Efficiency Improvement of the Flyback Converter Based on High Frequency Transformer Winding Rearrangement

In this paper, a novel method for loss reduction and efficiency optimization of the high frequency flyback transformers is proposed based on rearrangement of the windings. According to detailed analysis of the high frequency flyback transformer using FEM technique, a novel and simple approach for its design improvement and loss reduction is introduced. It is shown that leakage flux scattering in core air-gap is one of the main reasons for hot-spot point generation in the windings. So, this problem and its possible solutions are analyzed in more detail. Moreover, FEM analysis is used for investigation of the developed method and rearrangement of the winding structure. In fact, some winding structures for efficiency improvement of the flyback transformer is presented and analyzed. Finally, in order to verify accuracy and effectiveness of the developed approach, simulation and experimental results are presented. Experimental results show 3.3% improvement in total efficiency of the converter and 41.78% loss reduction in the flyback transformer.