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Paul Scherrer Institut

10.05.2014
Ren Knzi
Filter Design - Passive Power Filters
CERN ccelerator School !"#$% &a'en% Swit(erlan'
Suitable Filter Structures
R. Knzi Power Filter Design CAS 2014 10.05.2014 2
Suitable Filter Structures
R. Knzi Power Filter Design CAS 2014 10.05.2014 3
H-Bridge
R. Knzi Power Filter Design CAS 2014 10.05.2014 4
H-Bridge with CM filter
R. Knzi Power Filter Design CAS 2014 10.05.2014 5
2
nd
order filter - Transferfunction
R. Knzi Power Filter Design CAS 2014 10.05.2014 6
Z s =
1
C
1
s +
1
R

+
1
C

s
=
R

s +1
C
1
R

s
2
+(C
1
+ C

)s
0 s =
:
2
s
:
1
s
=
Z(s)
I
1
s + Z(s)
=
R
D
C
D
s + 1
L
1
C
1
R
D
C
D
s
3
+L
1
C
1
+ C
D
s
2
+R
D
C
D
s + 1
k
1
= R

k
2
= I
1
C
1
+ C

k
3
= I
1
C
1
R

0 s =
k
1
s + 1
k
3
s
3
+ k
2
s
2
+k
1
s + 1
with
3
rd
order PT
(1)
1
st
order PD
2
nd
order filter - Transferfunction
R. Knzi Power Filter Design CAS 2014 10.05.2014 7
0
P1
s =
1
(1 + o
1
s

0
) (1 + o
2
s

0
+ b
2
s
2

0
2
)
3
rd
order PT in its
normalized form:
(2)
2
nd
order filter - Transferfunction
R. Knzi Power Filter Design CAS 2014 10.05.2014 8
By expanding (2) and comparing the coefficients with (1) we get:
0
P1
s =
1
o
1
b
2

0
3
s
3
+
o
1
o
2
+b
2

0
2
s
2
+
(o
1
+o
2
)

0
s +1
k
1
= R

=
o
1
+ o
2

0
k
2
= I
1
C
1
+C

=
o
1
o
2
+b
2

0
2
k
3
= I
1
C
1
R

=
o
1
b
2

0
3
(3a)
(3b)
(3c)
The 3 independent equations (3a.3c) contain 5 unknowns (L
1
, C
1
, R
D
, C
D
and

0
). Therefore we have the choice to select 2 of them and the remaining 3 depend
on that selection.
2
nd
order filter - Selection of
0
R. Knzi Power Filter Design CAS 2014 10.05.2014 9
For a given frequency
B
well in the blocking area (
B
>>
0
) we can define the
desired attenuation G
B
. In the blocking area the highest order terms of both the nu-
merator and denominator in equation (1) dominate, therefore (1) can be simplified to:
0
B
=
R

s
I
1
C
1
R

s
3
=
o
1
+ o
2

0
s
o
1
b
2

0
3
s
3
=
o
1
+o
2
o
1
b
2

0
2
s
2
= -
o
1
+o
2
o
1
b
2


0
2

B
2

0
=
B

0
B
o
1
b
2
o
1
+ o
2
]
2
= -1
(4)
2
nd
order filter - Definition of L
1
R. Knzi Power Filter Design CAS 2014 10.05.2014 10
For cost reasons L
1
should
be as small as possible,
but a too small inductance
will result in an excessive
ripple current!
The DC-voltage across C
1
is m*V
DC
. When the IGBT is on, the current in L
1
increases
and the peak-peak ripple current I
L1
can be calculated:
I
L1
= I
1

Ji
L1
Jt
= I
C
-I
C1
= I
C
1 - m
AI
L1
= m I
Ji
L1
Jt
= m
1

s

I
C
1 -m
I
1
=
I
C
1 -m m

s
I
1
I
1
=
I
C
u.2S

s
AI
L1
Maximum 0.25
for m = 0.5
(5)
2
nd
order filter - Definition of L
1
R. Knzi Power Filter Design CAS 2014 10.05.2014 11
Alternative approach to determine L
1
:
I
L1_ppIc_pp
=
:
1_ppIc_pp
2 n
ppIc
I
1
I
1
=
:
1_ppIc_pp
2 n
ppIc
I
L1_ppIc_pp
(6)
2
nd
order filter Calcualting filter elements
R. Knzi Power Filter Design CAS 2014 10.05.2014 12
Substitute (3a) in (3c) and we receive:
C
1
=
o
1
b
2
I
1

0
2
(o
1
+ o
2
)
I
1
=
o
1
b
2
C
1

0
2
(o
1
+ o
2
)

0
=
o
1
b
2
I
1
C
1
(o
1
+ o
2
)
Selection: L
1
and
0
Selection: C
1
and
0
Selection: L
1
and C
1
C

=
o
1
o
2
+ b
2
I
1

0
2
- C
1
R

=
o
1
+o
2
C

0
Solve (3b) for C
D
:
Solve (3a) for R
D
:
(7a) (7b) (7c)
(8)
(9)
2
nd
order filter Example 1
R. Knzi Power Filter Design CAS 2014 10.05.2014 13
DC-link voltage: 200V
DC-link current: 500A
I
L1
50App.
C
1
must be 22mF (because of high ripple current)
Design a 2
nd
order filter for all three given optimization methods and compare the results.
2
nd
order filter Example 1
R. Knzi Power Filter Design CAS 2014 10.05.2014 14
Select L
1
to meet the ripple
current requirement:
Select C1:
Calculate the remaining
filter elements
(6)
(7c, 8, 9)
I
1
=
:
1_ppIc_pp
2 n
ppIc
I
L1_ppIc_pp
I
1
=
2uu u.1S Ipp
2 n Suus
-1
SuApp
= SuupE
C
1
= 22mF
2
nd
order filter Example 1
R. Knzi Power Filter Design CAS 2014 10.05.2014 15
x3
x5 x8
Results:
2
nd
order filter Example 1
R. Knzi Power Filter Design CAS 2014 10.05.2014 16
Maximum amplitude of resonance:
Butterworth 4.5 dB
Bessel 3.1 dB
Critical damping 2.3 dB
Frequency, for -3 dB attenuation:
Butterworth 74 Hz
Bessel 67 Hz
Critical damping 59 Hz
Attenuation: -28dB @ 300Hz
2
nd
order filter Example 2
R. Knzi Power Filter Design CAS 2014 10.05.2014 17
DC-link voltage: 120V
f
s
= 20kHz
I
Out_max
= 500A
I
L1
50App.
Attentuation: G
B
= 250 @
B
= 2**20kHz
Same premises as
for example 3
Design a 2
nd
order filter for all three given optimization methods and compare the results.
2
nd
order filter Example 2
R. Knzi Power Filter Design CAS 2014 10.05.2014 18
I
1
=
I
C
u.2S

s
AI
L1
=
12uI u.2S
2ukEz SuA
= SupE
Select L
1
to meet the ripple
current requirement:
Select
0
to meet the
attenuation requirement:
Calculate the remaining
filter elements
(5)
(7a, 8, 9)
(4)

0
=
B

0
B
o
1
b
2
o
1
+ o
2
2
nd
order filter Example 2
R. Knzi Power Filter Design CAS 2014 10.05.2014 19
x3
x5
x8
Results:
2
nd
order filter Example 2
R. Knzi Power Filter Design CAS 2014 10.05.2014 20
Maximum amplitude of resonance:
Butterworth 4.5 dB
Bessel 3.1 dB
Critical damping 2.3 dB
Frequency, for -3 dB attenuation:
Butterworth 1.5 kHz
Bessel 1.4 kHz
Critical damping 1.2 kHz
Attenuation: -48dB @ 20kHz
4
th
order filter - Transferfunction
R. Knzi Power Filter Design CAS 2014 10.05.2014 21
Z s =
1
C
2
s +
1
R

+
1
C

s
=
R

s + 1
C
2
R

s
2
+(C
2
+ C

)s
0 s =
:
3
(s)
:
1
(s)
=
1
C
1
s +
1
I
2
s +Z(s)
I
1
s +
1
C
1
s +
1
I
2
s + Z(s)

Z(s)
I
2
s + Z(s)
0
2
s =
:
3
s
:
2
s
0
1
s =
:
2
s
:
1
s
4
th
order filter - Transferfunction
R. Knzi Power Filter Design CAS 2014 10.05.2014 22
0 s =
R

s + 1
I
1
I
2
C
1
C
2
R

s
5
+ C
2
+ C

I
1
I
2
C
1
s
4
+ I
1
C
1
R

+ I
1
+I
2
C
2
R

s
3
+

+ I
1
C
1
+ I
1
+I
2
C
2
+ C

s
2
+R

s +1
0 s =
k
1
s +1
k
5
s
5
+k
4
s
4
+k
3
s
3
+k
2
s
2
+ k
1
s +1
k
1
= R

k
2
= I
1
C
1
+ C
2
+ C

+ I
2
C
2
+ C

k
4
= I
1
I
2
C
1
(C
2
+C

)
k
3
= R

(I
1
C
1
+ I
2
C
2
+ I
1
C
2
)
k
5
= I
1
I
2
C
1
C
2
C

with
1
st
order PD
5
th
order PT
(10)
4
th
order filter - Transferfunction
R. Knzi Power Filter Design CAS 2014 10.05.2014 23
5
th
order PT in its normalized form:
(11) 0
P1
s =
1
(1 + o
1
s

0
) (1 + o
2
s

0
+b
2
s
2

0
2
) (1 + o
3
s

0
+ b
3
s
2

0
2
)
Optimisation methods:
4
th
order filter - Transferfunction
R. Knzi Power Filter Design CAS 2014 10.05.2014 24
0
P1
s =
1
o
1
b
2
b
3

0
5
s
5
+
(b
2
b
3
+ o
1
o
2
b
3
+ o
1
o
3
b
2
)

0
4
s
4
+
(o
2
b
3
+ o
3
b
2
+ o
1
b
3
+ o
1
o
2
o
3
+ o
1
b
2
)

0
3
s
3

+
b
3
+ o
2
o
3
+ b
2
+ o
1
o
3
+ o
1
o
2

0
2
s
2
+
o
1
+ o
2
+ o
3

0
s + 1
By expanding (11) and comparing the coefficients with (10) we get:
k
1
= R

=
o
1
+ o
2
+ o
3

0
k
2
= I
1
C
1
+ C
2
+ C

+ I
2
C
2
+ C

=
b
3
+ o
2
o
3
+ b
2
+ o
1
o
3
+ o
1
o
2

0
2
k
3
= R

I
1
C
1
+ I
2
C
2
+ I
1
C
2
=
o
2
b
3
+ o
3
b
2
+ o
1
b
3
+ o
1
o
2
o
3
+ o
1
b
2

0
3
k
4
= I
1
I
2
C
1
C
2
+ C

=
b
2
b
3
+ o
1
o
2
b
3
+ o
1
o
3
b
2

0
4
k
5
= I
1
I
2
C
1
C
2
C

=
o
1
b
2
b
3

0
5
(12a)
(12b)
(12c)
(12d)
(12e)
4
th
order filter selection of
0
and L
1
R. Knzi Power Filter Design CAS 2014 10.05.2014 25
The 5 independent equations (12a.12e) contain 7 unknowns (L
1
, C
1
, L
2
, C
2
, R
D
, C
D
and
0
). Therefore we have the choice to select 2 of them (
0
and L
1
) the remaining 5
depend on that selection.
For a given frequency
B
well in the blocking area (
B
>>
0
) we can define the
desired attenuation G
B
. In the blocking area the highest order terms of both the
numerator and denominator in equation (10) dominate, therefore (10) can be
simplified to:
0
B
=
R

s
I
1
I
2
C
1
C
2
R

s
5
=
o
1
+o
2
+o
3

0
s
o
1
b
2
b
3

0
5
s
5
=
o
1
+ o
2
+ o
3
o
1
b
2
b
3

0
4
s
4
=
o
1
+ o
2
+ o
3
o
1
b
2
b
3


0
4

B
4

0
=
B

0
B
o
1
b
2
b
3
o
1
+o
2
+o
3
4
(13)
]
4
= +1
Select L
1
according to ripple current requirements with (5) or (6)
4
th
order filter Calculating filter elements
R. Knzi Power Filter Design CAS 2014 10.05.2014 26
By solving the equation system (12a12e) we get:
k
1
=
o
1
+ o
2
+ o
3

0
k
3
=
o
2
b
3
+ o
3
b
2
+ o
1
b
3
+ o
1
o
2
o
3
+ o
1
b
2

0
3
k
2
=
b
3
+ o
2
o
3
+ b
2
+ o
1
o
3
+ o
1
o
2

0
2
k
4
=
b
2
b
3
+ o
1
o
2
b
3
+ o
1
o
3
b
2

0
4
k
5
=
o
1
b
2
b
3

0
5
I
2
=
I
1
(k
3
k
4
- k
2
k
5
)(k
1
k
2
- k
3
)
(k
1
k
4
-k
5
)
2
- 1
C
2
=
k
5
(k
1
k
2
- k
3
)
k
1
(k
1
k
4
-k
5
)(I
1
+ I
2
)
C
1
=
k
5
k
1
I
1
I
2
C
2
R

=
k
1
k
5
C
2
(k
1
k
4
- k
5
)
C

=
k
1
R

with
(14a)
(14b)
(14c)
(14d)
(14e)
4
th
order filter Example 3
R. Knzi Power Filter Design CAS 2014 10.05.2014 27
Design a 4
th
order filter for all three given optimization methods and compare the results.
DC-link voltage: 120V
f
s
= 20kHz
I
Out_max
= 500A
I
L1
50App.
Attentuation: G
B
= 250 @
B
= 2**20kHz
Same premises as
for example 2
4
th
order filter Example 3
R. Knzi Power Filter Design CAS 2014 10.05.2014 28
I
1
=
I
C
u.2S

s
AI
L1
=
12uI u.2S
2ukEz SuA
= SupE
Select L
1
to meet the ripple
current requirement:
Select
0
to meet the
attenuation requirement:

0
=
B

0
B
o
1
b
2
b
3
o
1
+o
2
+o
3
4
Calculate the remaining
filter elements
(5)
(14a.e)
(13)
4
th
order filter Example 3
R. Knzi Power Filter Design CAS 2014 10.05.2014 29
Results:
4
th
order filter Example 3
R. Knzi Power Filter Design CAS 2014 10.05.2014 30
Maximum amplitude of resonance:
Butterworth 8.6 dB
Bessel 5.4 dB
Critical damping 3.8 dB
Frequency, for -3 dB attenuation:
Butterworth 5.5 kHz
Bessel 5.0 kHz
Critical damping 3.9 kHz
Attenuation: -48dB @ 20kHz
Comparison of different filter designs
R. Knzi Power Filter Design CAS 2014 10.05.2014 31
+64%
+42%
Comparison of different filter designs
R. Knzi Power Filter Design CAS 2014 10.05.2014 32
Practical Aspects - Wiring
Effect of a 0.5m long
wire 16mm
2
(wiring of C
1
and C
2
)
Skin Effect
Skin depth in Cu @
20kHz: 0.5mm
Reduces the effective
cross section to 6.3 mm
2
Wire resistance @
20kHz: 1.4m
Wire inductance is
approx. 0.5H
R. Knzi Power Filter Design CAS 2014 10.05.2014 33
To be avoided !
Practical Aspects low inductive setup
R. Knzi Power Filter Design CAS 2014 10.05.2014 34
C
1
L
1
L
2
C
2
R
D
C
D
Life time of electrolytic capacitors
R. Knzi Power Filter Design CAS 2014 10.05.2014 35
The useful life time of an electrolytic capacitor depends very
much on the ripple current and the ambient temperature.
Nominal ripple current at
nominal frequency (100Hz) and
nominal capacitor temperature (85C).
17.4A in our example
Life time of electrolytic capacitors
R. Knzi Power Filter Design CAS 2014 10.05.2014 36
Apply frequency factor:
For 10kHz a current factor
of 1.35 is applicable
23.5A @ 10kHz
Life time of electrolytic capacitors
R. Knzi Power Filter Design CAS 2014 10.05.2014 37
Determine the allowed ripple
current for a desired useful
life and Ta:
For 25000h (3 years)
and Ta = 50C,
2.6 * 23.5A = 61A
For 250000h (30years)
and Ta = 50C
0.85 * 23.5A = 20A
The useful life time dramatically decreases at higher ambient temperatures!
References
U. Tietze, Ch. Schenk; Halbleiter-Schaltungs-
Technik, 12. Auflage, Pages 815ff
Epcos, Datasheet, Capacitors with screw
terminals Type B43564, B43584, November
2012
R. Knzi Power Filter Design CAS 2014 10.05.2014 38