Transformer and Frequency Optimization in a GaN-Based Active-Clamp Flyback Converter

Magnetics optimization is paramount to overall power converter optimization. We introduce a method of transformer optimization applied to the example of a GaN-based active-clamp flyback converter using waveforms produced by a circuit simulator, allowing us to account for frequency-dependent waveform changes. An optimization routine is then used to find the minimum loss transformer design for a given RM core and frequency. With this holistic design approach, design calculations predict a 42% reduction in average transformer loss and a 19% reduction in total circuit loss in an already high-performing stock converter module.