Isolated 5V/30W flyback power supply designed and simulated for phone charging
An EGR494 power electronics project (ASU, the course instructor) by a teammate and Saif Elsaady to design an isolated AC-DC power supply for cellphone charging. The supply targets a regulated 5V DC output at 30W from a universal single-phase AC input of 85V to 265V RMS at 60 Hz, with galvanic isolation between input and output for safety. A flyback converter topology was selected, sized through hand calculations, and verified in circuit simulation. Despite the repository name, the deliverables document a power-supply design project rather than a robotics or ML one. **Highlight:** 75.65% simulated efficiency at 5V/30W
The team followed a systematic design methodology: topology selection and justification, key specification definition, transformer turns-ratio and inductance design, component stress analysis and sourcing, and circuit simulation for verification. Calculations were carried out analytically and the converter was modeled and simulated to capture input, transformer secondary, and output waveforms. Loss and efficiency estimation was then used to evaluate the design and identify optimization opportunities.
Simulation verified a regulated output (steady 4.79V, ripple under 50mV) across the 85-265V RMS input range, with an estimated overall efficiency of 75.65% and an 8.86% current ripple against 9.665W total losses. Full design detail and waveforms are in docs/EGR494 Report.docx and the accompanying presentation.