The integration of input filters in electrical drives

Abstract

The integration of passive components such as inductors and capacitors has gained significant popularity in integrated drive research, and future power electronics systems will require more integrated and standardised packages. These give rise to better power density and improved performance. However, packaging techniques and passive components have been considered a technological barrier which is limiting advances in power electronics. The focus on size reduction should be turned towards the passive components, such as converter chokes, DC-link capacitors and electromagnetic interference (EMI) filters, and achieving greater power density depends on innovative integration concepts, flexibility in structures and extended operating temperature ranges while system integration and modularity are not mutually exclusive. This research considers the possibility of integrating input power filter components into electric machines. Particular attention is paid to the integration of electromagnetic line filter inductors to give better utilisation of the motor volume and envelope. This can be achieved by sharing the machine’s magnetic circuit. An LCL line filter has been chosen to be integrated with a gridconnected permanent magnet synchronous machine. Machines have been proposed in this study for low speed (3000 RPM) and high speed (25000 RPM) operation. The two machines have similar dimensions, but the low-speed machine is less challenging in terms of losses and filter integration, so attention is directed more to the high-speed machine. Both are supplied with low- and high-power drives at power ratings of 4.5 kW and 38 kW respectively. Several novel techniques have been investigated to integrate filter inductors into the electrical machines to produce a single mechanically packaged unit without significant increases in size and losses. Different approaches have been simulated using finite element analysis (FEA) to assess the effectiveness of the integration of passives within the machine structure. Each design has been iteratively optimised to determine the best mass of copper and core for the integrated filter inductors, targeting parity in power density when compared to traditional separate packages. The research demonstrates that an approach utilising a double-slot stator machine (named the integrated double slot (IDS) machine) with input filters wound into the outermost slots is the most appropriate choice in terms of achieving higher power density. The integrated filter inductors mimic the electromagnetic behaviour of the discrete industrially packaged inductors but with a volume reduction of 87.6%. A prototype of the IDS machine design of a 38 kW, 25000 RPM, including filter inductors was manufactured and tested