Paper describes methods that control EMI noises generated in power converters. Two kinds of differential and common mode uoises are generated in the motor drive system. Simulations show that differential mode currents can be almost completely eliminated. Another method is also proposed that controls the shunted common mode currents.
Paper describes methods that control EMI noises generated in power converters. Two kinds of differential and common mode uoises are generated in the motor drive system. Simulations show that differential mode currents can be almost completely eliminated. Another method is also proposed that controls the shunted common mode currents.
Paper describes methods that control EMI noises generated in power converters. Two kinds of differential and common mode uoises are generated in the motor drive system. Simulations show that differential mode currents can be almost completely eliminated. Another method is also proposed that controls the shunted common mode currents.
Controlling Methods of EM1 Noises Generated in Motor Drive Systems
Nobuyoshi Mutoh, Mitsukatsu Ogata, Gulez Kayhan and Fumio Harashima
To!qo Metropolitan Institute of Technology 6-6, Asahigaoka, Hino-shi, Tokyo, 191-0065 Japan Abstract - The paper describes methods that control EMI noises generated in power converters (rectifier and inverter) hy using power printed circuit techniques. Two kinds of differential and common mode uoises are generated in the motor drive system. A method is proposed that controls the differential mode uoises by symmetrically forming the structure of the positive and negative power transmission lines of the power converter using a four-layer printed power circuit technique. Simulations done using the method show that differential mode currents appearing between the terminals of the power converters and the smoothing capacitors can he almost completely eliminated and the common mode cnrrents are shunted into the artificial ground plane. Another method is also proposed that controls the shunted common mode currents so as to prevent series resonance phenomena by inserting a damping impedance between the frame of the machine and the ground. Experiments verify that the common mode currents generated in the motor drive system can be effectively reduced by the two proposed methods. Key words: EMI noises, Common mode currents, Inverter, Convener, Motor drive, Switching, Resonance I. INTRODUCTION Motor drive systems using power converters composed of the PWh4 converter and inverter have been widely used for various kinds of applications such as industrial machines and transportation systems. Switching speeds of power devices used in power converters have become higher and higher due to requests for higher performance. This leads to increased frequencies of EMI noises [I], and then they easily diffise through not only power transmission lines of power converters but also their converters into another electric equipment. Thus, motor drive systems have the potential of causing electromagnetic interference problems between electric equipment. Especially, because common mode noises are transmitted as common mode currents through stray capacitors distributed between the ground and the machine frame such as the cooling fin of power converters or the frameof the motor, they have the ability to make the influence of EM1 noises even larger. The methods proposed until now have suppressed EM1 noises by inserting control means such as active cancellers [2] or EM filters [3] between the power converter and the motor (or AC reactor). In these cases, there are possibilities to newly generate from the inserted control means. So, other methods must bestudied that can solve the problem. E . CONTROL METHODS FOR EM NOISES New methods proposed in this paper are comprised of two techniques. One is a packaging technique that forms power converters applied to motor drives using a 4-layer printed power circuit board. The other is a method to control common mode currents by shunting them into three parts: i.e., the machine frame installed at the source side like an AC reactor, the cooling tin of power converters and the frame of the motor. The methods are based on the idea that EM1 noises generated in power converters should be suppressed within their system and common mode noises transmitted to the frames of the AC reactor or the motor from the terminal of the power converters should be controlled between each frame and the ground. Methods are studied based on the idea that the path of the common mode current can be confined and EMI noises can be prevented from diffusing into another apparatus. A. Method to Conhol Differential and Common Mode Currents by Packaging Fig.1 shows the motor drive systemdiscussed here. Fig.2 shows the packaging structure when the motor drive system illustrated by Fig.1 is formed using a multi-layer printed power circuit technique. Power converters are comprised of the P W M converter and P W M inverter using IPMs. The size of the board is 48cm x l2cm (in length and breadth), The power converters are laid out so that the distance between the converter and the inverter is shortened as much Fig. I Motor drive system using a power circuit board 07803-7262-Xx12/%10.00 Q 2W2 EEE. 1531 as possible. Moreover. the P-and N-power transmission lines are laminated. As a result the line inductance between the inverter and the soothing capacitor is 19.8nH and the inductance behveen the converter and the soothing capacitor is 58.9nH. As a result. differential mode noises generated due to switching operations, i. e. Ldi/dt are expected to be suppressed. On the other hand, as common mode noises are produced by the differential of the voltage levels output from PWM converter (or inverter), i.e. dddt related to switching speeds of the power devices used, they cannot be controlled by the wiring inductance. Thus, a method is proposed in the paper that common mode noises generated between the P- (or N-) transmission line and the ground are controlled by newly installing the ground plane for each 1" ompm (a) Outline ofthe proposed sWct ur e. ( r o AC SOURCE) (To MOTOR) (a) Top surface of P-transmission line transmission lines in the 4"-layer of the printed power board. The stmcture of the studied multi-layer is as follom: first-layer. gate circuit, voltage source, and current and voltage detectors; second-layer. P-power transmission lines; third-layer, N-power transmission lines. Wesimulate the proposed stmcture to suppress differential and common mode noises at high frequencies between lMHz and ISMHz, which generate series resonance phenomena [ I ] to venfy the effects of the stmctu~. Fig.3 shows surface current distributions on the top surface and under side of the P- and N- power transmission lines when the differential mode noises of 15MHz are applied to the terminals of the PWM inverter and PWM converter. P trs"rmi.llon line .. ,.. @) 3-dimensional s mmre of the printed board. Fig.2 Smcturc of fully printed power converters in t he motor drive system shown in Fig.1. su*e.rumnt ~ o,s ..... ....... ..................... 0 0.25 0.75 1 P-termind of Converter P-terminal of P-lermind of I (c) Top surface of N-transmission line @)Underside of P-transmission line (d) Under side of N-transmission line Fig.3 Simulations of surface current distributions on the power transmission line. (a) Under sideof P-transmission line N-termind of Converter ._-________.__.______ N-t el mi nal of N-terminal of Inverter (b) Top surface ofN-transmission line Fig.4 Simulations of the surface current flows on power transmission lines. 1532 We find from Fig. 3 that the differential mode currents generated by switching operations from the PWM converter and PWM inverter are flowing only between the under side of the P-transmission line and the top surface of the N-transmission line and hardly any are on the top surface (Fig.3 (a)) of the P-transmission line and the under side (Fig.3 (d)) of the N-transmission line. Moreover. it is proved from Fig.4 that the differential mode current on the under side of the P-transmission Lineand the top surface of the N-transmission line are flowing in the reverse direction to each other. This means that the proposed strncture bas the ability to cancel the magnetic fields produced by the differential mode currents. Next, the method is studied to control the common mode currents. Fig.5 describes the capability of the ground plane to control the common mode currents as shown by simulations. FigS(a) is the current distribution when the ground plane was laid out only just below the transmission lines coMected with the PWM converter terminals. It is found from FigS(a) that the differential modecurrents flow into the installed ground plane where the symmetly between the P- and N- transmission lines is collapsed change to the common mode currents. As shown in Fig.5@), the differential modecurrents also flow into the newly installed ground plane near regions connected with the terminals of the PWM iwerter as the common mode currents. Finally, we control the collected common modecurrents using the following method. . . ....... ... Ma elk co"Etor Smoo&g i bverteir : Capacitor IPM j . . ...... . . . . . . . . . . ......... .............. (8-1) P-transmission line (under side) i c or (8-2) N transmission line (top surface) (a-3) Ground plane (upper side) B. A4erhod to Control Common Mode Currents bvblatching Impedances Between the Machine Frame and the Ground Our method controls common mode currents collected on the ground plane by inserting impedance between the ground plane and the ground that is large enough to suppress series resonance phenomena generated in common mode current paths. The method is proposed on the basis of the idea that transient circuit loops which induce series resonance are formed in common mode current paths every time switching operations are repeated by PWM control. We study a method that estimates parameters of transient circuits in which series resonance phenomena are occurring from analyzing waveforms of the common mode currents using the FFT method. This method is applied to analysis of waveforms of the actual common mode current flowing between the frame of the motor (or AC reactor) and the ground, as shown in Fig.6. Flows of common mode currents are examined by separating the motor drive system into three parts. the power converter side. the motor (load) side and the AC reactor (source) side. Fig.7 shows FFI analyses of common mode currents flowing on each side. As shown by the figure, the frequencies of resonance components are 1.8MHz, 3.5MHzl 14.5MHz and 17MHz. which are circulating as common mode currents in the motor drive system. s mo o t h i ~nverthr Capadlor IpM .. " .......... @- I) P transmission line (under side) (b-2) N transmission line (top surface) (b-3) Ground plane (Upper side) (a) Where t he ground plane is laid out only under transmission lines @)Where the ground plane is laid out under all transmission l i nes. on the converter side. Fig.5 Calculared resuI1s of t he surface current and flow on power transmission lines. 1533 Fig.6 Method to C O ~ W I corn" mode currents appe-g i n the motor &i ve system. (a) 0-SMHz (a) 0-5MHz (a) 0-5MHz (b) 12-20MHr (%)12-ZOMHz (b) 12-20MHz (ii)AC reactor frame side. (i) Motor frame side. Fig.7 FFT analyses of common mode currents i nmotor drive system. (iii) Power Converter frame side. ( c) 3.SMHz + m=w - (d) ;;"M;;, (d) 14.5MHz (d) 14.5MHr ( i ) h<otorfrme side, (ii)AC reactor (iii) Powerconvertm Fig.8 Transiem waveform separated from the common mode current frame side frame side using the FFT band-pass filtering technique. First, the equivalent circuits of each side. motor side, AC reactor side and power converter side, need to be determined for controlling common mode cnrrents. The equivalent circuits have various kinds of resonance frequencies related to voltage fluctuations produced by switching operations. Parameters of equivalent circuits are estimated based on the transient waveforms separated from the measured common mode currents into resonance components using the FFT band-pass fdtering technique. Fig.8 shows transient waveforms obtained using the above method Parameters of the distributed constant circuit for the common mode current are determined by the following method based on the separated transient waveforms. Only the method to determine circuit parameters on the motor frame side. which are related to the resonance component of 1.8MHz is explained as the determination is the same for the other resonance components. The envelop of the separated transient wave is given by eq. (1). The peak value of the transient waveform expressed by eq.(l) isE/ L/C and its time constants W2L are 1.19[A] and 0.76[pfispectively.'As the common mode voltage is 350[Vl/3,,/E becomes 98.5. Here, assuming that the due to series resonance phenomena, the resonance frequency5 is given by eq. (2). abmpt peak o f / the common mode currents is generated Accordingly, the inductance L is expressed by eq. (3), as a function of (LIC) and (W2L). (3) By substituting the above values 0.91 [p], (=2L/R): 9 8 . 5 ( = = ), and 1.8MHz(=5) into eq.(2), We obtain 8.67[pH] obtained as the inductance L . Using the numeric values obtained, we can obtain other circuit parameters C andR as 894[pF] and 19.0[n], respectively. Also? as for the other separated transient wave of the resonance components of other frequencies, wecan obtain circuit parameters related to their separated waves by the same procedure, as shown in Fig. 9(a). Moreover. the distributed constant circuits for common mode currents flowing out from the frame of the AC reactor and the cooling fin of power converters are shown in Figs. 9(b) and (c). respectively. Next, the suppressing method is verified by experiments and simulations. Fig.10 shows suppression effects of the common mode currents when resistances inserted between the ground and the machine frame are varied. All paths of common mode currents must be controlled to completely suppress common mode currents flowing in the motor drive system. Todo so, we use the method shown in Fig.6. Fig. 10 shows simulation results that examine effects of the damping impedance of Fig.6 using the circuit of Fig.9. It is found from Fig. 10 that the common mode currents can be reduced by the increase in the damping impedance and the fact can be proved by comparing with experimental measurements in the actual motor drive system. This means that we can find the most suitable damping impedances to completely suppress common mode currents flowing in the motor drive system by optimizing them on each side using estimated distributed constant circuits. These suitable impedances of the motor side. the AC reactor side and the power converter side are around 1.3 [kB], 450 [ 611, and 900[B], respectively. 1534 m. VERIFICATION OF THE PROPOSED METHODS BY Crm" b W C EXPERIMENTS A. Suppressing Effects of Differential and Common Mode Current.r b.v Packaging Weverify effects of the pmposed packaging method to suppress differential mode cuwnt on DC power transmission lines through experiments. The frequencies obtained from FI T analyses of differential mode noises are 14.5MHz on the comJ erter side and 17.5MHz on the inverter side. So. focusine on these two freuuencies. (a) Distributed comtant circuit for the motor side. o mo 400 6w Bw i w) neslsrom", (c) Dampmg impedance on the power convater side. Fig.10 Estimated damping impedances to suppress common mode current. appearing in the motor dri ve system. measurements are perfcrmed with the ksonance frequencies 14.5MHz and 17MHz, at which series resonance phenomena occur due to switching operat~ons of the converter and welter, respectively. Fig.11 shows effects to suppress differential mode current estimated from thesurface cuwnt flowing on the power transmission lines which is measured using the magnetic probe for the surface current. Measurements show they are rapidly reduced as much as 30 [ dE3LI A/m] as the measuring point moves farther away from point A or F which are near noise sources around terminals of the com'erter and the inverter. As a result. only the common mode current remains and they are shunted to the ground plane of the fourth layer. Finally, they flow into the ground via the frame of the machine as common modecurrents without any suppressing means. IPM (a)Measuring point.. @) Magnetic field intensity. Fig.11 Magnetic fields produced by high frequency currents flowing i nthe power transmission l i es . B. Effects of the Proposed Method to Suppress Common Mode Currents Weexamine effects of the proposed method to suppress common mode current using suitable damping factors obtained thmngh in the former session. As shown in Fig. 12, analyses of the experiments show that the motor drive system has two kinds of the common mode currents, i.e. outer current loop circulating behveen the machine frame outside of the power convertem and the system ground and the inner current loop cuculating between the cooling fm of the power converters and the system earth. Thus. the damping factors should be adjusted so as to suppress the common mode current appearing on each side. i.e. AC rector, power converter and motor sides. Fig.12 shows effects of the proposed method to control common mode 1535 currents when the damping factors are optimized on each side. It is found from Fig.13 that each common mode current can be almost completely suppressed by matching impedances between the machine frame and the earth so as to restrain series resonance phenomena produced by common mode current paths. Finally, effects of the proposed method to suppress EM1 noises transmitted to the AC source side using the measurement system are shown by Fig.14. The evaultions are done by measuring the zem phase current flowing to the AC source side. As shown in Fig.15, hardly any EMI noises which produce common mode currents are transmitted to the AC source side. Accordingly, the proposed methods have the ability to effectively suppress EMI noises, i.e. differential and common mode currents all over the motor drive systems. Fig.12 Common mode current paths formed in the motor dive system. (a) Motor side. o IO tm i m rm 110 XUI II IO ~m >io m 150 ~DD -4 -1-i (b1)Without control. (h-2) With control. (b)AC reactor side. 1 i (~-1)Witholrt control. (c-2) With mntrol. Fig.13 Effects of the proposed method to suppress common mode currents appekng in the motor drive system. (c) Power converler side. CONVERTER Fig.14 Measurement system l o cmml common mode currents leaking lo AC source. (h) With control. (a) Without control. Fig.15 Effect of the proposed contrd method lo prevent EM1 noises transmitted to AC soume side. Tv. CONCLUSIONS The control methods were studied to supress EMI noises appearing in the motor drive system. Features of the developed methods are summarized as followings. (1) The differencia1 mode noise produced by switching opreations could be suppressed by the multi-layer printed power circuit technique. (2) The common mode currents appearing in the motor dnve system were almost completely controlled by installing the damping factors between the frame of the machines and the system ground so as to suppress series resonance phenomena. (3) The influence of E M noises transmitted to the AC source side could be almost completely eliminated using the above two methods REFERENCES [ I ] G. L. Skibinla, R. J. Kerkman, and D. Schelegel, EM Emissions of Modern PWM AC Drives. IEEE L4 Magazine, Nov./Dec. pp.47-81,1999 [2] S. Ogasawara, H. Ayano, H. Akagi, Active Cancellation of the Common-Mode Voltageby a Voltage-Source PWM Inverter: Trans. IEE ofJ apan, Vol. 117-D, N0.6, pp.565-571, 1997 131E. Zhong, T. A. Lipo, Improvement in EMC Performance of Inverter-Fed Motor Drives, IEEE I A, Vo.31, N0.6, pp1247-1256, 1995 [4] N.Mutoh, S. Shirakawa, K. Komatu, N. Ohnuma, S. Hokari, F Harashima, Electromagnetic characteristics of a High Density Motor Drive SystemUsing a Printed Circuit Board; Trans. IEE ofJ apan, Vol.l21-D,No.l, pp.111-117,2001 [5] N. Mutoh, M. Ogata, K. Guler, F. Hamhima, New Methods to Suppress EMI Noises in Motor Drive SystemEPE 2001 Graz-AUSTRIA, CD-ROM, SystemEngineerig-EMC, 2001 1536