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Essential details：810-014025-001 Lam Research voltage input module
The power input voltage has a certain range, for example, China’s power grid voltage is 220VAC, the input range is required to be 165-264VAC, in order to be compatible with the European standard 110VAC, usually the power input voltage range is 85-264VAC. In DC-DC switching power supply applications, there are usually multiple input bus categories, such as the communication industry generally 48VDC input, which ranges from 36-75VDC. The industrial control industry is generally 24VDC and 12VDC, the 24V input range is 18-36VDC, the 12VDC input range is 9-18VDC, the railway industry bus is 110VDC, the input voltage range is 66-160VDC.
Voltages in between are sometimes found, but because of cost, power supply manufacturers are usually reluctant to develop different power supplies for each input voltage. Therefore, a wide power input range is required, and the following describes how to design a power supply with a wide input voltage range.
The requirements are for low power flyback converters from 19 to 265VAC and 19 to 375VDC (in the 500mW range), and the low power flyback reference design requires two outputs. One output rail provides the microcontroller and analog circuit (5.0V at 15mA), while the other provides 12V at 40mA to control the relay. Because the input and two outputs require a 2.5kV isolation voltage, the simple and well-known flyback converter was first thought of.
810-099175-011
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810-014025-001 Lam Research voltage input module
The wide input voltage range is not only a challenge for the controller, but also for the design of the transformer. For low-power applications, flyback converters are designed to operate in discontinuous on-mode (DCCM) in order to achieve small solution sizes because the inductance of coupling inductors is also smaller. The peak currents in this mode of operation are larger than those in continuous on-mode (CCM), but they are still relatively small because of the small power. For higher power applications, flyback converters usually operate in CCM mode. At first glance DCCM seems to be the right mode for this flyback design, with an output power of around 500mW.
In order to avoid large switching losses in the upper range of the input voltage, the switching frequency should be relatively low. In this design, it is set to 130kHz so that the fundamental wave is below the lower limit of electromagnetic interference (EMI) measurement of 150kHz. If the converter is assumed to operate only in DCCM mode, the duty cycle ranges from 70% to 4% (a primary inductor with a turn ratio of 3.58:1,750 μH). To reduce component stress, you should increase the minimum duty cycle by leaving the turn ratio unchanged and changing the primary inductor to 4mH. Now, for low input voltages, the converter operates in CCM mode. For high input voltages, the converter operates in DCCM mode.
