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Magnetics Designer Application Note
Gardena, CA
90248-4223

Designing a 50W Forward Converter Transformer With

Magnetics Designer

In order to introduce you to the power of Magnetics Designer,

we will synthesize a transformer for a forward converter which is Vpri
similar to that shown in Figure 1.
D1

D2 Np Ns D3 Ipri

Vsec
Nm

Isec
Figure 1, Magnetics Designer can synthesize transformers for designs
like this forward converter. Ton
Tsw
When the transistor turns on, the voltages on the starts
(dotted ends) of the transformer are driven positive, forward Figure 2, Key waveforms for the forward converter.
biasing D1. While the voltage is positive, the inductor current
increases towards its maximum value while magnetizing current The following equations describe the converter behavior:
builds up in the transformer. When the transistor turns off, trans-
former magnetizing must continue to flow. Therefore, the only
path for magnetizing current to flow is through D2, thus reversing Output voltage: Vo = Dkt η Vin
the polarity across the transformer and providing a voltage to reset
the flux. However, when the current in the transformer winding where Vo is the output voltage, D is the duty cycle of the switch,
reaches zero, the voltage across the winding reduces to zero, η is the efficiency of the converter, Vin is the input voltage, and Kt
indicating that the transformer flux has returned to the residual flux is the turns ratio transformer.
of the core material.
(1 − D )Tsw
Throughout the off-time of the transistor, inductor current
P-P Inductor Current: ∆I l =
L
(Vo + Vfwd)
decays. However, if the inductance is large enough, the inductor
current will not return to zero and the converter is described as where IL is the peak-to-peak inductor current, Vfwd is the rectifier
operating in the continuous conduction mode. If the inductance is forward voltage, Tsw is the switching time and L is the inductance.
small, the inductor current returns to zero during the off time. The
second case is described as operating in the discontinuous mode. Vo
In this example, we will assume that the converter is operating in Ave. Inductor Current: I l ( ave) = I o =
the continuous mode. The forward converter waveforms are
Ro
shown in Figure 2. where Io is the output current, and Ro is the load resistance.
 Magnetics Designer Application Note

Generally, a converter must operate over a wide dynamic The transformer’s design assumptions are summarized below:
range of input voltage and load current. However, Magnetics
Designer only needs to consider the case which results in the Core Type = Pot Core, Ferrite, Magnetics
maximum transformer ratings. For the forward converter, this is Material type = F (High Frequency, 100 deg. C data)
low line where the RMS current in the windings is maximum and Max Temp. Rise = 50 deg C
Max. Amb. Temp. = 25 deg C
duty cycle is .5 (50%). Since the average output voltage from the
Max. Window File = 90%
regulator is maintained at a constant, the core losses, on a first Flux Type = Half Wave
order basis, are unaffected by line and load changes. Output power = 57 Watts
Frequency = 100 kHz
The maximum required steady state output for our design is Waveform Type = Square Wave
+5Vdc at 10Adc with a minimum input voltage of 40V. The Vpri = 40 V ave
transformer output voltage must, on the average, be equal to the Idc-pri = 1.43 Adc
output voltage plus the rectifier drop. Assuming that the 5 volt Iac-pri = 1.44 Aac (rms)
Vsec(5v) = 11.4 V average
output uses conventional rectifiers, the transformer output volt-
Idc(5v) = 5 Adc
ages should be somewhat greater than 5.7V. Using the previous Iac(5v) = 5.06 Aac (rms)
equations, with a frequency of 100kHz, and an 8µH inductor, the Vflyback = 40.0 V average
peak-to-peak inductor current is 3.56A. Ipk (Ip) is therefore 11.78A Iac(40v) = 200m Aac (rms)
(Ip=Idc + Ip-p/2, Im=Idc - Ip-p/2). The average voltage across the
secondary is (Vo+Vfwd)/D = 5V+.7V/.5 = 11.4V. Initial Computer Generated Design
The core material and family are first selected in the Core
For a unipolar trapezoidal waveform, the DC current is: Selection screen (Figure 3). After entering the power and fre-
D ( Ip + Im) quency, the Core Browser is used to make an initial core selection.
I dc = 2
= .5(11.78 + 8.22)/2 = 5A The Core Browser will select the smallest core that can handle the
frequency and power specified.
The RMS current in the winding is given by:

 1 
Irms = D I p × I m + ( I p − I m ) 2 
 3  = 7.11A

Knowing the DC and RMS currents, the AC current is:

I ac = I 2 rms − I 2 dc = 5.05A

The required turns ratio is then Vpk-pri/Vpk-sec = 3.508. (The

average voltage on the primary, which is the same as the peak
voltage for a square wave, is 40 V while Vpk-sec is 11.4 V). The
DC (Idc-pri) current on the primary is 1.43 Adc (=5/3.508) and the
AC component of current is 1.44 Arms (=5.05/3.508).

A forward converter has a flux swing which begins at Br and Figure 3, The Core selection screen, after using the Core Browser to
achieves a maximum value, Bmax. Therefore, the flux type is half make an initial core selection.
wave. The output power is 57 watts (5.7 Vdc x 10 Adc). We also
assume that the converter operates at 100 kHz, that the ambient The electrical requirements for the three windings are then
air temperature is 25 degrees C, and that the maximum desired entered on the Transformer design screen (Figure 4). The pencil
surface temperature is 75 degrees C (50 degree rise). icons indicate fields where data can be entered. The eye glasses
indicate calculated “per winding” results that can be viewed. The
Finally, it is assumed that the inductor ripple current and User Data section on the right contains input and output param-
transformer magnetizing current are small relative to the various eters associated with the entire design. Design constraints (tem-
winding currents and that they do not appreciably affect the RMS perature rise, window fill, etc.) are entered at the top.
current in any of the transformer windings. Without this assump-
tion, the waveforms for each winding would be more complicated,
and additional effort would be required in order to calculate the
transformer requirements.

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 Magnetics Designer Application Note

When the New option is selected, Magnetics Designer will

iterate the design for successively larger cores until the tempera-
ture rise constraint is met or a new core can’t be selected. For each
core, Magnetics Designer will try to find the wire size, turns, and
number of strands required to achieve the specified voltages, low
AC/DC resistance, and optimal layer utilization, all while fulfilling
the stated constraints of window fill and temperature rise.

As we have demonstrated in this case, the powerful

algorithms in Magnetics Designer will normally produce a design
that meets all stated requirements without any further user
input required! Figure 6 shows that the layers are utilized quite
well, and the Trise and Window fill values are approximately 42.38
degrees C and 67%, respectively.

While the initial design is satisfactory, it could be improved.

Figure 4, The Transformer design screen after entering the basic The History of Core Trials dialog provides some recommenda-
electrical requirements. tions on possibly improving the design. These may include
changes to the wire type, number of parallel windings, and hints
To start the initial calculation and optimization of the trans- on smaller cores that may, with some adjustment, be able to
former design, we first check the New box (bottom right, Figure 4) handle the design parameters. For instance, Figure 5 shows that
and then select the Apply button. The History of Core Trials dialog, the smaller 22mm x 13mm core almost made the temperature
in Figure 5, displays the results of the optimization process. This rise. It may be a good candidate for further optimization.
includes the window fill and temperature rise for each core that has
been tried in the selected family. Magnetics Designer may select a different core geometry,
depending on the data changed in the Transformer screen. This
geometry change may dramatically affect the overall transformer
performance, and make it difficult to optimize a particular design.
Therefore, it is best to “lock down” the core geometry (Figure 7).

Figure 5, The History of Core Trials screen shows which cores were
tried by Magnetics Designer.

The resulting transformer performance for the selected core

(23mm x 17mm) is then displayed in the Transformer screen.

Figure 7, You can lock a particular core geometry in order to

experiment with a different design improvements.

As shown in Figure 7, the 22mm x 13mm core is selected and

the “Lock Geometry” option is checked. Since we have changed
the core geometry, we must first check New and then select Apply
so that Magnetics Designer can update the windings characteris-
Figure 6, The Transformer screen and resulting design values after tics for the newly selected core. We find that the temperature rise
Magnetics Designer’s optimization. is now 56.41 degrees, which is above our set constraint.

3
 Magnetics Designer Application Note

Let’s try one of the previous suggestions and split winding 1

and 2 (once each) and then perform the New and Apply opera-
tions. Splitting the highest power winding can provide several
benefits (i.e. better temperature rise for the same core area). The
resulting transformer screen then looks like Figure 8.

Figure 8, The transformer design after setting the maximum number of

strands per winding to 4.

Figure 8 shows the resulting transformer screen which now

meets all of the design goals again. The split winding information
can be shown by scrolling the spreadsheet window. The ID
Figure 8, The transformer design after splitting the highest power numbers account for the paralleling of the various windings. By
winding. scrolling down the main spreadsheet window and the User Data
button column on the right, we are able to see other calculated
Magnetics Designer knows that we are splitting a winding, design data such as the efficiency, leakage inductance and
rather than adding a new winding, and automatically splits the parasitic capacitance (Figure 9).
current between the two windings.It should be noted that the AC
resistance calculation includes both skin and proximity ef-
fects. You can move the windings around and change the layer
configuration by using the << and >> buttons at the bottom of
transformer dialog. Magnetics Designer will recalculate the AC
resistance based on the new configuration.

The simple operation of splitting the windings achieves the

design goals for this smaller core. However, four of the windings
now require 8 strands, which could be costly to manufacture.

We can set the maximum number of strands per winding via

the Max Strands field. Located in the User data section of the
Transformer screen, this series of buttons and fields provides
access to both input variables and output results. Later in this
article, we will explore how you can derive your own customized
output results. In this case, we will change Max Strands from 8 to
a more manageable 4. Magnetics Designer also allows you to Figure 9, Magnetics Designer displays a wealth of calculated data in
change the type of wire for each windings. You have the choice of the spreadsheet (left) and User Data (right) areas.
heavy formvar, small formvar, foil, square, double square, litz, or
pcb traces (for planar magnetics). Magnetics Designer Has Unique Features
Magnetics Designer has two very unique features. The first is
Changes that affect the transformer geometrically should be the ability to produce a SPICE Model of your transformer or
accompanied by a recycling of the design using the New option. inductor design. Figure 10 shows the SPICE screen which allows
The Apply button alone (without New checked) is primarily used you to configure a schematic symbol and save the resulting
for minor design changes. With the New and Lock Geometry SPICE 2 compatible subcircuit netlist. The model includes all the
options checked, Magnetics Designer will “stir up” the windings core and copper losses, AC/DC resistance, leakage and magne-
using the selected geometry in order to arrive at the best set of tizing inductance and winding capacitances. The leakage induc-
characteristics. tance is calculated based on a reluctance model while the capaci-
tance values are based on a charge conserving representation.

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 Magnetics Designer Application Note

SpiceNet, OrCAD, and Protel compatible schematic symbols The second unique feature is the exposure of virtually all of
are produced. This allows you to immediately use your new the design variables used in the program. Magnetics Designer
design in a schematic capture program and perform circuit allows the user to freely create new output measurements and
simulations of your entire power system. even affect the optimization criteria of the program. Parameters
such as core area and flux density, thermal conductivity, power
losses, leakage inductance and capacitive parasitics, resistance
values, and mechanical specifications are all available.

Figure 12 shows an example of a new temperature variable

which was created using the copper loss, core loss, core area, and
ambient temperature parameters. Both user input and calculated
output parameters are available, and additional equations may be
added.

Figure 10, Magnetics Designer produces a SPICE model of your

transformer or inductor design.

As an example of this capability, Figure 11 shows a SpiceNet

schematic and IsSpice4 simulation results of a 50W forward
converter using our transformer design.

IsSpice4 includes models for many PWM ICs, power Figure 12, An example of a user generated equation that was added
semiconductors, and power electronics devices. When coupled to the User Data area of the Transformer screen. The result of the
with Magnetics Designer, the two make a complete circuit design equation will be shown in the User Data field next to the button.
and analysis system that no other software vendor can match.

21.9 11.9
Tran Tran
VSEC I(LEAK) 9.09U
-24.3 -3.89 Tran
1.30M time 1.31M 1.30M time 1.31M VIND
6.23U
4 0 time 1.50M
V(22)
D4 DN4150 V(24) R8 C7 V(41)
VFLY
20 22 VSEC 4.7 4700P VIND
6
8.14 13 41X10 V(1)
8 LEAK .1U D1 SSR8045 MP58121 VOUT
Tran
IVCC 2 24 3 30 1
-8.52 I(V1) 4 5.26
1.30M time 1.31M IVCC L6 18.8U 13 1 C2 Tran
D2 R2 VOUT
R5 100 2 1 3 400U -65.4M
832M 17 40 SSR8045 6 .5 0 time 1.50M
Tran
ISENSE V(15) D3 DN4150 L3 5.01
5.22M ISENSE R3 R1 Tran
1.30M time 1.31M C4 1U
.01 VOUT
680P 10 8.15 4.99
7 Tran 1.30M time 1.31M
I(L3)
-388M
1.30M time 1.31M
R4 1K Figure 11, IsSpice4 simulation
13 12
V(14) results of a 50W forward
VCOMP 89.4
14
COMP REF Tran converter. The transformer
X12 V(7)
3.86 C8 21
FDBK VC
16 PSW1 -3.90 design and its SPICE model
Tran 1.30M time 1.31M
VCOMP .01U 15
IS OUT
26 were generated by Magnetics
3.82 9
1.30M time 1.31M RT/CT GND
Designer. In this particular
R11 X9 LT1243 V4 simulation, the transformer turns
PULSE R9 2.5K
10K ratio has been changed from
.285 to .5, thus changing the
Q1 QN2222A R13 1K R10 duty cycle to approximately
V(12) 18 2.5K
VREF 25%.
R12 47K
19

C9 .047U

5
 Magnetics Designer Application Note

This feature gives Magnetics Designer extreme flexibility and

opens up many design boundaries for exploration.

Magnetics Designer Reports

Magnetics Designer produces a complete report of the char-
acteristics of your design in the form of an electrical performance
summary and a winding sheet. Output from a typical report will
appear as follows:

Figure 13, The Winding Sheet contains the manufacturing information

for your transformer.

Figure 14, A summary of the electrical performance of your magnetic

design includes all the information found in the core screen, trans-
former or inductor screens, and User Data fields.