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The escalating demand for small, compact, and economical consumer electronics necessitates efficient power conversion at higher switching frequencies. The active-clamp flyback (ACF) converter, offering isolation, efficient performance at low and medium power levels, and cost and volume efficiency, is frequently employed in consumer electronics, including USB PD devices. However, designing and selecting components for the ACF converter remains a challenging task, particularly for fast charging and USB-PD standards. This paper introduces a comprehensive design and optimization methodology for the ACF converter under constraints of power loss, volume, and efficiency. This methodology employs the particle swarm optimization algorithm, a nature-inspired optimization technique. The proposed design and optimization algorithm provides a detailed design process and aids designers in determining the optimal size of the ACF converter. The optimization algorithm orchestrates the circuit design by selecting design parameters within a certain frequency range, utilizing transformer, switches, and diode elements from the database. In consideration of the requirement for high-frequency operation, the database also includes GaN semiconductor switches and high-frequency operated magnetic components. The design presenting the highest benefits in terms of volume, cost, and losses is selected using the converter level fitness function, which incorporates cost, volume, and loss considerations. To evaluate the proposed design and optimization methodology, a USB PD converter capable of providing 5V/9V/15V/20V DC voltages (max. 65W) from a 230 VAC/50 Hz supply was designed and its performance analyzed. |
