Dual Output DC-DC Converter Design
Budget: ₹37,500 – ₹75,000 INR
Project Title
Design & Development of Wide Input Isolated Dual Output DC-DC Flyback Converter (20V–160VDC Input | 12V/1A & 5V/0.5A Outputs)
Project Overview
We are looking for an experienced Power Electronics Engineer with proven expertise in isolated SMPS and flyback converter design to develop a compact, industrial-grade DC-DC converter module.
The converter will operate from a 20VDC to 160VDC input and provide two fully regulated isolated outputs:
12V DC @ 1A
5V DC @ 0.5A
The product will be used in industrial control systems, battery-powered equipment, and EV-related applications. The design must emphasize high reliability, stable operation over the complete input voltage range, thermal performance, electrical isolation, and manufacturability.
Only freelancers with prior experience in designing isolated flyback power supplies and custom high-frequency transformers should apply. Please include details of similar projects completed.
Project Scope
The selected freelancer will be responsible for complete hardware development from design to production-ready documentation.
1. Circuit Design
1.Select suitable Flyback Controller IC.
2.Design input stage for 20V–160VDC operation.
3.Design primary and secondary power stages.
4.Design isolated feedback regulation.
5.Design auxiliary power/start-up circuit.
6.Design output filtering for low ripple and noise.
7.Design EMI/EMC input filtering.
8.Implement proper grounding and isolation techniques.
2. Transformer Design
1.Design custom high-frequency flyback transformer.
2.Calculate turns ratio, air gap, wire gauge, insulation, and core selection.
3.Minimize leakage inductance.
4.Provide complete winding diagram and manufacturing drawing.
5.Recommend transformer material and insulation class.
3. Protection Features The design shall include:
1.Reverse polarity protection
2.Input surge protection
3.Over-voltage protection
4.Over-current protection
5.Short-circuit protection
6.Output overload protection
7.Thermal protection
8.Soft-start function
9.Auto recovery after fault
4. Performance Requirements
1.Input Voltage: 20VDC to 160VDC
2.Output 1: 12VDC ±1%, 1A
3.Output 2: 5VDC ±2%, 100mA
4.Isolation Voltage: 3000VAC minimum
5.Efficiency: ≥85% (Target)
6.Switching Frequency: 100–200kHz
7.Ripple & Noise:
12V Output: <120mVp-p
5V Output: <80mVp-p
8.Continuous operation at full load.
9.Stable operation throughout the complete input voltage range.
10.Ambient operating temperature: -40°C to +85°C
5. PCB Design
1.Two-layer or four-layer PCB (based on design requirement).
2.Proper creepage and clearance for 3kVAC isolation.
3.Optimized layout for EMI reduction.
4.Thermal management using copper planes and thermal vias.
5.Manufacturing-ready PCB layout.
6.Design in KiCad (preferred).
6. Testing & Validation
Provide test procedures for:
1.Start-up testing
2.Full-load testing
3.Line regulation
4.Load regulation
5.Efficiency measurement
6.Temperature rise test
7.Isolation (Hi-Pot) test
8.Output ripple measurement
9.Short-circuit test
10.Overload protection verification
7. Deliverables
The final deliverables shall include:
1.Complete schematic source files
2.PCB layout source files
3.Gerber files
4.Drill files
5.Pick & Place files
6.Bill of Materials (BOM) with manufacturer part numbers
7.Transformer design calculations
8.Transformer manufacturing drawing
9.Design calculations
10.Assembly drawings
11.Testing procedure
12.Prototype support during bring-up
13.Engineering documentation for manufacturing
Preferred Skills
1.Power Electronics Design
2.Flyback SMPS Design
3.Wide Input DC-DC Converter Design
4.Transformer & Magnetic Design
5.Analog Circuit Design
6.KiCad PCB Design
7.EMI/EMC Compliance
8.Industrial Power Supply Design
9.EV Power Electronics
10.Preferred Experience
Note: The selected freelancer may be required to provide online technical discussions during the design and prototype validation phase. Production-ready design quality is expected.
Prototype Requirement: Preference will be given to freelancers who can manufacture, assemble, test, and validate at least one working prototype. Please specify whether your proposal includes PCB fabrication, transformer winding, assembly, and testing, along with the additional cost.
Design & Development of Wide Input Isolated Dual Output DC-DC Flyback Converter (20V–160VDC Input | 12V/1A & 5V/0.5A Outputs)
Project Overview
We are looking for an experienced Power Electronics Engineer with proven expertise in isolated SMPS and flyback converter design to develop a compact, industrial-grade DC-DC converter module.
The converter will operate from a 20VDC to 160VDC input and provide two fully regulated isolated outputs:
12V DC @ 1A
5V DC @ 0.5A
The product will be used in industrial control systems, battery-powered equipment, and EV-related applications. The design must emphasize high reliability, stable operation over the complete input voltage range, thermal performance, electrical isolation, and manufacturability.
Only freelancers with prior experience in designing isolated flyback power supplies and custom high-frequency transformers should apply. Please include details of similar projects completed.
Project Scope
The selected freelancer will be responsible for complete hardware development from design to production-ready documentation.
1. Circuit Design
1.Select suitable Flyback Controller IC.
2.Design input stage for 20V–160VDC operation.
3.Design primary and secondary power stages.
4.Design isolated feedback regulation.
5.Design auxiliary power/start-up circuit.
6.Design output filtering for low ripple and noise.
7.Design EMI/EMC input filtering.
8.Implement proper grounding and isolation techniques.
2. Transformer Design
1.Design custom high-frequency flyback transformer.
2.Calculate turns ratio, air gap, wire gauge, insulation, and core selection.
3.Minimize leakage inductance.
4.Provide complete winding diagram and manufacturing drawing.
5.Recommend transformer material and insulation class.
3. Protection Features The design shall include:
1.Reverse polarity protection
2.Input surge protection
3.Over-voltage protection
4.Over-current protection
5.Short-circuit protection
6.Output overload protection
7.Thermal protection
8.Soft-start function
9.Auto recovery after fault
4. Performance Requirements
1.Input Voltage: 20VDC to 160VDC
2.Output 1: 12VDC ±1%, 1A
3.Output 2: 5VDC ±2%, 100mA
4.Isolation Voltage: 3000VAC minimum
5.Efficiency: ≥85% (Target)
6.Switching Frequency: 100–200kHz
7.Ripple & Noise:
12V Output: <120mVp-p
5V Output: <80mVp-p
8.Continuous operation at full load.
9.Stable operation throughout the complete input voltage range.
10.Ambient operating temperature: -40°C to +85°C
5. PCB Design
1.Two-layer or four-layer PCB (based on design requirement).
2.Proper creepage and clearance for 3kVAC isolation.
3.Optimized layout for EMI reduction.
4.Thermal management using copper planes and thermal vias.
5.Manufacturing-ready PCB layout.
6.Design in KiCad (preferred).
6. Testing & Validation
Provide test procedures for:
1.Start-up testing
2.Full-load testing
3.Line regulation
4.Load regulation
5.Efficiency measurement
6.Temperature rise test
7.Isolation (Hi-Pot) test
8.Output ripple measurement
9.Short-circuit test
10.Overload protection verification
7. Deliverables
The final deliverables shall include:
1.Complete schematic source files
2.PCB layout source files
3.Gerber files
4.Drill files
5.Pick & Place files
6.Bill of Materials (BOM) with manufacturer part numbers
7.Transformer design calculations
8.Transformer manufacturing drawing
9.Design calculations
10.Assembly drawings
11.Testing procedure
12.Prototype support during bring-up
13.Engineering documentation for manufacturing
Preferred Skills
1.Power Electronics Design
2.Flyback SMPS Design
3.Wide Input DC-DC Converter Design
4.Transformer & Magnetic Design
5.Analog Circuit Design
6.KiCad PCB Design
7.EMI/EMC Compliance
8.Industrial Power Supply Design
9.EV Power Electronics
10.Preferred Experience
Note: The selected freelancer may be required to provide online technical discussions during the design and prototype validation phase. Production-ready design quality is expected.
Prototype Requirement: Preference will be given to freelancers who can manufacture, assemble, test, and validate at least one working prototype. Please specify whether your proposal includes PCB fabrication, transformer winding, assembly, and testing, along with the additional cost.