High-Density Discrete Passive EMI Filter Design for Dc-Fed Motor Drives

This works systematically presents various strategies to reduce both differential mode (DM) and common mode (CM) noise using a passive filter in a dc-fed motor drive. Following a standard approach a baseline filter is first designed to be used as reference to understand and compare the available filter topologies. Furthermore, it is used to analyze the grounding scheme of EMI filter and more specifically provide guidelines to ground single or multi stages filter. Finally, the baseline filter is investigated to recognize the possible solutions to minimize the size of the whole filter. It turns out that the CM choke and DM capacitors are the two main downsides to achieve a small EMI filter. Therefore, ideas are proposed to improve the CM choke by using other type of material such as nano crystalline core, different winding technique and new integrated method. A material comparison study is made between the common ferrite core and the nano crystalline core. Its advantages (high permeability and saturation flux density) and drawback (huge permeability drop) are analyzed thought multitudes of small and large signals tests. A novel integrated filter structure is addressed that maximizes the window area of the ferrite core and increases its leakage inductance by integrating both CM and DM inductances on the same core. Small- and large-signal experiments are conducted to verify the validity of the structure showing an effective size reduction and a good improvement at low and high frequencies. To conclude, a final filter version is proposed that reduce the volume of the baseline filter by three improve the performances in power tests.