Could PI xls.6.0 software would be available on web?
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Can you tell me which design (spec) you have having trouble optimizing?
If you want force the software to use a bigger transformer with PeakSwitch that negates the benefit of using high frequency switching. However, your argument about using too small a transformer and dealing with 2.5 kV surge is also valid. How about a EE16 size? EF20 is also perfectly fine if you have them in stock otherwise generally speaking larger the magnetic larger the cost.
If you want to use PeakSwitch here is what I suggest -
1) Make sure you select the P package (DIP 8) for this level of power. Y package (TO-220) will be cost ineffective.
2) Increase the continuous power to about 6 W (12V, 0.5 A) If you are going to use a larger transformer then increasing the average power will help the software zero in on the core size you want...
3) You should not be suprised with 2 turns selection. Again your transformer size is so huuge that at the power level you are talking at the flux density excursion is not that large. Plus since its a single output, the feedback loop will take care of the regulation regardless of the turns. 2 turns should be just fine.
If you want to use TinySwitch-PK family
1) Enter the spec as is - 12V, 2 W continuous and 24 W peak.
2) from the Solutions filter enter the start core and end core to be the same size (EF20) as you want to use. Check the PI Expert video on "Designing with a Fixed PI Device and/or a Fixed Transformer Core" if you are not familiar with this
3) This should allow succesfull optimization.
I am attaching 2 possible solutions that you can look at. Obviously, you know your requirements best so only you will be able to decide which solution is better for you, but hopefully this post should help.
To minimize power consumption at standby/noload it is adviseable to externally bias the TNY-PK chip. This is done by feeding an external current from the bias winding via a simple resistor into the BP pin. For the TNY379 the DRAIN supply current (current required to feed the internal controller) is about 1 mA. So choose the resistor such that it can deliver 1 mA from the external bias winding