A novel regenerative snubber circuit for flyback topology converters

1. Introduction

The improvements in power semiconductors and magnetic components make converters based on flyback topology more efficient and hence make it more attractive to implement flyback topology into practical applications. Flyback topology finds broadening usage due to its low component count, simple schematics, robustness and possibility to provide galvanic isolation. But the main problem with flyback topology are voltage stresses on semiconductor switches caused by flyback transformer leakage inductance. There are number of solutions [1] proposed to limit voltage spikes on a main switch. The most desirable of them would be a non-dissipative snubber for better power efficiency and a cost effective one to keep low cost. The RCD snubber circuits are the simplest and robust solutions but unfortunately cannot match increasing power efficiency requirements [2].

In a scientific literature there are well known active clamp snubbers with regenerative capabilities [3-10]. Active clamp can help effectively recover the transformer leakage energy clamped in snubber capacitor; it can also help to provide zero voltage switching mode for the main power switch [3, 5, 9]. But all of these benefits come with the complexity of an active clamp. Other feature of an active clamp in flyback topology, that it increases current RMS value for a secondary circuit and high current peak for secondary rectifier diode before switch off. Also, active clamp reduces the robustness of a flyback, because the auxiliary clamp switch commutates snubber capacitor to output capacitor through transformer leakage inductance [9].

There are also number of passive non-dissipative snubber circuits for flyback converter [11-19]. These passive snubbers significantly and cost effectively reduce turn off switching losses and regenerate leakage energy from snubber capacitor. They recover energy back to power supply DC bus or store in the magnetizing inductor of a flyback transformer. There are some integrated regenerative circuits [15-18], that offer advantage of reducing component count and circuit simplification. Other advantage of these passive integrated regenerative snubbers is that they can partially recover transformer leakage energy forward to the secondary output, thus can potentially demonstrate higher efficiency. The considered regenerative snubbers work in discontinues conduction mode or resonant mode thus with increased RMS in snubber circuits.

There are also some snubber solutions [20, 21] that are worth to mention. Their idea is quiet straight forward and involves commutation of clamp capacitor to the input to restore transformer leakage energy temporarily caught in that clamp capacitor. The snubber [20] actually exploits the idea of a DC/DC converter that recovers energy from clamp capacitor back to input. It is complicated but potentially has the best recovery efficiency, therefore better suits for high power applications. The snubber [21] is a semi-active one with auxiliary switch that synchronously with the flyback main switch commutates clamp capacitor to an input through an auxiliary inductor. The snubber is simpler but potentially has the same best recovery efficiency as the snubber in [20].

In this paper a novel regenerative semi-active snubber circuit with an auxiliary inductor integrated with a main transformer is proposed [22]. It consists of the voltage spike limiting clamp capacitor to catch most of the leakage energy and a transformer auxiliary winding with auxiliary semiconductor switches to recover most of the energy from clamp capacitor. The auxiliary winding is integrated with the main flyback transformer and connected to the flyback schematic in a way to have stage voltages conformed with main transformer windings. The integration of the snubber inductor with the main transformer reduces components count and safes space on a PCB. The main advantage of the proposed snubber over the snubber in [21] is that it have potential to recover most of the energy to the secondary output, therefore promises higher leakage energy recovery efficiency. The behavior of the proposed solution is dependent on multiple parameters, therefore the desirable snubber properties and its side effects can be achieved through particular realization. The snubber can be designed to operate in non-resonant continues conduction mode (CCM) or discontinues conduction mode (DCM). Therefore, the advantage is that it has reduced RMS currents in the snubber circuits compared to the conventional regenerative LCD snubbers [15-18] with recharging in a resonant way flying capacitor. In this work only one of the promising recover strategies has been analyzed. The simulation has been provided to reveal the advantages of the proposed solution. Stage-by-stage consideration has been given, and equivalent schematics was provided for stages along with principal governing equations where it is needed for better comprehension of stage processes.

2. The proposed regenerative snubber circuit for flyback topology

The advantage of the proposed snubber have been achieved by integration of auxiliary inductance with the main transformer, thus the transformer have the third auxiliary winding now. The advantage with this is that the energy can be recovered directly to the secondary output with potential to increase efficiency. The principal schematic of the proposed recovering solution is presented in Fig. 1.

On Fig. 1 one can see a flyback topology converter with a clamp voltage limiter consisting of clamp capacitor $C_c$ and clamp diode $D_c$, and to drain clamp energy here is the circuit formed by auxiliary transistor $Q_{aux}$, auxiliary diode $D_{aux}$ and auxiliary transformer winding $W_{aux}$. The auxiliary switch $Q_{aux}$ is synchronized with the main switch and can be driven passively or actively. The synchronization and driving of $Q_{aux}$ with the main switch can be accomplished by tapping from $W_{aux}$ winding or by means of additional 4th winding. It is clearly seen that the behavior of the circuit is highly dependent on parameters like leakage inductance between transformer windings and auxiliary winding, turns ration $W_{aux}$/$W_p$ and switching timing parameters of auxiliary transistor $Q_{aux}$. The governing equation system for the proposed three winding transformer looks like Eq. (1):

where $L_p$ – transformer primary winding inductance, $L_s$ – transformer secondary winding inductance, $L_{aux}$ – auxiliary winding inductance, $L_{ps}=L_{sp}$ – transformer primary to secondary windings mutual inductance, $L_{pa}=L_{ap}$- primary to auxiliary mutual inductance, $L_{as}=L_{sa}$ – secondary to auxiliary mutual inductance. The winding’s current positive directions and voltage drop positive directions on the transformer windings are shown in the Fig. 2.

Fig. 1The proposed regenerative integrated snubber circuit and flyback converter

Fig. 2The proposed transformer winding voltages and currents designations and chosen positive directions

We propose to start studying of the schematic on Fig. 1 with some clear assumptions: the auxiliary winding turns number is equal to the primary winding turns number, $W_{aux}=W_p$; coupling between $W_{aux}$ and other transformer windings is weaker than coupling between primary $W_p$ and secondary $W_s$ windings. For analytical proposes we consider that all semiconductor switches are ideal. We consider the case when auxiliary transistor $Q_{aux}$ switches complementary to the main transistor $Q_m$, and here is a delay after $Q_{aux}$ switch off and $Q_m$ turn on. With these assumptions let’s consider six operating stages in a steady state condition for the circuit on the Fig. 1, and they are all presented in a Table 1.

The equivalent circuit diagrams are given in Fig. 3 for each of six stages.

The waveforms have been generated in the simulation software LTspice for the particular circuit parameters: transformer magnetizing inductance $L_m=$ 6400 uH, coupling coefficient between primary and secondary windings 0.98, coupling coefficients between auxiliary to primary winding and between auxiliary to secondary windings are both 0.8; switching frequency about 67 kHz; input voltage $V_{in}=$ 400 V, output voltage 14 V and output power 145 W. The duration of the stages and simulated operation waveforms are presented in Fig. 4. From Fig. 4 one can see that in our particular study case the auxiliary winding current $I_{aux}$ flows in discontinues conduction manner. We will consider the case in which the main switch $Q_m$ turns on at the time moment $t_0$ after the current in the auxiliary winding $W_{aux}$ calms down to zero. By the moment $t_0$ all primary side semiconductor switches are non-conducting only secondary diode $D_s$ is conducting current to the output helping the flyback transformer to discharge it’s remaining power energy through secondary winding $W_s$.

Fig. 3Equivalent stage circuits. Vaux – auxiliary winding voltage during non-conducting condition, Vp – primary winding voltage during non-conducting condition, Vo – output voltage, Vc – clamp capacitor voltage

a)

b)

c)

d)

e)

f)

2.1. Stage 1 (${\mathit{t}}_0$-${\mathit{t}}_1$)

In this stage, see Fig. 3(a) main switch $Q_m$ is turned on, the transformer primary side $W_p$ is connected to the input mains $V_{in}$, the secondary current rapidly goes down. After the output rectifier $D_s$ gets reversed biased the transformer starts to gain power. On Fig. 3(a) the secondary winding $W_s$ and rectifier diode $D_c$ are partially shadowed, because most of the stage time they do not provide any current. At the same time the auxiliary diodes $D_c$ and $D_{aux}$ remain non-conducting. Clamp diode $D_c$ is under reversed voltage of the clamp capacitor $C_c$. The transformer governing equations at this stage will look like Eq. (2):

2

$\left\{\begin{array}{l}{V}_{in}=L_p*\frac{d{i}_p}{dt},\\ U_s=-L_{sp}*\frac{d{i}_p}{dt},\\ U_{aux}=-L_{ap}*\frac{d{i}_p}{dt},\end{array}\right.\Rightarrow \left\{\begin{array}{l}\frac{d{i}_p}{dt}=\frac{V_{in}}{L_p},\\ U_s=-\frac{L_{sp}}{L_p}{V}_{i}n,\\ \left|U_{aux}\right|=\frac{L_{ap}}{L_p}{V}_{in}<V_{in}.\end{array}\right.$

On the auxiliary winding $W_{aux}$ here is a reflected voltage from the primary winding $W_p$, and because in this specific example it happened that $W_p=W_{aux}$ thus the voltage applied to the auxiliary diode $D_{aux}$ is near zero. Actually, diode $D_{aux}$ under slight stress of reversed voltage because reflected voltage on $W_{aux}$ is less than input voltage by voltage drop on equivalent primary side leakage inductance. The auxiliary winding is non-conducting, and the auxiliary switch $D_{aux}$ is under stress of clamp capacitor voltage.

Fig. 4Simulation waveforms of the flyback converter circuit with the proposed regenerative snubber. VQm – drain to source voltage on the Qm switch, IQm – current of the Qm switch, φS and φAUX are the potentials of the corresponding nodes on secondary and primary sides (see Fig. 1), Is – current of the secondary side, ICc – current of the clamp capacitor Cc, Iaux – current of the auxiliary winding Waux

3. Discussion

The better the coupling coefficient between auxiliary and secondary transformer windings the more portion of the transformer leakage energy is recovered directly to the secondary output. This is a promising feature to increase the snubber efficiency. The value of a magnetic leakage between auxiliary and main transformer windings influences the RMS currents of the secondary side. The simulation shows that the leakage parameter could be adjusted to reduce secondary side RMS. The conditions to provide secondary side reduced RMS can be found from Eq. (5) valid for stage 4, see the Eq. (8):

The synchronization and driving of an auxiliary switch of the proposed snubber could be done with tapping from the auxiliary transformer winding or with help of an additional forth transformer winding. This driving solution could help keep snubber implementation cost-effective. Slight delay between main switch turn-off and auxiliary switch turn-on facilitates ZVS for auxiliary switch. In particular consideration given in the paper it was proposed to make another delay between auxiliary switch turn-off action and main switch turn-on action. This delay reduces secondary current before secondary rectifier turns off. That delay could be made for example by adaptive adjusting based on previous time period measurement. Insertion of that kind of delay is optional and will certainly complicate the snubber. Simulation shows that if a flyback converter is working close to discontinues conduction mode that delay facilitates ZCS and ZVS for both secondary rectifier and primary main switch. This is because after auxiliary switch off the transformer magnetizing inductance current gained during stage 4 starts to flow in secondary side reducing secondary current.

G. Balbayev designed the theoretical basics and proposed regenerative snubber circuit for flyback topology. A. Nussibaliyeva developed the circuit simulation in software, literature search and manuscript preparation. B. Tultayev made literature search, data analysis. E. Dzhunusbekov and G. Yestemessova worked on literature search, data acquisition, circuit design and paper preparation. A. Yelemanova worked on literature search, simulation and paper preparation.

4. Conclusions

In this paper a new integrated semi-active regenerative (lossless) snubber is analyzed. In the proposed novel regenerative snubber an auxiliary inductor is integrated with the flyback transformer, thus the power supply schematics has less magnetic component count and saves PCB space. The properties of the proposed solution is critically dependent on multiple parameters, therefore the resulting snubber effect and it side effects are sensitive to the particular realization. The promising feature to increase the snubber efficiency is that most of a transformer leakage energy is recovered directly to the secondary output. The value of a magnetic leakage between auxiliary and main transformer windings influences the RMS currents of the secondary side and playing with that parameter could reduce secondary side RMS and increase efficiency further. Delay between main switch turn-off and auxiliary switch turn-on facilitates ZVS for auxiliary switch. It can also help to provide zero voltage switching mode for the main power semiconductors.