2023 IEEE 14th International Symposium on Power Electronics for Distributed Generation Systems
A High-Efficiency Multiple Output Flyback
2023 IEEE 14th International Symposium on Power Electronics for Distributed Generation Systems (PEDG) | 979-8-3503-2823-3/23/$31.00 ©2023 IEEE | DOI: 10.1109/PEDG56097.2023.10215295
Converter Based on Variable Width Winding Planar
Magnetics
Yixuan Xu Shaoliang An
Department of Electronics: Department of Electronics:
Xi’an University of Technology Xi’an University of Technology
Xi’an, China Xi’an, China
1071406921@qq.com shaoliang.an@xaut.edu.cn
Qing Wu
Department of Electronics:
Xi’an University of Technology
Xi’an, China
Abstract—This paper introduces the principle of DCM active
clamp Flyback converter based on transformer leakage inductor
resonance. Using transformer leakage inductor resonance can
further reduce the volume and core loss of the system. The design
method of variable width winding planar transformer is
introduced in detail. The theory of variable width winding is
proved. Advantages of variable width winding are compared with
constant width winding. Finally, an active clamp Flyback
converter with six outputs is designed to verify the feasibility of
the variable width winding theory.
Keywords—multiple-output converter, variable width winding,
multiwinding planar transformer
I. INTRODUCTION
There have been many multiple output auxiliary power
supply topologies, including Forward converter, Half-bridge
converter, Pushpull converter, Flyback converter, etc. Flyback
converter has the advantages of a simple circuit, small size and
simple driving circuit. The traditional multiple output Flyback
converter works in the hard switching mode, it mostly works
below the switching frequency of 100kHz. Therefore, it has a
lot of turns and low efficiency. With the rapid development of
printed circuit board (PCB) technology, low height switching
power supplies have attracted extensive attention. PCB
transformer can not only reduce the size of the converter, but
also improve the efficiency and controllable parasitic
parameters of the transformer through the auto-mated
manufacturing process. However, the high cost caused by too
many PCB layers limits the application of PCB transformers in
switching power supplies. With the application of active clamp
Flyback converter, the performance of multiple output auxiliary
power supply are significantly improved.
979-8-3503-2823-3/23/$31.00 ©2023 IEEE
Authorized licensed use limited to: Vladimir Alexiev. Downloaded on January 14,2024 at 10:48:14 UTC from IEEE Xplore. Restrictions apply.
Shaogang An Yuhao Wu
Department of Electronics: Department of Electronics:
Xi’an University of Technology Xi’an University of Technology
Xi’an, China Xi’an, China
Qi Zhang
Department of Electronics:
Xi’an University of Technology
Xi’an, China
The primary and secondary winding of Flyback trans-
former cannot flow current at the same time. First, energy is
stored inside the core material by the primary winding. Second,
this energy is transferred to the secondary side windings when
primary side turn off. Therefore, the classic transformer
relationships and primary-to-secondary turns ratios do not
apply directly. The most critical disadvantage of this converter
is that high ripple currents flow in the trans-former. This
drawback often cause Flyback converter is designed at power
levels below 150W.
This Flyback converter is mostly useful for multiple-output
applications where isolated outputs are required from a single
supply, because it provides isolation between branches. But the
transformer problem of large volume and low efficiency caused
by multiple output Flyback converter has been troubling people.
At high frequency, the application of planar transformer
provides a solution to solve the problem of transformer size and
efficiency.
In [1], a 65W Flyback converter with single output is
designed using PCB transformer. The maximum efficiency of
the whole machine reaches 93.2%. In [2], a Forward convert
using planar transformer is designed as a multiple output
auxiliary power supply. The maximum efficiency of the whole
machine reaches 86.8%.
This paper introduces an active clamp Flyback converter
with six outputs. The circuit structure is shown in Fig. 1.
The main benefits of Flyback converter with active clamp
circuit are summarized as follows [1].
⚫ When the main switch is turned off, the drain-source
voltage is clamped to prevent the voltage overshoot of
the main switch.
773
 ⚫ ZVS can be achieved for both main switch and clamp secondary side voltage and the resonance only generates
switch by magnetizing current. The dv/dt is Significantly between the leakage inductance and the clamping capacitor.
reduced and therefore the common-mode noise is also
reduced. Model5:(t5-t6):At t5,magnetic current iLm is equal to leakage
inductance current iLk. the current flowing across LLk begins to
Lk decrease from iLk(t5).inductance Lm is not clamped and starts to
participate in resonance. At t6 the current resonates to the
D1 C1 R1 negative peak value,then this mode end.
C clamp Q1
Model6:(t6-t7):From t6, capacitor Cds of Q2 is discharging.At
t7,the capacitor voltage drops to zero. But the current iLk is still
Vin negative, so body diode of Q2 starts to conduct until the next
D2 C2
R2 switching cycle achieves ZVS.
Q2
This kind of active clamp Flyback under DCM can transfer
leakage inductive energy to the secondary side. And ZVS of
D3 C3
R3 both switch can be realized without additional resonant inductor.
It can further reduce the loss and improve the efficiency of the
coverter.
D4 D5 C5
C4 R5 In this paper, aiming at the magnetic components in active
R4 clamp Flyback converter.Firstly, a suitable type of magnetic
C6
D6 R6 core and magnetic material are selected. Secondly, The design
of variable width winding has been depicted in detail. Then, the
Fig. 1. Circuit Diagram of ACF
width of transformer winding are optimized using variable
width winding theory.Compared with the constant width
winding design, the improved transformer has more advantages
Q2 Q1 Q2 Q1
in efficiency.
Vgs
II. TRANSFORMER DESIGN
A. Selection of Core
1000
Vds(Q2) 100
Power Loss Pv(kW/m3)

100

iLm

10
DEMGC-DMR95
Ferroxcube-3C95
i Lk Ferroxcube-3C97
Ferroxcube-3F36
ic DMEGC-DMR50
1
10 100
Flux Density B(mT)

Fig. 3. Core loss of 5 materials under 400kHz

isec
t1 t2 t3 t4 t5 t6 t7

Fig. 2. Waveforms of schematic

Fig. 2 shows the waveform of the active clamp Flyback

converter. The following will briefly describe the principle of
DCM active clamp Flyback converter.
Model1:(t1-t2):At t1,Q2 turn on.The current iLm rises linearly. Fig. 4. EL type Fig.5. ER type
At this stage, the primary inductor stores energy.
Model2:(t2-t3):At t2, Q2 turn off and Secondary rectifier
diode neither turn on. Vds(Q2) begin to rise until Vclamp.
Model3:(t3-t4):From t3,The body diode of Q1 turn on. the
leakage inductor current iLk flow continuously through the body
diode to charge the clamping capacitor Cclamp.
Fig. 6. EI type Fig.7. EIR type
Model4:(t4-t5):At t4 ,Q1 turn on in ZVS and the secondary
side rectifier diode turn on , Lm voltage is clamped by the

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 It is very important to select the transformer core material at Let the turns N=2, assume that the inner radius of the inner
high frequency. Core loss is one of the key constraints. Fig. 3 winding is r, the outer radius of the outer winding is R, the outer
shows the relationship between the loss per unit volume and the radius of the inner winding is x,  is copper resistivity, h is
magnetic flux density of different magnetic core materials in copper thickness.
400kHz. All materials are Mn-Zn ferrite in Fig. 3.
The independent impedance expressions (3) and (4) of the
DMR50 core material of DMEGC has the lowest power loss two turns winding are listed respectively. (5) is a continuous
per unit volume when the magnetic flux density is function related to x. Calculate the first derivative and the
10mT~100mT, so the magnetic core material of transformer in second derivative of (5) respectively. According to the extreme
this paper choose DMR50. value theorem, when the first derivative of the function RDC-2 is
The magnetic core structure commonly used in planar equal to 0, the value of x is called the stationary point of the
transformers is shown in Fig. 4~Fig. 7 such as EL type, ER type, function. When the second derivative of the function R DC-2 is
EI type, EIR type. Compared with the other three types of cores, calculated at the stationary point, and its derivative is greater
the ER type core has a circular column, the circumference of than 0, it can be known that this is the minimum point of the
the circular middle column is the shortest under the same cross- function. The minimum value of impedance can be obtained.
sectional area, so the winding impedance is the smallest. The expressions of the first and second derivative of the
Therefore, the core shape of the Transformer in this paper select function are shown in (6) and (7).
ER type [3].
2π
B. Winding Optimization Method ρ
h (3)
The winding impedance can be optimized by changing the RDC1 =
ln x − ln r
width and thickness of the transformer winding. For planar
transformers, there are multiple turns on one layer of PCB.In
this paper,the design of variable width winding is one of the 2π
ρ
methods to realize its impedance optimization. h (4)
RDC 2 =
ln R − ln x
The single circular winding is shown in Fig. 8, and the
impedance is calculated by the microelement method.
2π 2π
ρ ρ
2 x RDC _ 2 = h + h
dRDC ( x) =  (5)
(1) ln x − ln r ln R − ln x
h dx
1 1
2 2 2 2
  dRDC _ 2 x(ln( R) − ln( x))2 x(ln(r ) − ln( x)) 2
= − (6)
RDC = h = h (2) dx h h
R1 ln R − ln r
r x dx
 1 2 
2  2 − 2 3
d 2 RDC _ 2  x (ln(r ) − ln( x))
2
x (ln( r ) − ln( x)) 
The DC impedance expression of a single winding is shown =
in (2), which is an equation about the inner diameter r and the dx 2 h (7)
outer diameter R.  1 2 
2  2 − 2 3
 x (ln( r ) − ln( x )) 2
x (ln( R ) − ln( x )) 
The design theory of variable width winding is proved by −
mathematical induction and extreme value theorem following h
[6]-[8]. The following three conditions shall be assumed.
It can be obtained that the radius ratio
1. The gap between windings is not considered.
2. Connection between windings is not considered. R 1
kideal _ 2 = ( ) 2 (8)
r
3. This windings are concentric current path.

N+1
N
2
1
dx r
r r1 x1
x
x
R R R1

Fig. 8. Winding diagram

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 Calculate the minimum DC impedance of the two turns s R
k N + (k N −1 + k1 ) = (16)
r r
2π 2 2
RDC _ 2 _ Min = ρ ( ) (9) The function can be solved by using mathcad. Given
h ln R − ln r
R=13.85mm and r=6.4mm, when N=4,5 and 6, the relationship
Set the minimum DC impedance of N turns as: between different conductor spacing is shown in Fig. 9.

1.3
2  N2 N=6
RDC _ N = ( ) (10) 1.25 N=5
h ln x1 − ln r1 N=4

Radius Ratio k
1.2
As shown in Fig. 10, the DC impedance of N+1 turns is:
1.15
2π N 2
1
RDC _ N +1 = ρ ( + ) (11) 1.1
h ln( x1 ) − ln(r1 ) ln( R1 ) − ln( x1 )
1.05
0 0.2 0.4 0.6 0.8
For (12), respectively calculate the stationary point and the conductor spacing(mm)
second derivative at the stationary point. At this moment, the
impedance reaches the minimum value. The minimum point of Fig. 9. Effect of conductor spacing on radius ratio
its function can be obtained as follows.
lgap lgap
r Sec2
R N R
Insulator
Sec3
x1 = ( 1 ) N +1 r1 (12) Insulator

r1 Insulator
Pri
Sec1
Insulator
Pri
At this time, the minimum impedance of the N+1 turns and
Insulator
Sec5
the radius ratio of the N+1 windings are obtained as follows:
Insulator
Sec6
Insulator
Pri
Insulator
Sec4
2π ( N + 1) 2
RDC _ N +1_ M in = ρ ( ) (13)
h ln( R1 ) − ln(r1 )
Fig. 10. Transformer winding instructure

R1 N1+1 TABLE I. DIFFERENT LAYER WINDING RADIUS RATIO

kideal _ N +1 = ( ) (14)
r1
N=6 N=4 N=3 N=2

Suppose the radius ratio of 1~N+1 turns is kideal _ N +1 .At this

1.097 1.174 1.257 1.44
time, the impedance of the DC winding is RDC _ N +1_ M in .The
radius ratio of the N turns is equal to that of the N+1 turns as
(15). According to Fig. 9, it can be seen that when the conductor
spacing is less than 0.8mm, its radius ratio error is less than
R1 NN+1 6.5%, so the above conclusion is still applicable in actual
1
(
) r1 1 conditions.
x r1 R 1 (15)
kideal _ N = ( ) =（
N
）N = ( 1 ) N +1 = kideal _ N +1
r1 r1 r1 Aiming at a Flyback converter with six outputs, in order to
optimize the loss caused by the large number of turns of
The following conclusions can be drawn from the above Flyback transformer with the adoption of the conventional
proof: under ideal conditions, when the winding radius ratio is magnetic core ECW32C. The width of transformer winding is
R 1 optimized. The design method is variable width winding.
satisfied kideal = ( ) N , the DC impedance of a layer of the According to (16), determining the values of R and r is to
r
determine the actual available window width of the transformer
winding is minimum. Where R is the outer diameter of the
winding. When designing transformer windings, the calculation
outermost winding, r is the inner diameter of the innermost of available window width needs to consider the air gap
winding, and N is the number of turns of a layer. As for the avoidance, in order to reduce the AC winding loss of
actual situation, the conductor spacing cannot be ignored, so the transformer windings. Generally, the width of air gap avoidance
radius ratio of the winding should be set as k in the actual is 3~5 times air gap length [14]. The distribution of the winding
situation and k can be obtained by the following equation. and the number of turns are shown in Fig. 10.

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 s R − 5lgap
kN + (k N −1 + k1 ) = (17) Switch frequency 180kHz~300kHz
r + 5lgap r + 5lgap
Primary inductance 180uH
0.12

0.1 Variable width Vin 90VAC~220VAC

DC Resistance(Ω)

Constant width
0.08
VO1 5V 0.75W
0.06
VO2 24V 2.4W
0.04

0.02 VO3 18V 9W

0
0 1 2 3 4 5 6 7 Auxiliary winding 18V
turns number n

Fig. 11. Impedance comparision VO5 +12V 6W

VO6 -12V 6W

Hardware circuit parameters are shown in the Tab. 2. The

winding structure of the transformer and the radius ratio of each
layer have been given in the previous section.

Fig. 12. Winding loss

Consider the radius ratio after the air gap avoidance as

shown in (17). According to the above variable winding width
design theory, Calculate the radius ratio of different winding
layers about Fig. 10.
At the same time, the impedance of the DC winding Fig. 13. Hardware platform
designed in constant width winding is calculated. with the
increase of winding turns, the impedance of DC winding in
variable winding width design has obvious advantages 12mm
compared with that in constant winding width design in Fig. 11,
which can effectively reduce the winding loss of transformer 31.8mm
and improve the efficiency of converter. This theory is very
suitable for converters with more turns. In order to further
verify the feasibility and superiority of variable width winding Fig. 14. Transformer master view
optimization, a 3D model of the designed is built.The loss of
different winding in the single layer is maintained at a low level,
and the winding loss is evenly distributed.
III. IMPLEMENTATION
With the aim to verify the theory of variable width winding,
The six outputs active clamp Flyback converter hardware
platform is built.

TABLE II. HARDWARE PARAMETER

Basic parameter Value Power

Fig. 15. Primary inductance

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 The hardware circuit is shown in Fig. 13. the PCB area of
Fig. 13 is about 63.5mm × 54.1mm and the height of the
machine is 12mm. The main view of the transformer is shown
in Fig. 14. It can be applied to the occasions where the converter
height is strictly required. The experimental platform is
composed of transformer winding PCB and main power PCB.
The winding PCB consists of two six-layer boards, and the
main power PCB is a single four-layer board. The primary
inductance of the transformer was measured by R-L-C tester at
300kHz shown in Fig. 15 and the test value meets the
theoretical design requirement.
Respectively, it is tested at the lowest input voltage and the
highest input voltage. First, it is measured at the lowest input
voltage of 140V. Then, the output power is 12W (Six outputs
Ipri
(1A/div)
VDS
(50V/div)
VGS
(5V/div)
Fig. 16. Vin=140V,Main experiment waveforms in half load
Ipri
(1A/div)
VDS
(50V/div)
VGS
(5V/div)
Fig. 17. Main experiment waveforms in full load
V06
(5V/div)
Vo1
(5V/div)
Fig. 18. Vin=140V,Full load output voltage test waveform
IV. CONCLUSION
In this paper, a multiple output active clamp Flyback
converter is studied. Because of its advantages of low cost,
small size, easy to realize, it is often used in the design of
auxiliary power supply in the low-power field under 150W. For
planar magnetics, the variable width winding structure was
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with half load.). Fig. 16 shows the main experiment waveform
in half load. The blue waveform is the primary current, the
green waveform is the drain-source voltage, and the yellow
waveform is the drive voltage of the switch. This six outputs
active clamp Flyback converter works stably and normally.
ZVS can be realized for each switching cycle. In Fig. 17, The
converter operates at minimum input voltage or maximum input
voltage. The converter can realize soft switching in a wide input
voltage range respectively Then, the output power reaches
29.25W.Fig. 18 shows the output voltage of the main outputs,
when Vin=140V and all six outputs are full load. At this point,
the converter efficiency reaches 89.9%. Because of the
Secondary side use diode rectifier, the efficiency of the multiple
output Flyback converter is not very high. It can be further
optimized.
Ipri
(1A/div)
VDS
(50V/div)
VGS
(5V/div)
Ipri
(1A/div)
VDS
(100V/div)
VGS
(5V/div)
V03
(5V/div)
Vo2
(10V/div)
proved in this paper, which can greatly reduce the
corresponding resistances. Finally, a hardware experiment
platform is built to verify the superiority of the optimization
method. The efficiency of multiple output Flyback converter is
improved significantly. Variable width winding optimization
theory is very suitable for the application of multiple output
Flyback converter.
 ACKNOWLEDGMENT
Thanks to DMEGC. for supporting the transformer sample
of this subject. Here, I would like to express my heartfelt thanks
to the staff in each link of sample production and I wish the
company have a prosperous future.
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