Active Clamp Forward Converter 12V/10A

The active clamp forward converter offers a combination of higher efficiency, reduced stress on components, compact design, high power density, wide input voltage range, and lower EMI, which makes it a suitable choice for a variety of applications. That's why I couldn't stand not try make one of these. For this converter voltage mode control used for the close loop system, and sychronous rectification at the output to boost the efficiency to maximum.The bill of materials (BOM) for the board is 24 euros.(elements+PCB+winidings). This converter was made solely for experimental purposes. This converter was created with the goal of maximizing the cost-to-efficiency ratio.To maximize efficiency, synchronous rectification was used. Isolated drivers were also used to eliminate noise transmission from the power stage to the analog signals.

The efficiency graphs considers both wire harness resistance and the analog circuitry current consumption that controls the converter. Because the input current is relatively high at 20V input voltage, we can see a significant drop in efficiency at higher output currents. Overall, because these data were generated automatically, as shown in the video above, I decided to leave them alone. With rough measurements that do not account for harness resistances, the efficiency of the converter could reach 93.8% by measuring the voltage exactly at the input and output of the converter.

Yellow Trace: Output Voltage(AC Mode)

Pink Trace: Signal at the gate of electronic switch(20ns rise/fall time)