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Summary of problems related to single-ended flyback switching power supply circuit debugging
**Conclusion of Issues in Single-Ended Flyback Switching Power Supply Circuit Debugging**
- **Issue 01: Excessive Temperature Rise of the MOS Tube**
During debugging, we identified the MOS tube as a significant heat source, alongside the high-frequency transformer and the output diode. Specifically, the MOS tube's temperature rose to 45 degrees Celsius. Initially, we attempted to address this by adjusting the switching frequency of the TOP246YN from 132 kHz to 66 kHz, but the results were minimal. We then replaced the MOS tube with a lower RDS TOP247YN model, reduced the external current limit point, and enhanced the heat sink’s surface area for better heat dissipation. These changes brought the MOS tube's temperature rise down to a more manageable 25 degrees Celsius.
- **Issue 02: High Temperature of the Output Rectifier**
The output diode also presented challenges, reaching a temperature of 42 degrees Celsius during testing. Our initial prototype used a TO220-packaged MUR1060 diode, which had a conduction voltage drop of approximately 1.1V. We replaced this with an MBR10200 diode, which offered a lower voltage drop of 0.7–0.8V. Additionally, we shifted to a wider-body heat sink for the TO220 package, resulting in a significant reduction in the diode's temperature rise. The final temperature was stabilized at around 22 degrees Celsius.
- **Issue 03: Large Output Overshoot on Power-Up**
Testing revealed that the output overshoot was excessively large during power-up, exceeding the safe voltage limits of the downstream power supply module. This was likely due to the feedback loop's sluggish dynamic response. By introducing a TL431 feedback mechanism and fine-tuning the poles within the loop, we were able to significantly mitigate the overshoot issue. After optimization, the output voltage smoothly climbed to its target level and stabilized without any significant overshoot.
- **Issue 04: High 100 Hz Power Frequency Ripple**
When assessing the output ripple, we discovered a substantial 100 Hz power frequency ripple. We tested several solutions: increasing the output electrolytic capacitor's capacitance, selecting capacitors with lower ESR, enhancing the input electrolytic capacitor's capacity, and boosting the feedback loop's DC gain. None of these yielded significant improvements. However, connecting a Y capacitor (103-sized) between the output voltage ground and the chassis ground (which is grounded) dramatically reduced the ripple, bringing it down to 0.5–1% of the output voltage.
- **Issue 05: High Transformer Temperature Rise**
During testing, the transformer's surface temperature reached 50 degrees Celsius, posing challenges in environments operating at 85 degrees Celsius. To address this, we experimented with different core materials, replacing the original PC40 material with PC44, which provided slight improvements. We also increased the number of strands in the windings to minimize the skin effect, added copper surfaces to the transformer's soldering pins on the PCB, and implemented slotting under the transformer to improve airflow. While these measures only led to minor improvements individually, their combined effect brought the transformer's temperature rise down to approximately 40 degrees Celsius.
- **Improving Switching Power Supply Efficiency**
Our initial efficiency measurement stood at 85.3%, which was functional but not optimal. To enhance efficiency further, we adjusted the feedback proportional voltage dividers, removed the power output indicator circuit, reduced the loop DC gain where possible, and switched to a low-recovery, high-reverse-voltage fast recovery diode. Additionally, we optimized the RCD clamp circuit parameters to avoid unnecessary energy absorption. These modifications collectively boosted the efficiency to 87.6%.
- **Issue 06: High-Frequency Transformer Howling**
After completing theoretical calculations and building the prototype transformer, we encountered a high-frequency whistling sound during operation, particularly during debugging. This issue persisted even after adjusting the feedback loop parameters, verifying the MOS tube switch waveforms, and replacing some ceramic capacitors with plug-in decoupling capacitors. Replacing the transformer with both dipped and non-dipped versions helped, but the most effective solution came after using a varnish-treated transformer, which eliminated the whistling almost entirely. This suggested that the whistling was likely caused by high-frequency oscillations in the transformer coils.
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This debugging journey highlighted the importance of iterative testing and optimization in power supply design. Addressing each issue systematically ensured a reliable and efficient power supply solution.
• **End**