Smart Control Active Clamp Flyback

Author: Eric Faraci When I first started cooking, I preferred to work alone, thinking that having others in the kitchen would distract me. But as I began experimenting with more complex recipes and multi-step processes, I realized that having a helper made things easier and much more enjoyable. As the saying goes: If you can't beat them, join them. This same idea applies to active clamped flyback converters. Everyone wants smaller AC/DC power supplies, especially for devices like smartphones or tablets. The flyback topology is often the go-to choice because it’s simple and uses few components to efficiently convert AC to DC. However, there's a limit to how small a flyback circuit can be—mainly due to losses from transformer leakage inductance. Traditionally, designers have tried to minimize this by reducing leakage inductance. But now, active clamp flyback technology breaks that cycle.  *Figure 1: Active Clamp Flyback, Red Leakage, Active Clamp Blue* Active clamping allows energy to be stored and transferred back to the output, rather than being dissipated through an RCD or Zener clamp. Smart control clamps also enable zero voltage switching, which significantly reduces two major sources of loss. This leads to a much smaller design. If you pair it with a GaN FET that has lower output capacitance and on-resistance, you can even cut the size of the adapter in half. But here's the catch: the details matter. If the active clamp isn’t properly controlled, it can actually hurt efficiency. In the past, active clamped flyback was more of a myth because there wasn’t enough intelligent control to make it work well. That changed with the UCC28780. This controller is specifically designed for Si or GaN-based power stages, making active clamp flyback a viable option for a wide range of applications. Additionally, the UCC24612 synchronous rectifier meets the US Department of Energy (DoE) Class VI or the CoC Tier 2 standard, ensuring high efficiency and compliance with modern energy regulations. With these advancements, active clamp flyback is no longer just a concept—it’s a real, practical solution for next-generation power supplies.

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