INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION IN SOCIAL SCIENCE (IJRISS)
ISSN No. 2454-6186 | DOI: 10.47772/IJRISS | Volume IX Issue X October 2025
Page 641
www.rsisinternational.org
A Case Study on the Development and Simulation of a High-Efficiency
Flyback Converter for Portable Solar LED Lighting
Mohd Fauzi Ab Rahman
*
, Abdul Halim Dahalan, Farah Shahnaz Feroz, Md Ashadi Md Johari
Fakulti Teknologi dan Kejuruteraan Elektronik dan Komputer (FTKEK), Universiti
Teknikal Malaysia Melaka, 76100 Melaka, Malaysia
DOI:
https://dx.doi.org/10.47772/IJRISS.2025.910000054
Received: 29 September 2025; Accepted: 04 October 2025; Published: 03 November 2025
ABSTRACT
This paper presents the detailed design and analysis of a compact and highly efficient flyback converter intended
for a portable solar-powered LED lighting system. This case study originated as an essential assignment within
a Power Electronics course, designed to solidify students' theoretical knowledge of isolated DC-to-DC
converters, while simultaneously assessing their proficiency in technical report writing. The primary objective
of the design is to convert a variable 24VDC solar input into a regulated 40VDC output at 40W, critically
addressing the severe lack of electricity in rural and disaster-affected zones. The methodology focused on
designing the flyback topology for Continuous Conduction Mode (CCM), emphasizing the determination of the
optimal transformer turns ratio (1:2.5), the selection of a 100kHz switching frequency, switching duty ratio (D)
of 0.4, and precise component sizing to control voltage ripple. Simulation results, verified using PSIM software,
confirmed excellent voltage regulation (achieving 39.7V) with a remarkably low peak-to-peak voltage ripple
(only 0.5%, or 0.2V), alongside a simulated efficiency of approximately 94%. This study promotes a robust,
sustainable, and easily maintainable power solution that directly contributes to energy access, sustainability, and
electronic waste minimization in off-grid contexts.
Keywords— Flyback Converter, Off-grid Power System, Solar Energy, LED Lighting, Energy Efficiency,
Sustainable Engineering.
INTRODUCTION
A. Study Context and Background
This research originates from a project assignment within a Power Electronics course. The task was specifically
formulated to mandate the design and analysis of an isolated DC-to-DC converter, serving the dual purpose of
strengthening students' theoretical understanding of power electronics, particularly in the realm of flyback
converters, and evaluating their technical comprehension and report-writing skills in English. The use of design
projects and integrated computer simulation modules is widely recognized as an effective pedagogical approach
for enhancing engineering education in electrical systems [1]. The adoption of software like PSIM in this project
aligns with contemporary educational trends that utilize interactive tools for simulation and learning [2].
Globally, access to stable and sustainable electricity remains a critical challenge, with an estimated 700 million
individuals still lacking fundamental electricity access, a deficit that severely restricts progress in critical areas
like healthcare, education, and economic development, particularly in remote and disaster-stricken regions. To
bridge this gap, decentralized power solutions utilizing solar photovoltaic (PV) energy have emerged as the most
practical and clean alternative for off-grid scenarios. However, the operational effectiveness of these solar
systems is highly dependent on the quality of their power conversion stages, which must handle the inherently
fluctuating voltage output from solar panels.
B. Energy Access Issues, Topology Selection, and Rationale
Portable solar-powered LED lighting systems are vital infrastructure in disaster relief efforts, providing
immediate and sustained illumination crucial for search-and-rescue operations and basic nocturnal activities.
Nevertheless, the variable 24VDC output from the solar/battery source is incompatible with high-efficiency LED
loads that require a precisely regulated voltage, such as 40VDC. For this reason, the flyback converter topology
INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION IN SOCIAL SCIENCE (IJRISS)
ISSN No. 2454-6186 | DOI: 10.47772/IJRISS | Volume IX Issue X October 2025
Page 642
www.rsisinternational.org
was strategically selected. The flyback converter is ideally suited for this application due to its galvanic isolation
an essential safety feature and its intrinsic ability to step-up the voltage from a lower-voltage source to the higher
voltage required by the LED string. Moreover, its high efficiency, circuit simplicity, and cost-effectiveness are
key factors in promoting a sustainable and robust power solution that addresses concerns regarding electronic
waste (e-waste) and ensures energy equity in underserved communities. Recent literature continues to emphasize
the optimization of power converters for high power density and quality, aligning with the core goals of this
project [3]. The flyback topology is a commonly utilized solution for converting the output from photovoltaic
sources to a stable DC voltage [4], [5], [6].
C. Objectives and Review of Recent Studies
The main objective of this study is to design and validate the performance of a flyback converter operating in
Continuous Conduction Mode (CCM) at a switching frequency of 100kHz. The primary focus is to achieve tight
voltage regulation and minimal output ripple (≤0.5%) while converting a 24V input to the required 40V output
at 40W. Contemporary research underscores the necessity of optimizing DC–DC converters for demanding off-
grid applications [7] and highlights the importance of high power density control for enhancing power quality
[8], which directly supports this study’s goal of a stable output. Furthermore, the literature validates the selection
of a high switching frequency and precise component sizing as essential steps for maximizing efficiency [3].
Therefore, this study aims to contribute a robust, analytically sound, and high-efficiency power solution to the
field of sustainable engineering, underpinned by advanced power electronics design principles. The flyback
converter is a prominent choice for LED driver applications, particularly where isolation and voltage step-up are
needed [9], [10].
LITERATURE REVIEW
The literature review consolidates recent advancements in isolated DC-DC converter technology, particularly
the flyback topology, focusing on applications within solar energy, off-grid systems, and power quality
improvements. This section synthesizes findings from approximately twelve relevant studies, with a strong
emphasis on recent demonstrated literature, identifying current trends and the specific research gap addressed
by this paper.
A. Off-Grid Power Conversion and Topology Selection
The shift towards decentralized renewable energy has highlighted the need for robust and efficient power
electronic interfaces. Studies confirm that the converter topology is a critical factor influencing the overall
efficiency and reliability of photovoltaic (PV) systems in remote areas [5], [11]. The flyback converter is
consistently identified as highly suitable for low-to-medium power applications (<70W) due to its simple
structure, inherent galvanic isolation a mandatory safety feature and ability to manage the wide input voltage
variations typical of solar panels [6], [7]. Gökçegöz et al. [3] established the performance trade-offs of various
topologies, underscoring the flyback’s utility where simplicity and isolation are prioritized over complex power
tracking features. Zhu et al. [4] specifically highlighted its effectiveness in achieving high voltage conversion
gain for PV applications. The challenge remains in optimizing these converters for practical, deployment-ready
solutions for contexts like disaster relief.
B. Efficiency, Operating Mode, and Component Optimization
To achieve high efficiency and low output ripple, the selection of the operating mode and switching frequency
is crucial. Most research, including that of Widagdo et al. [12], discusses the benefits of operating the flyback
converter in CCM for higher efficiency and reduced peak currents compared to Discontinuous Conduction Mode
(DCM) at similar power levels. However, CCM requires meticulous design. Lodh et al. [13] provided
foundational work on the switching frequency optimization, noting that while higher frequencies reduce the size
of magnetics, they drastically increase switching losses, demanding a careful balance a key motivation for
selecting 100kHz in the present design. Recent trends also focus on component-level improvements: Kornaga et
al. [9] analyzed the critical role of high-frequency output capacitor selection in minimizing voltage ripple and
extending system lifespan in renewable energy applications.
INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION IN SOCIAL SCIENCE (IJRISS)
ISSN No. 2454-6186 | DOI: 10.47772/IJRISS | Volume IX Issue X October 2025
Page 643
www.rsisinternational.org
C. Advancements in Power Quality and Sustainable Design
Contemporary research in power electronics emphasizes power quality and power density [8]. Afonso et al. [8]
highlighted the necessity of high-power density designs to enhance power quality and mitigate grid disturbances,
which translates directly to the need for minimal output ripple in a lighting application. Furthermore, the
introduction of Wide Bandgap (WBG) devices, specifically Silicon Carbide (SiC) and Gallium Nitride (GaN),
has revolutionized isolated converter design. Recent reviews, such as those by Meshael et al. [7] in Topological
Advances in Isolated DC–DC Converters, confirm that WBG devices enable operation at significantly higher
switching frequencies (e.g., 1MHz), drastically reducing the size of passive components and achieving superior
power density and efficiency. This direction aligns with the goal of creating a compact, portable unit for
emergency use. From a societal standpoint, Fang et al. [14] pioneered the concept of Eco-Design for flyback
converters, advocating for the inclusion of sustainable parameters like component lifespan and recyclability,
directly informing the long-term maintainability goal of this disaster-relief solution. The integration of the
flyback into hybrid topologies, such as the Zeta/Flyback converter [11], and integrated Boost-Flyback solutions
[15], is also a key research area, simplifying circuit complexity and improving battery charge/discharge balance
in solar systems.
D. Problem Statement and Contribution
Current literature generally focuses on three main areas: high-power grid-tied PV systems [4], [13] complex
Maximum Power Point Tracking (MPPT) algorithms, or general CCM/DCM comparisons. The specific problem
statement this study addresses is the lack of detailed design validation for a specialized, low-power (40W), high-
stability, isolated DC–DC converter for a niche application. While the foundational principles are established
[3], [10] few studies provide granular simulation validation and parametric analysis focused strictly on achieving
ultra-low voltage ripple (≤0.5%) from a variable 24V solar source to a specific 40V LED load for disaster relief
and off-grid stability [9]. This paper contributes by offering a rigorous simulation-based design case study that
confirms the theoretical design parameters (e.g., 1:2.5 turns ratio, 57.4μH inductance) effectively meet the
stringent power quality and efficiency requirements for a robust, deployable lighting solution, thereby
synthesizing the principles of high-quality power conversion [8] and sustainable engineering [14].
METHODOLOGY
The methodology describes the design process, theoretical foundation, and simulation setup employed to develop
and validate the 40W flyback converter for the portable solar LED system. The approach is structured to ensure
that the design parameters enable CCM operation, which is critical for achieving high efficiency and low output
ripple. This section provides sufficient detail to allow for the replication of the simulation as well as the
assessment criteria.
A. System Overview and Design Specifications
The proposed system integrates the flyback converter as the isolated power processing stage between a 24VDC
nominal solar source and the 40VDC LED load. The primary function of the converter is to provide stable
voltage regulation despite variations in the solar input. The overall system architecture is depicted in the flow
diagram (Figure 1).
Figure 1. Overall System Architecture of the Portable Solar-Powered LED Lighting Unit, detailing the DC-DC
Flyback Converter interface between the Solar Source and the LED Load.
INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION IN SOCIAL SCIENCE (IJRISS)
ISSN No. 2454-6186 | DOI: 10.47772/IJRISS | Volume IX Issue X October 2025
Page 644
www.rsisinternational.org
The key operational specifications for the flyback converter are detailed in Table 1, serving as the foundation
for all subsequent theoretical calculations. The design targets a stringent output voltage ripple of less than 0.5%
(≈0.2 V) to ensure the longevity and stable illumination of the LED load.
Table 1. Key Design Specifications and Operating Parameters for the CCM Flyback Converter
Parameter
Symbol
Value
Rationale/ Condition
Nominal Input Voltage
Vs
24VDC
Typical solar/battery voltage
Output Voltage Target
Vo
40VDC
Required LED forward voltage
Output Power
P
o
40W
Design load power
Switching Frequency
fs
100kHz
Chosen for component size reduction and
efficiency balance
Desired Voltage Ripple
ΔVo/ Vo
≤0.5%
(≈0.2V)
Required power quality for stable LED operation
Operating Mode
-
CCM
Selected for higher efficiency and lower peak
currents
B. Theoretical Design and Key Formulas
The theoretical design results in the critical component values required for stable
CCM operation, which are
tabulated in Table 2. These values were subsequently used in the PSIM simulation to validate the converter's
performance against the specifications detailed in Table 1.
Table 2. Designed Component Values for the CCM Flyback Converter, including Critical Parameters for CCM
and Ripple Control.
Component
Designed Value
Rationale
Transformer Turns
Ratio
1:2.5 (n=0.4)
Optimizes duty cycle (D ≈ 0.4) for nominal
Vs to ensure stability across Vs range.
Primary Magneti-
zing Inductance
57.4μH
Ensures CCM operation at minimum input
voltage and full load (Po = 40W).
Switching Frequency
100kHz
Balances component size reduction with
acceptable switching losses for efficiency.
Primary Switch
(MOSFET)
Selected based on
V
DS
,max and Ip,peak
Must handle high voltage stress (requires
V
DS
rating ≥120V).
Output Diode
Selected based on
V
R
,max and Is,avg
Must handle high reverse voltage stress
(requires V
R
rating ≥ 100V).
Output Capacitor
22μF
Ensures voltage ripple (ΔVo) is less than
0.5% (0.2V).
C. Simulation and Validation Setup
The complete flyback converter circuit was implemented and analyzed via simulation using PSIM software
(Figure 2) to validate its theoretical performance, specifically focusing on voltage regulation, output ripple, and
calculated efficiency. This setup incorporated a simple gate controller device operating at 100kHz to drive the
primary MOSFET switch. The validation strategy comprised two primary tests: first, Steady-State Performance,
where the circuit was operated under nominal conditions (Vs=24V, Po=40W) to precisely measure the final
regulated output voltage, the peak-to-peak voltage ripple (ΔVo), and the simulated efficiency. Second, a
INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION IN SOCIAL SCIENCE (IJRISS)
ISSN No. 2454-6186 | DOI: 10.47772/IJRISS | Volume IX Issue X October 2025
Page 645
www.rsisinternational.org
Robustness Test involved parametric sweep simulations to assess the converter's stability and transient response
across a realistic operational envelope, including an input voltage sag from 24V down to 20V.
The fundamental design equations (Equation 1-5) used to determine the critical component values for the flyback
converter are presented below. The variables utilized in these equations are defined as follows:
1. N
1
/N
2
: Transformer Turns Ratio (Secondary to Primary).
2. D: Duty Cycle (Switch ON Time Ratio).
3. I
Lm
: Average Current in the Magnetizing Inductance (L
m
).
4. Po: Output Power of the converter.
5. R: Load Resistance (equivalent resistance of the and relationship).
6. Co: Output Capacitance (used for output voltage ripple filtering).
7. i
Lm
: Primary Magnetizing Ripple Current
8. Vo/Vo: Output Voltage Ripple Percentage
󰇡

󰇢  (1)

󰇛

󰇜
󰇡
󰇢 (2)
(3)




 (4)
󰇡

󰇢
(5)
Figure 2. Detailed Schematic of the Continuous Conduction Mode (CCM) Flyback Converter as implemented
in PSIM, including the gate-controlled system for originating100 kHz switching frequency.
D. Assessment and Evaluation
The final assessment of this project, encompassing the simulation results and the quality of this technical report,
is evaluated against a structured rubric. This rubric is designed to comprehensively assess both the technical
depth of the design work and the effectiveness of the student's communication, covering the key areas detailed
in Table 3.
INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION IN SOCIAL SCIENCE (IJRISS)
ISSN No. 2454-6186 | DOI: 10.47772/IJRISS | Volume IX Issue X October 2025
Page 646
www.rsisinternational.org
Table 3. Rubric for the Assessment of the CCM Flyback Converter Design Project
Crite-rion
Excellent (4)
Proficient (3)
Developing (2)
Unsatisfactory (1)
1. Theoreti-
cal Design
Deep mastery of Flyback
topology; physics-based
justification for CCM
and N
P
:N
S
.
Clearly explains
Flyback and the
necessity of CCM for
stability.
Lacks depth in
justifying critical
design parameters.
Fundamental errors in
Flyback principle or
operating mode.
2. Simula-
tion Execu-
tion
Systematic switching
scheme validation;
incorpora-tes non-ideal
models across all
scenarios.
Clear methodolo-gy;
stable switching
scheme implementa-
tion across all test
scenarios.
Difficulty
achieving stable
switching scheme
controlling method.
Incomplete/ poorly
conceived methodology.
3. Quantita-
tive Accu-
racy
Flawless calculations;
performan-ce exceeds all
specifica-tions.
Calculations largely
accurate; performance
meets functional
specifica-tions.
Calculations
contain errors or
show moderate
deviation from
targets.
Key metrics fall
significantly outside
acceptable ranges.
4. Data
Analysis
Insightful analysis of
deviations; uses
irrefutable waveform
evidence.
Correctly compares
results; confirms CCM
operation and
component stress.
Only summarizes
results; no physical
interpretation of
waveforms.
Fails to analyze data or
provide supporting
evidence.
5. Sustaina-
bility &
Impact
Direct link between high
efficiency/ low ripple
and battery life/reduced
e-waste.
Links design choice
(CCM stability) to
long-term reliability.
Fails to specifically
connect technical
decisions
(efficiency/ ripple)
to sustainable
benefits.
Omitted or provides
irrelevant, generic
discussion.
6. Re-
porting
Quality
Meticulously organized;
profession-nal, precise
engineering terminolo-
gy.
Logically structured;
clear writing and
effective figures/
tables.
Structure is
inconsistent;
imprecise technical
language.
Disorganized or fails to
meet basic documentation
standards.
RESULTS AND DISCUSSION
The designed flyback converter, configured for
CCM, was simulated using PSIM software under nominal and
varied operating conditions to validate its performance against the design specifications outlined in Table 1. The
key metrics analyzed were output voltage regulation, voltage ripple, and overall system efficiency.
A. Steady-State Performance Analysis
Under the nominal input condition of Vs=24V and full load (40W), the converter demonstrated excellent steady-
state characteristics. The regulated output voltage (Vo) reached a stable average of 39.7V, confirming the
efficacy of the controller and the correctness of the 1:2.5 transformer turns ratio calculation.
B. Voltage Ripple and Power Quality
The primary design goal was to achieve minimal output ripple (ΔVo≤0.5%). As shown in the output voltage
waveform (Figure 3), the peak-to-peak ripple was measured to be approximately 0.2V. Relative to the target
40V output, this represents a ripple percentage of exactly 0.5%, precisely meeting the stringent requirement for
INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION IN SOCIAL SCIENCE (IJRISS)
ISSN No. 2454-6186 | DOI: 10.47772/IJRISS | Volume IX Issue X October 2025
Page 647
www.rsisinternational.org
stable LED operation. This low ripple confirms the effectiveness of the designed output capacitance (Co=22μF)
and the benefits of operating the converter in CCM, which maintains a continuous secondary current.
Figure 3. (a) Vs and Vo waveforms (b) Output Current (I
R
= 1A). (b) Vo Waveform demonstrates stable
regulation at 39.7V with 0.2V peak-to-peak ripple.
C. Magnetizing Current and CCM Verification
The primary magnetizing current (I
LM
) waveform (Figure 4) serves to verify the intended CCM operation. The
current never drops to zero during the switching cycle, confirming that the designed magnetizing inductance of
57.4μH is sufficient to keep the converter in CCM at full load. This operational mode is critical for minimizing
the peak secondary current and reducing stress on the output diode, contributing directly to higher simulated
efficiency.
Fig. 4 Primary Magnetizing Inductor Current (I
LM
) Waveform, confirming Continuous Conduction Mode
(CCM) operation where the current does not reach zero within the 100 kHz switching period.
INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION IN SOCIAL SCIENCE (IJRISS)
ISSN No. 2454-6186 | DOI: 10.47772/IJRISS | Volume IX Issue X October 2025
Page 648
www.rsisinternational.org
D. Robustness and Efficiency Analysis
Robustness against Input Fluctuation: The ability to maintain regulation despite a variable solar input is crucial
for off-grid applications. To validate the system's dynamic performance, the transient test simulated a rapid drop
in the input voltage, moving abruptly from the nominal 24V down to 20V. The switching scheme successfully
maintained the output voltage at 39.7 V with only a momentary undershoot of ≈5%. This voltage dip was fully
recovered within 500μs. This rapid recovery time conclusively demonstrates the system’s robust dynamic
response, confirming its suitability for operation in challenging environments characterized by input voltage
fluctuations.
Simulated Efficiency and Performance Summary: The overall simulated efficiency (η) was calculated by
measuring the ratio of average output power to average input power. The flyback converter achieved a high
nominal efficiency of 94%. This high value is attributed to the careful design for CCM operation, the use of a
100kHz switching frequency to balance losses, and the precise sizing of the magnetics and output filter. This
efficiency level surpasses that of many similar isolated DC-DC converters in this power range, promoting energy
sustainability and extending battery run time in the off-grid unit. Table 3 summarizes the key results, comparing
them against the initial design specifications.
Table 3. Summary of Simulated Performance Results versus Design Specifications.
Performance Parameter
Target
Specification
Compliance
Discussion
Output Voltage (Vo)
40VDC
Complied
Excellent regulation with
minimal steady-state error.
Voltage Ripple (ΔVo)
≤0.5% (≤0.2V)
Complied
Meets the stringent power
quality requirement for
LED stability.
Operating Mode
CCM
Complied
Confirmed by ILm
waveform analysis.
Nominal Efficiency (η)
High (Target
≥90%)
Complied
Attributed to optimized
CCM design and low
switching losses.
Dynamic Response Time
Fast Recovery
Complied
Demonstrates robustness
against input voltage
fluctuations.
E. Discussion and Comparison with Literature
The achieved performance is highly competitive. The 94% efficiency figure is comparable to or slightly exceeds
values reported for similar power-level flyback designs, which often range from 88% to 92% when utilizing
standard silicon MOSFETs at this frequency [5]. The success in achieving the 0.5% voltage ripple is a significant
finding, as power quality is often secondary to peak efficiency in published designs, yet it is paramount for the
longevity of the LED load in this application [8], [9], [10]. The stable CCM operation, confirmed by the I
Lm
waveform, directly validates the calculated parameters for the transformer (e.g., 1:2.5 turns ratio and 57.4μH
inductance), proving the theoretical design approach [3]. This study provides a concrete, validated design that
specifically fulfills the need for a sustainable, high-stability power solution for portable emergency lighting
systems, filling the gap identified in the literature review [7].
F. Societal Impact and Contribution to Energy Access
The successful simulation validation confirms the technical feasibility of deploying this optimized flyback
converter design in portable solar-powered LED systems. Beyond meeting the electrical performance metrics
INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION IN SOCIAL SCIENCE (IJRISS)
ISSN No. 2454-6186 | DOI: 10.47772/IJRISS | Volume IX Issue X October 2025
Page 649
www.rsisinternational.org
(low ripple, high efficiency), the design directly addresses critical societal challenges. In disaster-affected areas,
the ability of the system to provide 40VDC regulated power from a variable solar input means essential lighting
can be maintained immediately, improving safety and facilitating relief efforts. For rural, off-grid communities,
the high 94% efficiency translates directly into extended battery runtime and maximum utilization of harvested
solar energy, thus enhancing energy access and reliability where conventional grids are absent. The compact and
isolated nature of the flyback topology makes the entire system easily deployable and inherently safer for non-
expert users.
G. Sustainability and Electronic Waste Minimization
This research actively promotes sustainable engineering practices, aligning with the principles of Eco-Design
[14]. The high nominal efficiency of 94% minimizes power losses, reducing the thermal stress on components.
Lower operating temperatures and reduced electrical stress led to longer component lifespan for the MOSFET,
diode, and output capacitor. A longer lifespan directly contributes to electronic waste (e-waste) minimization,
as fewer units require premature replacement. Furthermore, the decision to operate in CCM at a controlled
100kHz switching frequency enabled the use of smaller, yet sufficiently robust, passive components. This
balance ensures the converter is compact for portability without compromising the long-term reliability required
in harsh off-grid environments [14]. The use of flyback topology in this application supports the global move
toward reliable and sustainable decentralized power solutions [11].
The flyback topology and design minimize capital expenditure, CAPEX by using standard silicon components.
This results in an estimated Bill of Materials cost of only $5–$8 USD per unit, ensuring solution affordability
for mass deployment. High efficiency and low ripple yield significant operational savings. This extends
component lifespan, reducing maintenance costs (e.g., $5–$20), and delaying costly battery replacement,
boosting long-term economic viability.
This is the simulation project, simulated at the best condition to give an overall problem solution. Other factors
like shading, temperature fluctuations, and component aging will be taken care of upon completion and real-
world testing of the hardware project.
H. Research Significance and Future Outlook
The primary significance of this study lies in its specific design validation for a niche yet critical application: a
high-stability 40W isolated DC–DC source intended for LED lighting in humanitarian and rural settings [3]. By
rigorously confirming the system's performance, particularly the minimal 0.5% voltage ripple and the rapid
500μs transient recovery, this research provides a crucial, validated benchmark for engineers developing similar
low-power, high-reliability off-grid solutions [6], [7]. Moving forward, this work serves as a foundational step,
and future research should focus on three key areas: firstly, conducting Hardware Prototyping and Thermal
Testing to validate the simulated 94% efficiency under real-world thermal conditions and parasitic effects, and
to assess the impact of thermal performance on long-term battery management and system reliability [16];
secondly, Implementing Maximum Power Point Tracking (MPPT) Control by integrating a simple, low-cost
algorithm to maximize solar energy harvesting across various weather conditions [13]; and thirdly, performing
a Comparative Analysis that directly compares the long-term reliability and cost-effectiveness of this CCM
design against a similarly rated DCM flyback, thereby providing empirical data essential for sustainable design
choices [12].
I. Student Achievement and Skill Set Enhancement
As established in the introduction section, this project served as a comprehensive case study within the Power
Electronics course, designed to assess not only technical competence but also to strengthen knowledge and
evaluate communication and reporting skills. The successful design, simulation, and analysis of this complex
CCM flyback converter clearly demonstrate several key student achievements, which are evaluated against the
case study rubric. The project validates a deepened theoretical knowledge, evidenced by the seamless transition
from conceptual understanding to rigorous practical application. The use of a simulation-based design and
validation process an increasingly vital component of modern electrical engineering curricula [2], directly
INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION IN SOCIAL SCIENCE (IJRISS)
ISSN No. 2454-6186 | DOI: 10.47772/IJRISS | Volume IX Issue X October 2025
Page 650
www.rsisinternational.org
supports pedagogical goals [1].
Furthermore, the simulation work itself was a cornerstone of the learning experience, instilling critical
knowledge, technical skills, and essential soft skills within the student group (Table 4). Students gained a
profound appreciation for how the simulation environment (e.g., PSIM) actively facilitated learning by
reinforcing theoretical concepts: By instantly visualizing the effects of design choices (e.g., transformer turns
ratio), students moved beyond abstract formulas to gain an intuitive, functional understanding of principles like
CCM operation, and transient response. This process also led to the development of technical proficiency by
providing hands-on experience with industry-standard tools, enhancing their practical work skills in modeling,
debugging, and iterative design optimization. Finally, the need to collaboratively model and analyze the circuit
in a group setting cultivated essential soft skills such as teamwork, communication, and problem-solving. The
project's culmination in a high-quality technical report confirms that the students achieved proficiency in
translating complex design parameters into a robust, validated solution, thereby fulfilling the core academic and
professional development objectives.
Table 4 Student Self-Assessment Survey Results (30 students): Change in Confidence Levels Post-Project
Completion.
Skill/ Knowledge
Area
Pre-Project
Confidence
Score (1–5)
Post-Project
Confidence Score
(1–5)
Change (↑/↓)
Educational Impact
Flyback CCM Design
Principles
2.5
4.5
↑2.0
Mastery of core topology and
operating modes achieved.
Output Ripple
Minimization
Techniques
2
4
↑2.0
Direct application of theory
(Cout sizing) confirmed.
Technical Writing in
English
3.5
4.1
↑0.6
Enhanced ability to articulate
complex technical findings
clearly.
CONCLUSION AND RECOMMENDATIONS
This study successfully concludes the design and rigorous simulation analysis of an efficient CCM flyback
converter, specifically developed to power portable LED lighting units using a solar source. This project fulfilled
its primary technical and academic objectives, demonstrating the crucial role of power electronics in addressing
global societal issues. The main finding confirms that the system achieves excellent power quality, with the
regulated output voltage stabilizing at 39.7V and, most importantly, meeting the stringent requirement of a
minimal voltage ripple of 0.5% (0.2V). This ultra-low ripple is a critical success factor, ensuring the long-term
reliability and stability of the LED load in remote and emergency scenarios. Furthermore, the design validated
the choice of 1:2.5 transformer ratio and 57.4μH inductance for stable CCM operation, yielding a highly
competitive simulated efficiency of 94% and a swift transient recovery time of approximately 500μs when
subjected to input voltage fluctuations.
The significance of this project extends beyond academic theory. Its successful validation provides a robust,
field-ready power solution that contributes directly to energy access in off-grid communities and supports
disaster relief efforts by ensuring reliable lighting infrastructure. The high efficiency and compact, isolated
nature of the design promote sustainable engineering principles by minimizing thermal stress, thereby extending
component lifespan and actively contributing to electronic waste minimization. Academically, the project
achieved its pedagogical goal by confirming students’ advanced mastery in isolated DC-DC converter design,
magnetics calculation, and simulation using PSIM. Crucially, the practical group work utilizing simulation
software was highly effective, with students reporting a strong appreciation for how the simulation environment
directly linked theoretical concepts such as CCM operation, switching mechanism and magnetics design to
INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION IN SOCIAL SCIENCE (IJRISS)
ISSN No. 2454-6186 | DOI: 10.47772/IJRISS | Volume IX Issue X October 2025
Page 651
www.rsisinternational.org
observable and quantifiable performance outcomes, profoundly enhancing their understanding of the Power
Electronics course curriculum.
ACKNOWLEDGEMENT
The authors sincerely acknowledge the Centre for Research and Innovation Management (CRIM) at University
Technical Malaysia Melaka (UTeM) for their support, including essential funding that facilitated both the
research and the subsequent publication of this work.
REFERENCES
1. Baharom, R., Hashim, N., Hannoon, N. M. S., & Rahman, N. F. A. (2025). Enhancing engineering
education in electric drive systems through integrated computer simulation modules. International
Journal of Power Electronics and Drive Systems (IJPEDS), 16(1), 45–54.
2. Carvalho, F., Chibante, R., & Vaz de Carvalho, C. (2024). An interactive pedagogical tool for
simulation of controlled rectifiers. Information, 15(6), 327.
3. Gökçegöz, F., Akboy, E., & Obdan, A. H. (2021). Analysis and design of a flyback converter for
universal input and wide load ranges. Electrica, 21(2), 235–241.
4. Zhu, B., Yang, Y., Wang, K., Liu, J., & Vilathgamuwa, D. M. (2023). High transformer utilization
ratio and high voltage conversion gain flyback converter for photovoltaic application. IEEE Trans
Ind Appl, 60(2), 2840–2851.
5. Devi, S., Krishnamoorthi, K., & Ilakkia, T. (2021). Design of enhanced flyback converter for PV
application. Turkish Journal of Computer and Mathematics Education, 12(9), 2864–2868.
6. Hasan, R., Hassan, W., & Xiao, W. (2020). A high gain flyback DC-DC converter for PV
applications. In 2020 IEEE REGION 10 CONFERENCE (TENCON) (pp. 522–526). IEEE.
7. Meshael, H., Elkhateb, A., & Best, R. (2023). Topologies and design characteristics of isolated high
step-up DC–DC converters for photovoltaic systems. Electronics (Basel), 12(18), 3913.
8. Afonso, J. L., et al. (2021). A review on power electronics technologies for power quality
improvement. Energies (Basel), 14(24), 8585.
9. Kornaga, V. I., Pekur, D., Kolomzarov, Y., Sorokin, V. M., & Nikolaenko, Y. (2023). Design of a
LED driver with a flyback topology for intelligent lighting systems with high power and efficiency.
Semiconductor Physics, Quantum Electronics and Optoelectronics, 26(2), 222–229.
10. Esteki, M., Khajehoddin, S. A., Safaee, A., & Li, Y. (2023). LED systems applications and LED
driver topologies: A review. IEEE Access, 11, 38324–38358.
11. [Tseng, S.-Y., & Fan, J.-H. (2022). Zeta/flyback hybrid converter for solar power applications.
Sustainability, 14(5), 2924.
12. Widagdo, R. S., Slamet, P., Andriawan, A. H., Hartayu, R., & Hariadi, B. (2024). Design of zero
current switching flyback converter for power efficiency in solar power system. In 2024
International Conference on Electrical Engineering and Computer Science (ICECOS) (pp. 71–76).
IEEE.
13. Lodh, T., Pragallapati, N., & Agarwal, V. (2018). Novel control scheme for an interleaved flyback
converter based solar PV microinverter to achieve high efficiency. IEEE Trans Ind Appl, 54(4),
3473–3482.
14. Fang, L., et al. (2023). Eco-design implementation in power electronics: A litterature review. In
International Symposium on Advances Technologies in Electrical Systems (SATES 23).
15. Luewisuthichat, K., Boonprasert, P., Ekkaravarodome, C., & Bilsalam, A. (2020). Analysis and
implement DC-DC integrated boost-flyback converter with LED street light stand-by application.
In 2020 International Conference on Power, Energy and Innovations (ICPEI) (pp. 197–200). IEEE.
16. Hannan, M. A., Hoque, M. M., Hussain, A., Yusof, Y., & Ker, P. J. (2018). State-of-the-art and
energy management system of lithium-ion batteries in electric vehicle applications: Issues and
recommendations. Ieee Access, 6, 19362–19378.