Weight Minimization of LCL Filters for High-Power Converters: Impact of PWM Method on Power Loss and Power Density

For high-power grid-connected voltage source converters (VSC), weight reduction of the LCL filter is one of the main concerns, where a LCL filter can weigh hundreds of kilograms. It is a multidomain optimization issue to find the minimum weight of a LCL filter considering pulse-width modulation (PWM) method, control bandwidth, filter design, and magnetic components with given constraints, such as harmonic standards, semiconductor power losses, and cooling conditions. The comprehensive design procedure and analytical limits of a LCL filter for a 690-V/1.2-MW VSC is provided. In addition, a prototype system of 400 V/40 kW has been built to verify the design methodology and to investigate the impact of different PWM methods on the LCL filter.