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AN-9737 Datasheet(PDF) 4 Page - Fairchild Semiconductor

Part # AN-9737
Description  Design Guideline for Single-Stage Flyback AC-DC Converter Using FL6961 for LED Lighting
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Manufacturer  FAIRCHILD [Fairchild Semiconductor]
Direct Link  http://www.fairchildsemi.com
Logo FAIRCHILD - Fairchild Semiconductor

AN-9737 Datasheet(HTML) 4 Page - Fairchild Semiconductor

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AN-9737
APPLICATION NOTE
© 2011 Fairchild Semiconductor Corporation
www.fairchildsemi.com
Rev. 1.0.0 • 4/13/11
4
0136
.
0
)
5
.
0
(
00003108
.
0
)
0004608
.
0
(
)
(
2
2
=
=
=
α
e
g
K
ENG
K
[cm
5]
Step 13.
See Table 2 for core size.
To prevent core saturation, select a little big core after
comparing two Kg values: calculate value at Step 12 vs. the
existing value in Table 2.
The PQ-42016 has a little bit big Kg value (0.01327) in
Table 2 with 2500 permeability (µi).
Step 14. Calculate the current density, J.:
265
)
4
.
0
)(
2484
.
0
(
35
.
0
10
)
0004608
.
0
(
2
10
)
(
2
4
4
=
×
=
×
=
u
P
m
K
A
B
ENG
J
[A/cm
2]
Step 15. Calculate the required wire area. AW(B):
001207
.
0
265
32
.
0
)
(
=
=
=
J
I
A
rms
B
W
[cm
2]
Step 16. Calculate the number of turns, N:
93
.
141
001207
.
0
4
.
0
4283
.
0
)
(
=
×
=
=
B
w
u
a
A
K
W
N
[T]
N=141.93; use 142 turns.
Step 17. Calculate the required gap, lg:
0489
.
0
35
.
0
10
)
96
.
0
)(
142
(
4
.
0
10
)
)(
(
4
.
0
4
4
=
×
=
∆
×
∆
=
−
−
π
π
m
g
B
I
N
l
[cm]
Step 18. Calculate the new turns using a gap from Step 15.
153
.
83
)
58
.
0
(
4
.
0
)
10
)(
2500
74
.
3
0489
.
0
(
10
1
)
(
4
.
0
)
(
8
3
=
+
×
=
+
=
−
π
π
µ
c
i
g
A
MPL
l
L
N
[T]
N=83.153; use 83[T].
where
i is permeability of selected core material and
MPL is Magnetic Path Length of selected core.
Step 19. Calculate the fringing flux, F:
238
.
1
)
0489
.
0
)
001
.
1
(
2
ln
58
.
0
0489
.
0
1
(
)
2
ln
1
(
=
+
=
+
=
g
c
g
l
G
A
l
F
where G is window height of selected core.
Step 20. Calculate the new turns, Nnew:
6
.
73
)
238
.
1
)(
58
.
0
)(
4
.
0
(
10
1
0489
.
0
)
10
(
)
)(
4
.
0
(
5
8
=
×
×
=
=
−
π
π
F
A
L
l
N
c
g
[T]
Nnew=73.6; use 74.
Step 21. Calculate the AC flux density in Tesla, BAC:
113
.
0
0489
.
0
)
10
)(
238
.
1
)(
2
96
.
0
)(
74
)(
4
.
0
(
)
10
(
)
2
(
)
4
.
0
(
4
4
=
=
=
−
−
π
π
g
PK
ac
l
F
I
N
B
[T]
Step 22. Calculate the new wire size, AW(B) :
002315
.
0
74
4
.
0
4283
.
0
)
(
=
×
=
=
new
u
a
B
W
N
K
W
A
[A/cm
2]
Step 23. Calculate the skin depth at expected operating
frequency at low input voltage. The skin depth is the radius
of the wire.
02960
.
0
10
50
62
.
6
62
.
6
3
=
×
=
=
f
γ
[cm]
Step 24.Calculate the required wire area under considering
skin depth :
0027535
.
0
)
(
2
=
=
r
Wire
A
π
[cm
2]
Step 25. Select a wire size with the required area from Table
4. If the area is not within 10% of the required area, then go
to the next smallest size.
AWG=#23
AW(B)=0.00259[cm
2]
µ /cm=666
Step 26. Calculate the required number of primary strands,
Snp:
8938
.
0
00259
.
0
002315
.
0
)
(
=
=
=
A
B
w
np
Wire
A
S
This means that the selected wire from the Step 25, AWG23,
is enough or has enough margins for supplying the primary-
side current on the flyback converter.
Step 27. Calculate the secondary and auxiliary turns, Ns
Naux:
05
.
27
)
35
.
0
)(
90
2
(
)
35
.
0
1
)(
1
24
(
74
)
(
)
1
)(
(
max
max
=
×
−
+
=
−
+
=
D
V
D
V
V
N
N
p
d
o
p
s
Ns=27.05; use 27.
31
.
17
)
35
.
0
)(
90
2
(
)
35
.
0
1
)(
1
15
(
74
)
(
)
1
)(
(
max
max
=
×
−
+
=
−
+
=
D
V
D
V
V
N
N
p
d
o
p
aux
Naux=17.31; use 17.
Step 28. Calculate the secondary peak current, Ispk:
153
.
2
35
.
0
1
)
7
.
0
(
2
)
1
(
2
max
=
−
=
−
=
D
I
I
o
spk
[A]
Step 29. Calculate the secondary rms current, Isrms:
0021
.
1
3
)
35
.
0
1
(
153
.
2
3
)
1
(
max
=
−
=
−
=
D
I
I
spk
srms
[A]
Step 30. Calculate the secondary wire area, Asw(B):
003781
.
0
265
0021
.
1
)
(
=
=
=
J
I
A
rms
B
SW
[cm
2]
Step 31. Select a wire size with the required area from Table
4. If the area is not within 10% of the required area, go to
the next smallest size.


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