Design and implementation of current mode controlled 150W miniature forward converter for defence application

This paper aims at design and implementation of light weight, smaller size, highly efficient and reliable single output DC-DC converter for defence application. To achieve miniaturization of the converter high switching frequency is selected, which in turn reduces the mass, size of magnetic and output filter components‥ To overcome the limitation of 50% duty cycle in auxiliary winding reset forward converter, RCD reset forward converter is designed and implemented to provide 55% duty cycle at the lower side of the input to deliver 30V/5A. Proposed converter is designed using RCD reset forward converter of switching frequency 150 kHz using UCC28C43 as a PWM controller. The proposed converter delivers 30V/5A from a 15V–45V input voltage range with efficiency better than 75%. The efficiency is greatly improved by clamping the MOSFET voltage stress from 150V to 94V at maximum input voltage. The proposed topology is realized with an experimental prototype of size 112 mm × 65 mm × 15mm.