Common-mode Inductor Saturation Analysis and Design Optimization Based on Spectrum Concept

Understanding the CM inductor core saturation mechanism and reducing core flux density is critical for CM inductor design optimization. Instead of a time domain method, this paper introduces frequency domain spectrum concept for CM inductor core saturation analysis and design optimization, which will provide designers a better understanding of CM inductor design. First, both core permeability and converter modulation index's opposite influence on DM flux density and CM flux density are identified. Then, CM flux density is further investigated based on the spectrum concept. Three components in the CM inductor which may cause large CM flux density and core saturation are summarized: (1) switching frequency related components, (2) impedance resonance frequency related components, and (3) modulation frequency related components. Each component is investigated for CM flux density reduction and filter design optimization. A connecting AC and DC side midpoint with notch filter structure is proposed to reduce modulation frequency related components. Experiment results are presented to verify the proposed concept and method.