is another magnetically coupled dc-dc converter.
The switching period is T, the switch is closed for time DT and open for (1 −¿ D)T. Steady-state
operation is assumed for the analysis of the circuit, and the current in inductance L x is assumed
to be continuous.

Figure 1. Forward dc-dc converter

The transformer has three windings: windings 1 and 2 transfer energy from the source to the
load when the switch is closed; winding 3 is used to provide a path for the magnetizing current
when the switch is open and to reduce the magnetizing current to zero before the start of each
switching period. The transformer is modeled as three ideal windings with a magnetizing
inductance Lm, which is placed across winding 1. Leakage inductance and losses are not
included in this simplified transformer model.

For the forward converter, energy is transferred from the source to the load while the switch
is closed. Recall that for the flyback converter, energy was stored in Lm when the switch was
closed and transferred to the load when the switch was open. In the forward converter, Lm is not
a parameter that is included in the input-output relationship and is generally made large.

Analysis for the Switch Closed

The equivalent circuit for the forward converter with the switch closed is shown in Fig. 2.
Closing the switch establishes the voltage across transformer winding 1, resulting in

v1 ¿ V s

v 2 ¿ v1
( ) ( )
N2
N1
= Vs
N2
N1
(1)

v3 ¿ v1
( ) ( )
N3
N1
= Vs
N3
N1
 Figure 2. Circuit for switch closed

The voltage across D 3 is

V D = −¿ V s −¿ v3 < 0
3

showing that D3 is off. A positive v 2 forward-biases D1 and reverse-biases D2.

The relationship between input and output voltages can be determined by examining the
current in inductor L x. Assuming the output is held at a constant V o ,

V L = v 2 −¿ V o = V s
x
( )
N2
N1
−¿ V o = L x
di L
dt
x

di L
dt
x
=
Vs ( )
N2
N1
−V o ∆ i L
=
∆t
=
∆ iL
DT
x x

Lx

( ∆i L )closed = V s
x
[( ) ] N2
N1
−V o
DT
Lx
(2)

The voltage across the magnetizing inductance Lm is also V s , resulting in

V s DT
∆ iL = (3)
m
Lm

Equations (2) and (3) show that the current is increasing linearly in both L x and Lm while the
switch is closed. The current in the switch and in the physical transformer primary is

i sw = i 1 + i L m
(4)

Analysis for the Switch Open

Figure 3 shows the circuit with the switch open. The currents in L x and Lm do not change
instantaneously when the switch is opened. Continuity of i L establishes i 1 = i L . Looking at the
m m

transformation from winding 1 to 2, current out of the dotted terminal on 1 would establish
current into the dotted terminal on 2, but diode D 1 prevents current in that direction.
 Figure 3. Circuit for switch open

For the transformation from winding 1 to 3, current out of the dotted terminal of winding 1
forces current into the dotted terminal of winding 3. Diode D 3 is then forward-biased to provide
a path for winding 3 current, which must go back to the source.

When D3 is on, the voltage across winding 3 is established at

v3 = −¿ V s

With v3 established, v1 and v 2 become

v1 = v3
( )
N1
N3
= −¿ V s
N1
N3 ( )
v 2 = v3
( )
N2
N3
= −¿ V s
N2
N3 ( ) (5)

With D1 off and positive current in L x, D 2 must be on. With D 2 on, the voltage across L x is

di L
v L = −¿ V o = L x x

dt
x

resulting in

di L −V o ∆ i L ∆ iL
x
= = = x x

dt L ∆t (1−D)T

−V o (1−D)T
( ∆i L )open = (6)
x
Lx

Therefore, the inductor current decreases linearly when the switch is open.

For steady-state operation, the net change in inductor current over one period must be zero.
From Eq. (2) and (6),

(∆i L )closed + ( ∆i L )open = 0

x x
 [( ) ]
Vs
N2
N1
−V o
DT
Lx
−¿
V o (1−D)T
Lx
=0

Solving for V o ,

Vo = Vs D
( )
N2
N1
(7)

Note that the relationship between input and output voltage is similar to that for the buck dc-dc
converter except for the added term for the turns ratio. Current in L x must be continuous for Eq.
(7) to be valid.

Meanwhile, the voltage across Lm is v1 , which is negative, resulting in

v L = v1 = −V s
m
( )
N1
N3
= Lm
di L
dt
m

di L
dt
m
= −¿
V s N1
Lm N 3 ( ) (8)

The current in Lm should return to zero before the start of the next period to reset the
transformer core (return the magnetic flux to zero). When the switch opens, Eq. (8) shows that
i L decreases linearly. Since D3 will prevent i L from going negative, Eq. (8) is valid as long as
m m

i L is positive. From Eq. (8),

m

∆ iL
∆t
m
= −¿
V s N1
Lm N 3 ( ) (9)

For i L to return to zero after the switch is opened, the decrease in current must equal the
m

increase in current given by Eq. (2). Letting ∆ T x be the time for i L to decrease from the peak
m

back to zero,

∆ iL
∆Tx
m
= −¿
V s DT
Lm
= −¿
V s N1
Lm N 3 ( ) (10)

Solving for ∆ T x,

∆ T x = DT
( ) N3
N1
(11)

The time at which the current i L reaches zero t 0, is

m

t 0 = DT + ∆ T x = DT + DT
( ) N3
N1
= DT 1+(N3
N1 ) (12)

Because the current must reach zero before the start of the next period,

t0 < T

s DT 1+ ( N3
N1
<T) (13)
 D 1+ ( )
N3
N1
<1

For example, if the ratio N 3/ N 1 = 1 (a common practice), then the duty ratio D must be less than
0.5. The voltage across the open switch is V s −¿ v1 , resulting in

for DT <t< t 0
v sw = ¿ (14)
for t 0< t<T

Figure 4. Current and voltage waveforms for the forward converter

Forward converter current and voltage waveforms are shown in Fig. (4).

The circuit configuration on the output of the forward converter is the same as that for the
buck converter, so the output voltage ripple based on an ideal capacitance is also the same.

∆Vo 1−D
= (15)
Vo 8 Lx C f 2
The equivalent series resistance of the capacitor often dominates the output voltage ripple. The
peak-to-peak voltage variation due to the ESR is

∆ V o , ESR =∆ i C r c = ∆ i L r c =
x
[ V o (1−D)
Lx f ]rc (16)

where Eq. (6) is used for ∆ i L .

x

Summary of Forward Converter Operation

When the switch is closed, energy is transferred from the source to the load through the
transformer. The voltage on the transformer secondary is a pulsed waveform, and the output is
analyzed like that of the buck dc-dc converter. Energy stored in the magnetizing inductance
while the switch is closed can be returned to the input source via a third transformer winding
while the switch is open.
 SECTION 2

MANUAL CALCULATION

The Forward Converter has following parameters:

V¿ = 100 V
Vo = 19 V
Io = 3.5 A
Duty cycle (D = D max ) = 0.45
Switching frequency ( f s) = 60 kHz

Circuit:

Figure 5. Forward Converter Circuit

Component:
SW : MOSFET IRFP460
D 1 = D2 : MUR 1560 (Ultra-Fast Recovery Diode)
D3 : FR307 (Fast Recovery Diode)
Inductor ( L x) : Ferrite Core PQ 3230 with cross sectional are ( Ac = 1.61 cm 2);
Bobbin diameter ( Dbob 1 = 16 mm)
Transformer (TR) : Ferrite Core PQ 3535 with cross sectional are ( Ac = 1.96 cm 2);
Bobbin diameter ( D bob 2 = 17 mm)
Co : Output capacitor (calculation), 50 Volt
R s1 : Snubber resistor (4.3k, 5-10 watt)
Cs1 : Snubber capacitor (0.00047 μF, 1kVolt)
Ds : Snubber diode (FR307 (Fast Recovery Diode)
A. High Frequency Inductor Design
 Output voltage
N
Vo = V¿×D × 2
N1
N2
19 = 100 × 0.45 ×
N1
N2
19 = 45 ×
N1
N 2 19
=
N 1 45
N2 1
=
N 1 0.422

 Filter inductor
1 1
T = = = 1.667 × 10−5 = 16.67 × 10−6 s
f 60 k
∆ i Lx = 20%× I o = 20% × 3.5 = 0.7
V o × ( 1−D ) ×T
Lx =
Δ i Lx
−6
19× ( 1−0.45 ) ×16.67 ×10
=
0.7
= 0.000248859 H
= 0.248859 mH

 Maximum inductor current

Vo 19
R = = = 5.429
Io 3.5
V 19
i L x(avg) = o = = 3.5
R 5.429
∆ i Lx
i L x(max ) = i L x(avg) +¿
2
0.7
= 3.5 +¿
2
= 3.85

 Winding number of inductor

Lx × i L x(max)
n = × 104 ; Bmax = 0.25 Tesla; Ac = in cm 2
B max × Ac
0.248859× 10−3 ×3.85
= × 104
0.25 ×1.61
= 23.8039 ≈ 24 windings

 Wire size is based on RMS current of inductor

√ ( )
2
Δi Lx
i L x(rms)t = 2 2
( i L x (avg )) + √ 3
 √ ( )
2
0.7
= 2 2
3.5 +
√3
= 3.50583 A

 Calculation of wire size

 Cross sectional area of wire
i Lx (rms)t
q w( Lx) = ; J = 4.5 A/mm2 (current density)
J
3.50583
=
4.5
= 0.77907 mm2
 Diameter of wire (d w )
d w (Lx) 4
×q=
√
❑ w ( Lx )
= 4 ×0.77907
❑ √
= 0.995963 mm
 Recalculate by assuming diameter of split wire = 0.25 mm2
d w (t )split =
1
√ 4
×q
❑ w (t ) split
q w (t ) split = × π × d w (t )split ²
4
1
= × π × 0.25²
4
= 0.0490874 mm2
i L(rms)split
q w(t )split = ; J = 4.5 A/mm2 (current density)
J
i L(rms)split q
= w (t ) split × J
= 0.0490874 × 4.5
= 0.2208933 A
i L(rms)t
i L(rms)split =
∑ split
i L(rms)t
∑ split =
i L(rms)split
3.50583
=
0.2208933
= 15.8711467
≈ 16 split

 Wire size
D bob 1 = 16 mm = 1.6 cm
Circumference of bobbin ( K bob 1) =  × D bob 1
=  × 1.6
= 5.02655 cm
Total wire length = ( (winding) × K bob 1 × ∑split ) + 40% × (n(winding) × K bob 1 × ∑split )
n
= (23.8039 × 5.02655 × 16) + 40% × (23.8039 × 5.02655 × 16)
= 1914.424 + 40% × 1914.424
= 1914.424 + 765.7696
= 2680.1936 cm
= 26.801836 m ≈ 27 m
B. High Frequency Transformer Design
 Output voltage
N
Vo = V¿×D × 2
N1
N2
19 = 100 × 0.45 ×
N1
N2
19 = 45 ×
N1
N 2 19
=
N 1 45
N2 1
=
N 1 0.422

 Number of primary winding

V ¿(min) = V ¿ −¿ (10% × V dc(¿))
= 100 −¿ (10% × 100)
= 100 −¿ 10
= 90 V
V ¿(min) × Dmax
N 1 (min) = × 104 ; Bmax = 0.25 Tesla; Ac = in cm 2
A c × B max × f × η
90× 0.45
= × 104
1.96× 0.25 ×60000 ×85 %
= 16.20648
N1 = 1.5 × N 1 (min)
= 1.5 × 16.20648
= 24.30972 ≈ 25 turns

 Number of secondary winding

V o × N1
N2 =
V ¿(min) × D
19× 24.30972
=
90 × 0.45
= 11.40315 ≈ 12 turns

 Number of tertiary winding

N 3 = N 1 = 24.30972 ≈ 25 turns

 RMS primary current

Pout = V o × I o = 19 × 3.5 = 66.5 W
1.2× Pout
I1 =
η× V ¿(min) × D max
1.2× 66.5
=
85 % × 90× 0.45
= 2.31808 A
For example, using 0.579A wire with diameter of 0.4mm.
2.31808 A
I1 =
0.579 A
= 4.0035924
 ≈ 5 split

 RMS secondary current

N1
I2 = × I1
N2
24.30972
= × 2.31808
11.40315
= 4.94178 A
For example, using 0.579A wire with diameter of 0.4mm.
4.94178 A
I2 =
0.579 A
= 8.535026
≈ 9 split

 RMS tertiary current

I 1 (rms)
I3 =
10
2.31808
=
10
= 0.231808 A
For example, using 0.579A wire with diameter of 0.4mm.
0.231808 A
I3 =
0.579 A
= 0.400359
≈ 1 split

 Primary wire size

d1 =
√ 4 × I 1(rms)
×s
; s = 4.5 A/mm2

=
√
4 ×2.31808
× 4.5
= 0.809866 mm

 Secondary wire size

d2 =
√ 4 × I 2(rms)
×s
; s = 4.5 A/mm2

=
√
4 × 4.94178
×4.5
= 1.18247 mm

 Tertiary wire size

d3 =
√ 4 × I 3 (rms)
×s
; s = 4.5 A/mm2

=
√
4 × 0.231808
× 4.5
= 0.256102 mm
  Inductor magnetizing of transformer
V ¿(min) × D ×T

( )
Lm = N2
20 % × i 1+ ×i
N1 2
−6
90 × 0.45× 16.67 ×10
=
( 19
20 % × 2.31808+ × 4.94178
45 )
= 0.000766396 H
= 0.766396 mH
 Length of wire
Diameter of bobbin PQ3535 ( D bob 2) = 17 mm = 1.7 cm
Circumference of bobbin ( K bob 2) =  × D bob 2
=  × 1.7
= 5.34071 cm
P1 = ( N p × K bob 2 × split) + 30%
= (24.30972 × 5.34071 × 4) + 30%
= 519.62466 cm
= 5.1962466 m
P2 = ( N s × K bob 2 × split) + 30%
= (11.40315 × 5.34071 × 4) + 30%
= 243.90367 cm
= 2.4390367 m
P3 = ( N t × K bob 2 × split) + 30%
= (24.30972 × 5.34071 × 4) + 30%
= 519.62466 cm
= 5.1962466 m

 Pattern of winding
Primary =5
Secondary =9
Tertiary =1
P1-S1-S2-P2-S3-S4-T1-P3-S5-S6-P4-S7-S8-P5-S9
When additional winding is added, it becomes as follows.
P1-S1-S2-P2-S3-S4-T1-P3-S5-S6-P4-S7-S8-P5-S9-P6-S10-T2-P7-S11-T3-P8-S12-T4

C. Filter Capacitor Output

∆V o = ±0.1% × V o
= 0.001 × V o
= 0.001 × 19
= 0.019 V
∆Vo
rV o =
Vo
0.019
=
19
= 0.001
1−D
rV o = 2
8 × Lx ×C o × f
 1−D
0.001 = 2
8 ×0.00024885 ×C o × 60000
1−0.45
Co = 2
8 ×0.00024885 ×0.001 ×60000

= 7.67419 × 10−5 F
= 76.7419 × 10−6 F
= 76.7419 µF

D. Design of Snubber Circuit

 Snubber capacitor
I o × t fall
Cs =
2× V off
−9
3.5× 25 ×10
=
2 ×100
= 4.375 × 10−10
= 0.0004375 × 10−6
= 0.0004375 μF ≈ 0.00047 μF
Snubber capacitor value can be chosen by 0.00047 μF.

 Snubber resistor
D× T
Rs ¿
2× C s
0.45× 16.67 ×10−6
¿
2 × 4.375× 10−10
¿ 8573.142857
Rs ≈ 4250
Snubber resistor value can be chosen by 4.3k.
 SECTION 3

DESIGN OF FORWARD CONVERTER

A. Schematic Circuit of Forward Converter

Figure 6. Schematic Circuit of Forward Converter

B. Board Circuit of Forward Converter

Figure 7. Board Circuit of Forward Converter

C. Schematic Circuit of PWM

Figure 8. Schematic Circuit of PWM

D. Board Circuit of PWM

(a)

(b)
Figure 9. Board Circuit of PWM (a) bottom view, (b) top view
 SECTION 4

FORWARD CONVERTER RUNNING TEST

A. Equipment and Material

B. Figure of Circuit
C. Testing Procedure
D. Partial Test
1. PWM test
Table 1. PWM testing result

No Duty Cycle Frequency PWM wave

1 25% 60 kHz

2 35%

3 45%

4 55%

5 65%
2. Inductor Test

Figure 10. Inductance and Q factor testing

L=257.18 µH
Q=2543
3. Transformer Test
a. Magnetizing Inductance ( Lm)

Figure 11. Magnetizing Inductance testing

Lm= 3.0613 mH

b. Leakage Inductance ( Lk )

Figure 12. Magnetizing Inductance testing

Lk= 0.00314 mH
 c. Testing of turn winding ratio

Figure 13. Ratio of N2/N3

Figure 14. Ratio of N1/N3

E. Integrated Test
F. Data Analysis
In this practicum, we are fabricating a Forward DC-DC Converter, an electronic tool that
convert DC power to DC power with lower or higher output voltage that utilize galvanic
isolation or transformer. The rate of the Forward DC-DC Converter that we made is given
below:

V¿ = 100 V
Vo = 19 V
Io = 3.5 A
Duty cycle (D = D max ) = 0.45
Switching frequency ( f s) = 60 kHz

The first thing that we do is that designing the PWM Generator. PWM generator that we
made is that an analog kind of thing, we don’t use microcontroller here. The design of the
analogue PWM generator could be seen from the figure 8 and figure 9. To establish this circuit,
we need IC Timer NE555. This IC produces ramp voltage signal that is compared to the DC
voltage signal that could produce pulse with duty cycle ranging from 0-100%. The output of the
pin number 2 of the IC Timer NE555 that produce ramp wave signal will be compared to DC
voltage that produced by the modified voltage divider by using LM393 Comparator. Next, there
is a driver mosfet circuit that is established from the totempole configuration (double emitter
follower) of the BD139 and BD140 BJT. This driver is used to drive the mosfet switching since
the output of the microcontroller is unable to do that.

The testing of the PWM circuit is resulting into the data shown in table 1. We use constant
frequency 60 kHz with varied Duty Cycle, 25%, 35%, 45%, and 65%. The table shows the
pictures of the PWM pulses for every duty cycle rate. It could be seen that the width of the pulse
that indicates the t on and the t o ff of the PWM is correlated to the number of the duty cycle set.
The higher the duty cycle set, the higher the t on obtained. In the other side, the lower the duty
cycle set, then the t off will be higher.

In designing the forward converter circuit, we should fabricate the Inductor and the Transformer
first. From the testing process, it is found that the inductor has already fulfilled the prerequisite
of the expected inductor, those are L=0.25718 mH and Q=2543. Measured Inductance L has
been equal to the calculated L= 0.248859 mH, meanwhile Q factor is already >1000, which is
good already. For the transformer, it also has already fulfilled the prerequisite of the expected
transformer, those are L m=3.0613 mH and Lk=0.00314 mH . Measured Inductance Lm has
been more 1 mH, meanwhile Lk is already < 3% Lm, which is good already

G. Conclusion
Datasheet IRFP460 N-Channel 500V - 0.22 Ω - 20A - TO-247
STMicroelectronics
Datasheet MUR1560 Ultrafast Rectifiers 15A, 100−600V
ON Semiconductor