A Compact EMI Filter Design by Reducing the Common-Mode Inductance With Chaotic PWM Technique

Passive electromagnetic interference filters (PEFs) are the most common way to solve electromagnetic interference (EMI) problems in power converters. However, PEFs bring additional volume, weight, and cost for power converters, especially common-mode (CM) inductors in PEFs, and it is a tricky issue for the high-power-density converters that must meet the electromagnetic compatibility specification. In order to design compact PEFs for power converters with pulsewidth modulation (PWM), a volume reduction method of CM inductors with chaotic PWM (CPWM) is proposed in this article. First, the mechanism that CPWM reduces the CM inductance by increasing the corner frequency is analyzed. Second, the relationship between the reduction of EMI spectrum magnitude by CPWM and the decrease of the CM inductance is quantitatively calculated. Third, utilization rate of the magnetic core eta is defined to reasonably compare the size of the different inductors under traditional PWM and CPWM. Finally, the proposed design method of CM EMI filters is applied into a dc-dc converter and a dc-ac inverter, respectively, to verify its effectiveness and feasibility. In a dc-dc converter with the switching frequency 100 kHz, 275 W, the volume of the CM inductor and the volume of CM EMI filters are reduced by 63.5% and 48.3%, respectively, by using the proposed compact EMI filter.