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  • Author Author: rscasny
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Experimenting with Flyback Transformers - Winner's Announcement

rscasny

What is Experimenting with Flyback Transformers?

Flyback transformers are used in switched-mode power supplies, converters, inverters, and much more. They are a unique device, They function as an isolated inductor, storing energy in every cycle. (A typical transformer does not store any energy since it transfers energy immediately from a source to its load. Experimenting with Flyback Transformers is an element14 community competition where the participants had the opportunity to experiment with Bourn's flyback transformers and compete for some great prizes.

The element14 Community would like to thank our sponsor, Bourns, for providing the flyback transformer kits and support.

imageGrand Prize: javagoza

Final - Magic Lightbox: Project Summary

The Magic Lightbox addresses a photography lighting challenge, specifically designed for small objects like electronic components. Comprising two opposing LED panels resembling softboxes, the setup enhances contrast for photographing such components. The system integrates a PID controller for closed-loop regulation, adjusting Proportional, Integral, and Derivative actions based on the difference between actual and desired states. A Pulse Width imageModulation (PWM) controller modifies the duty cycle, regulating energy storage in the flyback transformer.

The flyback converter provides DC to DC conversion with galvanic isolation, transferring energy from the primary coil to the load through an output capacitor acting as an energy pump. Judge noted: A very interesting project. Javagoza did an excellent job taking the reader through all the experiments that were carried out, and stuck to the theme of flyback transformers. A lot was achieved, and the circuit diagrams were appreciated. check out the experiments

image

Runner Up Prize: Anthocyanina

DC to DC Demystified - Summary - It Flies Back!

At the start of the challenge, I had just a bit of knowledge about flyback transformers and converters from briefly exploring them in class. But from the day I saw the imagechallenge announcement, it piqued my interest and my curiosity to research this fascinating subject. I also learned many new things thanks to my constant reading on the topic since day one, and thanks to the other challengers' blogs and their comments on mine that knowledge was expanded even further. Judge noted: A great blend of simulation and practical results, it provided technical understanding for readers. Excellent measurements diagrams and photos. Check out the experiments

imageThird Prize: Gough Lui

Flybacks from the Ground Up – Part 6 (Final): “… Landing is Mandatory”

Power conversion is a key part of modern electronics designs. Almost every low-power, low-cost, energy-efficient, compact, light-weight mains power adapter has a flyback imagetransformer in it. As a result, I decided to participate in this challenge as a complete novice, having never studied electromagnetics and having no design experience in this domain, to see whether I could build something “from the ground up” experimentally and detail the results. Judge noted: Very readable, and it was great to see the novel approach of inserting flyback transformers into existing circuits, to see how they would perform. It was excellent to see attention to the choke and PLC transformers too. It was clear that there wasn’t enough time to systematically go through flyback designs, but nevertheless Gough pulled it together. Check Out The Experiments

imageFinisher Prize: abhishek2018

Final Results Blog : Playing with Bourns 2.25-22 W Flyback Transformers

imageWith the flyback transformer kit, I planned many main tasks and experiments which would include a tutorial, 5 blogs, and software files. I ended my participation in this design challenge playing with common mode chokes and AC-DC flybacks. Judge Noted: To get to the final blog is a significant achievement for all contestants. He stuck closely to the subject of flyback transformers. The final blog needed some extra work. Great effort for sticking through the entire challenge! Check out the experiments


Other Participants

We'd like to thank Don Bertke and Shabaz for judging the Experimenting with Flyback Transformers Challenge! Their input on the projects was invaluable to our final decisions.

Top Member: DAB
Don spent 35 years in the aerospace industry working on many advanced projects. His range of experience covers nearly every scientific field and most ranges of the electromagnetic spectrum. He has a very broad interest and knowledge in science with extensive analysis in image, multispectral and hyper-spectral analysis. He has also worked on a wide range of embedded computer applications, including integrated search and rescue systems.

Top Member: Shabaz
Shabaz has studied Electronics Engineering followed by Law, and worked primarily in the fields of radio communications (military), telecommunications (infrastructure used by phone companies), data networks, and information technology. He was originally involved in hardware design, followed by software engineering and technical marketing.

imageAbout the Sponsor
Bourns, Inc., is a leading manufacturer and supplier of position and speed sensors, circuit protection solutions, magnetic components, microelectronic modules, panel controls and resistive products. Headquartered in Riverside, California, USA, Bourns serves a broad range of markets, including automotive, industrial, consumer, communications, non-critical life support medical (low/medium risk), audio and various other market segments. Additional company and product information is available at www.bourns.com.

  • in reply to Anthocyanina

    The Kapton tape idea is not bad. I would still try it with the 20 W iron since it should be able to melt one pin. If too much heat is being drawn away by the Kapton bar, you might try a needle (held in pliers) to push the pins down one at a time. The solder won't stick to the needle.

    The heat gun will be tough to use. It will heat multiple pins but it will be hard to heat them all properly at the same time and it will be hard to press all pins down properly at the same time, especially if they are not all hot enough. You will need a lot of heat to melt all pins and it may loosen nearby components. The pins will need to be held in place until the solder freezes. The bar will get hot too, which will be harder to hold and will slow down the freezing time. If you don't press all pins down at the same time, the pins that are not pressed down may pop up.

  • in reply to dougw

    I thought of that, but I only have crappy irons with big conical tips, and an iron with a small conical tip but it's just 20W and I don't want to end up breaking a pad off with it while trying to melt the solder. I'm out of funds for a better iron or better tips so I was thinking of using a piece of aluminium or steel covered in kapton tape to push down on the pins while heating them with the hot air station. What do you think about doing it like that? 

    Thank you! Slight smile

  • in reply to Anthocyanina

    I would definitely try to re-solder those pins with an iron. I think the chances of success would be better. It appears each pin may need to be bent down a bit as it is soldered. I would use a good card holder, some flux, a fairly small iron tip and a dental pick.

    Apply flux, add a small dab of solder to the iron tip and hold the pin down with the pick as it gets heated by the iron.

  • in reply to shabaz

    It does help, thank you! I have very little experience with hot air guns, so I'll also be using some scrap boards to get a feel for how hot, how far from the board should the nozzle be, air speed...  to have a better chance of not causing any more damage to the scope. I haven't read the manual yet, only played with it for a while, but I'll look into the timer thing, I didn't think of that. I also like the idea of getting a head-mounted magnifier.

    Thank you!

    Here's what happened to the connector:

    image

    That's what they call the BLT board. That connector is fortunately not on the analog section, but it the display data goes through it, so without it, I can't use the scope. All the pins on the photorgraphed side were ripped from the PCB along with the plastic housing (fortunately no pads were lifted) while the other half of the pins remained on the board. I managed to place the connector back on, carefully sliding it over the pins that remained soldered, but these pins are obviously not making a good connection. I'm not willing to test if it works like this however, as that would mean another insertion cycle and I still need to figure out what's wrong with the USB host port. When I do figure out what's wrong with the USB port, I'll be attempting to resolder this connector but I'll also order a couple just in case I end up melting this one, but hopefully they just remain as spares Slight smile

  • in reply to Anthocyanina

    If it helps, I find using a head-magnifier is quite helpful with the hot air tool, keeps the heat away from eyes!  Also, a little desktop timer/stopwatch type of device (e.g. kitchen timer) is useful, for keeping an eye on how long things are being heated. Probably the hot air tool already has a timer built-in, but with the external one, you can see how long you were heating at a distance before bringing in the tool for more heat, etc.