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A Fly-Buck converter adapts a synchronous buck regulator to create one or more isolated bias rails: a coupled inductor or transformer replaces the buck’s output inductor, and secondary windings are rectified and filtered. It can be a compact, relatively simple choice for low-power auxiliary supplies, but its isolated outputs are passively regulated and can vary with load, duty cycle, and component parasitics. Designing one means checking the full input and load range, current limits, magnetic construction, and isolation requirements—not just choosing a turns ratio.

How a Fly-Buck converter makes isolated rails

Texas Instruments describes the topology in AN-2292 as replacing a synchronous buck’s output inductor with a coupled inductor or flyback-type transformer, then rectifying and filtering the secondary winding. In operation, the buck controller regulates the primary-side output in the familiar way. The magnetic component couples switching energy to its secondary winding or windings, where a rectifier and output capacitor produce isolated DC rails.

For a first-pass estimate, the secondary voltage follows the primary output voltage scaled by the secondary-to-primary turns ratio, minus the secondary rectifier’s forward drop. The actual output also depends on winding resistance, leakage inductance, switch impedance, load current, and operating conditions. Treat the turns-ratio calculation as a starting point, not a promise of tight regulation.

Multiple secondary windings can provide additional isolated rails. Each needs an appropriate turns ratio, rectifier, and output capacitor; output polarity depends on winding orientation and rectification. TI’s example uses a center-tapped secondary to produce isolated ±12 V rails, while AN-2292 presents a two-output design. Those are examples rather than standard outputs guaranteed by the topology.

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When a Fly-Buck is a good fit

Fly-Buck converters are primarily worth considering when a design needs low-power isolated bias rails and can tolerate the regulation behavior of secondary outputs that are not independently controlled. TI identifies industrial automation, building infrastructure, telecom, medical equipment, and test and measurement as potential application areas. That does not establish suitability for every product in those markets: the specific design still has to meet its power, regulation, safety, and EMC requirements.

Compared with a flyback, discrete transformer-driver, or push-pull implementation, a Fly-Buck may simplify some low-power designs by using a buck regulator and avoiding an optocoupler or dedicated secondary feedback. The trade-off is that secondary rails are passively regulated from primary-side control. Compare candidate topologies against the actual requirements:

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  • Required output power and current on every rail.
  • Input-voltage range, startup behavior, and input transients.
  • Number and polarity of rails, and their permitted regulation error.
  • Whether cross-regulation is acceptable or independent secondary feedback is necessary.
  • Switch and magnetics current limits, thermal conditions, and component availability.
  • Isolation grade, PCB spacing, EMC, and surge-protection requirements.

How to design the converter

1. Write down the rail and operating requirements

Record the complete input range, primary output, each isolated output’s voltage and polarity, load current, allowable regulation, startup and transient conditions, switching-frequency constraints, thermal environment, and required isolation. These determine whether the topology is appropriate and which regulator and magnetic component can work.

TI’s examples include an LM5160A design generating isolated ±12 V rails and an LM5017-based two-output design. The LM5160A ratings cited for that example are 65 V input and 1.5 A; they describe that IC, not a Fly-Buck-wide input or output limit. Check the current datasheet and lifecycle status of any selected device before committing to a design.

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2. Choose turns ratios and check duty cycle

Use the primary voltage, secondary-to-primary turns ratio, and rectifier forward drop to estimate each rail. Then account for winding and switch drops under load. Check the result across the entire input and load range, not only at nominal conditions.

TI’s 2015 white paper recommends keeping Fly-Buck duty cycle below 50% for good regulation. The secondary transfers energy during the low-side switch interval; as duty cycle rises, that interval shrinks, while reflected peak current and losses increase. Treat the figure as design guidance, then verify the selected IC and magnetic design over the required operating range.

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3. Check current, power, and regulation together

The regulator switch and magnetics must handle primary current plus current reflected from the secondary. AN-2292 gives cycle-by-cycle current relationships and maximum-output-current equations; its worked example is a practical two-output, 3 W isolated buck design. That 3 W value belongs to the example, not to the topology as a universal power ceiling or guarantee.

Turns ratio alone does not determine available output power. Winding resistance and synchronous-switch impedance contribute to losses, and the losses can rise as the secondary conduction interval contracts. Leakage inductance, winding DC resistance, and rectifier forward drop also affect regulation. Calculate currents and losses for the chosen IC, magnetics, rails, and loads; do not transfer an example’s power or regulation result to a different circuit.

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4. Select magnetics for performance and isolation

Choose a coupled inductor or transformer whose turns ratio, coupling, leakage inductance, winding DC resistance, thermal capability, and insulation construction suit the design. TI notes that interleaving primary and secondary windings can improve cross-regulation and reduce leakage inductance, but the specific component construction and resulting performance still need verification.

The component must meet the required basic, supplementary, or reinforced insulation grade. PCB creepage and clearance must meet the applicable standard for the product’s voltage, environment, and safety requirements; there is no single spacing value suitable for every Fly-Buck design.

5. Validate rectification and light-load behavior

A diode is a straightforward secondary rectifier, but its forward drop contributes to output error. Check each output at no load, light load, and full load, as well as during startup and transients. In a separate TI inverting Fly-Buckboost reference design, a synchronous-rectifier approach avoided a preload resistor or Zener clamp for no-load regulation, and the design reported ±5% regulation across its input and load range. That result applies to that particular design, not to synchronous rectification generally or to Fly-Buck converters as a class.

6. Treat EMC and transient protection as system design

One TI EMC example includes a common-mode inductor, X and Y capacitors, a damping resistor, a bidirectional TVS clamp, and ferrite beads at sensitive nodes. In that circuit, Y capacitors route transient energy from the input lines to chassis ground. These parts are not a mandatory Fly-Buck recipe: choose filtering, grounding, and protection to meet the product’s actual EMC, safety, and surge requirements.

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Sources and design limits

The topology and examples discussed here are from Texas Instruments design materials: AN-2292 Rev. B, revised May 2013; a Fly-Buck white paper dated November 2015; and two TI technical articles whose opened text did not state publication dates. The examples are useful design references, not substitutes for current component datasheets, applicable standards, or validation of the finished application.

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