EMI Filter Design for the Integrated Dual Three-Phase Active Bridge (D3AB) PFC Rectifier

Abstract

A dual three-phase active bridge (D3AB) power factor correction (PFC) rectifier features two dc ports, i.e., one on the primary side, which is not isolated from the mains, and the second, which is galvanically isolated dc port on the secondary side. A model for calculating the conducted electromagnetic interference (EMI) noise of a 7.5-kW D3AB PFC rectifier operating from a 400 V <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$_\mathrm{rms}$</tex-math></inline-formula> line-to-line mains and generating dc output voltages of <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$V_{\mathrm{dc,1}} =$</tex-math></inline-formula> 800 V and <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$V_{\mathrm{dc,2}} =$</tex-math></inline-formula> 400 V is presented in this article. The EMI model takes into account the implications of the power levels provided at the primary- and secondary-side dc ports, i.e., <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$P_{1}$</tex-math></inline-formula> and <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$P_{2}$</tex-math></inline-formula> , respectively, on the conducted EMI noise and is used to design an EMI filter for a hardware prototype of the D3AB converter topology, which is volume-optimized for the considered specifications. The designed filter has a volume of <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$0.17\,\text{dm}^{3} = 10.\text{4}\;\text{ in}^{3}$</tex-math></inline-formula> ( <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$0.09\text{ dm}^{3} = 5.5\text{ in}^{3}$</tex-math></inline-formula> for the differential mode filter and <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$0.08\text{ dm}^{3} = 4.9\text{ in}^{3}$</tex-math></inline-formula> for the common mode filter part). As part of the experimental verification of the model, the conducted EMI noise of the hardware prototype is measured under two different workload scenarios, i.e., <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$P_{1} = \text{4}\;\text{ kW}$</tex-math></inline-formula> , <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$P_{2} = \text{2.5}\;\text{ kW}$</tex-math></inline-formula> and <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$P_{1} = 0$</tex-math></inline-formula> , <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$P_{2} = 6.5\text{ kW}$</tex-math></inline-formula> . Measurements show that the level of conducted EMI noise increases with increasing load on the secondary side, which is consistent with the predictions of the noise model. The complete hardware prototype achieves sinusoidal mains currents with a power factor of <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$\lambda = 0.994$</tex-math></inline-formula> and a total harmonic distortion of currents lower than <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$5.6\%$</tex-math></inline-formula> at the considered loads and complies with the CISPR 11 class A quasi-peak conducted EMI limit.