Coupled Inductor Design For A Flyback With Very Wide Input Voltage Range
by Gregory Mirsky, Design Engineer, Deer Park, Ill., How2Power Today, Mar 14 2025
Focus:
There is an automotive and railroad class of flyback converters that demands operability
over a very wide input voltage range—from 30 V to 800 V. These are backup power supplies
that should operate when the traction battery decays. With such a wide input range, duty
cycle will vary widely. Yet rather than assuming a duty cycle range, most flyback designs
assume some average value for duty cycle. This can have serious implications for the
performance of the coupled inductor, particularly in a flyback design with a very wide
input voltage range. This article offers a procedure for designing the coupled inductor
that takes into account the full duty-cycle range of the flyback. The procedure is
demonstrated in a design example using the 30-V to 800-V input range.
What you’ll learn:
- How to design a coupled inductor for a flyback converter with wide input voltage range
- How to design a coupled inductor for a flyback while accounting for duty cycle range
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