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Push-Pull Converter Design and Circuit

This document summarizes the design of a push-pull converter circuit to step up a 12V DC input to 325V DC with 1KW of output power. It uses a KA3525 controller at a switching frequency of 21.6kHz. Component selections and calculations are shown for the transformer, MOSFET timing, primary and secondary windings, and output inductor to filter the voltage. Wire gauges are selected based on the current densities calculated for the primary and secondary windings and inductor.

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chinnathambij
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1K views

Push-Pull Converter Design and Circuit

This document summarizes the design of a push-pull converter circuit to step up a 12V DC input to 325V DC with 1KW of output power. It uses a KA3525 controller at a switching frequency of 21.6kHz. Component selections and calculations are shown for the transformer, MOSFET timing, primary and secondary windings, and output inductor to filter the voltage. Wire gauges are selected based on the current densities calculated for the primary and secondary windings and inductor.

Uploaded by

chinnathambij
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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PUSH PULL CONVERTER DESIGN AND CIRCUIT

Written by

GEORGE LEON
Nagercoil, India.
[email protected]

The circuit and calculation given are to step up 12V DC supply to 325V DC to deliver 1KW
Power. KA3525 push-pull SMPS controller is used. If the output is used for pure sine wave
inverter then output filter capacitor should be 2.5 times output power. Use 16 Sq mm copper
cable of length less than 1m each to connect battery with converter.

Ferrite core selected for Transformer: E 65/32/27


Area of ferrite core Ae = 540 mm2
Max flux density Bm = 0.1 Wb/m2 (for push-pull configuration)
Air gap = 0
Timing resistor RT = 3.3 KΩ
Timing capacitor CT = 0.01 µF
Dead time resistor RD = 0 Ω
Maximum duty cycle Dmax = 49 %
Frequency of oscillator FOSC = 1 / (CT (0.7 x RT + 3 x RD))
= 1 / (0.01x10-6 x (0.7 x 3.3x103 + 3 x 0))
= 43.2 KHz
Switching frequency Fs = FOSC / 2
= 43.2 / 2
= 21.6 KHz
Switching time period T = 1 / Fs
= 1 / 21.6x103
= 46.2 µS
T/2 = 23.1 µS
Minimum input voltage Vmin = 10.5V
Drain source on voltage VDS (on) = 1V
Primary turns Np (min) = Vi x T/2
∆B x Ae
-6
Np(min) = (10.5-1) x 23.1x10
2 x 0.1 x 540x10-6
Np(min) = 2.03 T
Take primary turns Np as 3 Turns per limb.
Output Voltage Vo = 325V
Diode voltage drop Vf = 1V
Secondary Voltage Vs = (Vo + 2 x Vf) / (2 x Dmax)
= (325 + 2 x 1) / (2 x 0.49)
= 334 V
Secondary Turns Ns = Np x Vs / Vi
= 3 x 334 / 9.5
Secondary Turns Ns = 106 Turns

Selection of wire gauge


Output Power = 1000 W
Output Current Io = 1000 / 325
= 3.1 A
Take current density of 5 A/mm2
Secondary wire cross section area = 3.1 / 5 = 0.62 mm2
So 20 SWG wire selected for secondary winding.
Assume efficiency = 85%
Input power = 1000 / 0.85 = 1176 W
Input current = Pi / (Vmin x 2 x Dmax) = 114 A
Per limb Input Current = 114 / 2 = 57 A
As primary turns are only 3, higher current density may be allowed (9 A/mm2).
Primary wire cross section area = 57 / 9 = 6.3 mm2
So 2 x 14 SWG wire selected for primary winding / Limb.

Design of Output Inductor L


Assume the maximum input voltage of 12 V under fully loaded condition
Secondary voltage Vs = Ns x Vi / Np
= 106 x (12-1) / 3
= 389 V
MOSFET on Time Ton = 23.1 X 325 / (389 - 2)
= 19.7 µS
Voltage applied across Output inductor VL = Vs - 2 x Vf - Vo
VL = 389 - 2 - 325
VL = 62 V
Assume Maximum allowed current ripple ∆Io = 0.3 x Io
= 0.93 A
Inductance L = e x dt / di
Output Inductor L = 62 x 19.7x10-6 / 0.93
Output Inductor L = 1.3 milli Henry

Peak Inductor current Ipeak = Io + ∆Io / 2


= 3.1 + 0.93 / 2
Ipeak = 3.6 A
Ferrite core selected for Output Inductor: E 42/21/15
Cross section area Ae = 178 mm2
Saturation flux density Bsat = 0.35 Wb/m2
From datasheet of core AL = 3600 nH/T2
Minimum Inductor Turns N = L x Ipeak / (Bsat x Ae)
= 1.3x10-3 x 3.6 / (0.35 x 178x10-6)
Inductor Turns N = 76 Turns
Air gap required = µo x Ae x ((N2/L) – (1/AL))
= 4 x π x 10-7 x 178x10-6 x ((762 / 1.3x10-3) – (1/3600x10-9))
= 0.93 mm
Per limb Air gap = 0.93 / 2 = 0.465 mm

Same secondary current flows through this inductor also, so the same 20 SWG wire may
be used.

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