LC FILTER FOR THREE PHASE INVERTER

A Project report submitted by:

MUTHURAJ P

13MQ37

ELDHO JACOB13MQ81
Dissertation submitted in partial fulfilment of the requirements for
the degree of

MASTER OF ENGINEERING
Branch: EEE
Specialization: POWER ELECTRONICS & DRIVES

OCTOBER -2014

ELECTRICAL & ELECTRONICS

PSG COLLEGE OF TECHNOLOGY

(Autonomous Institution)

COIMBATORE 641 004

Contents
LC FILTER DESIGN............................................................................................... 3
FLOW CHART TO DESIGN A PASSIVE(LC).............................................................4
FORMULA USED:................................................................................................. 5
DESIGN OF INDUCTOR:....................................................................................... 6
INDUCTOR DESIGN PROCEDURE.........................................................................6
Relationship of, Area Product Ap, to the Inductor Volt-Amp Capability............7
Fundamental Considerations...........................................................................8
INDUCTOR DESIGN STEPS................................................................................10
INDUCTOR WINDING DETAILS...........................................................................15
WINDING DETAILS.......................................................................................... 15
Core Details : EI 225...................................................................................... 16
CORE DIMENSIONAL DETAILS........................................................................16
WIRE TABLE................................................................................................... 18
SIMULATION CIRCUIT:........................................................................................ 19
SIMULATION RESULTS:...................................................................................... 20
Without Filter:................................................................................................ 20
With Filter:..................................................................................................... 21
REFERENCES:................................................................................................... 22

LIST OF FIGURES
Figure 1: Inverter Circuit........................................................................................ 3
Figure 2: LC Filter................................................................................................... 7
Figure 3: EI core Inductor....................................................................................... 9
Figure 4: Inverter and Filter Simulation Circuit.....................................................19
Figure 5: Inverter Output Without Filter...............................................................20
Figure 6: Inverter Output With LC Filter...............................................................21

LC FILTER FOR THREE PHASE INVERTER

LC FILTER DESIGN
A low pass LC filter is required at the output terminal of Full Bridge VSI to
reduce harmonicsgenerated by the pulsating modulation waveform. While
designing LC filter, the cut-off frequencyis chosen such that most of the low
order harmonics is eliminated. To operate as an ideal voltagesource, that means
no additional voltage distortion even though under the load variation or
anonlinear load, the output impedance of the inverter must be kept zero.
Therefore, the capacitancevalue should be maximized and the inductance value
should be minimized at the selected cut-offfrequency of the low-pass filter.
With thesedesign values, the voltage waveform of the inverter output can be
sinusoidal under the linear load orsteady state condition. But in case of a step
change of the loador a nonlinear load, the output voltage waveform will be
distorted.
Figure 1 shows the power circuit of the single phase PWM-VSI.

T1

T3

T5

T4

T6

T2

C1

n
V1
100Vdc
C2

Ra
1k
Rc
1k

Rb
1k

Figure 1: Inverter Circuit

FLOW CHART TO DESIGN A PASSIVE(LC)

START

HARMONIC ANALYSIS OF PWM VOLTAGEAND NONLINEAR CURRENT

SELECTING MINIMUM CAPACITANCE

INDUCTOR VALUE CALCULATION

ANALYSING OUTPUT VOLTAGE HARMONICS UNDER

THE LINEAR AND NON-LINEAR LOAD

THD = 5%

STOP

FORMULA USED:
(i)To find inductor,
1
Vdc1
8
L=
Fs
i Lmax

Where,
Vdc DC voltage of the inverter
i Lmax Current ripple

(ripple current can be chosen as 10% - 15% of rated current)

Fs Switching frequency

(ii)To find capacitor,

C=15

Prated
2
2 f V rated
3

Where,
Prated

Reactive power rated

(reactive power is chosen as 15% of the rated power)

Vrated AC rated voltage

DESIGN OF INDUCTOR:
FILTER DESIGN:
INVERTER LC FILTER
SWITCHING FRREQUENCY = 5 kHz
OUTPUT CURRENT

= 10 A RMS

PHASE VOLTAGE

= 230 V RMS

FREQUENCY

= 50 Hz

CAPACITANCE VALUE CALCUALATED = 10uF, 600V

INDUCTANCE VALUE CALCULATED

= 4.5mH

INDUCTOR DESIGN PROCEDURE

Several factors need to be considered while designing an inductor, few of which
are listed below
1. Frequency of Operation
2. Core Material Selection
3. Energy Handling Capability of the Inductor (determines the size of
the core)
4. Calculate Number of Turn
5. Selection of Copper wire
6. Estimation of Losses and Temperature Rise

In this application the Inductor has to handle large energy due to the RMS
current is 10A maximum. At this current most of the ferrite core shapes does not
support the design (computed from the Area Product). So we select Iron powder
core for this design.

The design of the ac inductor requires the calculation of the volt-amp (VA)
capability. In this applications the inductance value is specified.

Figure 2: LC Filter

Relationship of, Area Product Ap, to the Inductor Volt-Amp Capability

The volt-amp capability of a core is related to its area product, Ap, by the
equation that may be stated as Follows.

From the above, it can be seen that factors such as flux density, Bac, the
window utilization factor, Ku (which defines the maximum space occupied by
the copper in the window), and the current density, J, all have an influence on
the inductor area product, Ap.

Fundamental Considerations
The design of a linear ac inductor depends upon five related factors:
1 . Desired inductance
2. Applied voltage, (across inductor)
3. Frequency
4. Operating Flux density which will not saturate the core
5. Temperature Rise

The inductance of an iron-core inductor, with an air gap, may be expressed as:

Final determination of the air gap requires consideration of the effect of fringing
flux, which is a function of gap dimension, the shape of the pole faces, and the
shape, size, and location of the winding

Figure 3: EI core Inductor

Fringing flux decreases the total reluctance of the magnetic path, and therefore
increases the inductance by a factor, F, to a value greater than that calculated
from Equation

Where G is winding length of the core

Now that the fringing flux, F, has been calculated, it is necessary to recalculate
the number of turns using the fringing flux, Factor F

with the new turns, N(new), and solve for Bac

10

The losses in an ac inductor are made up of three components:

1. Copper loss, Pcu
2. Iron loss, Pfe
3. Gap loss, Pg

The copper loss, Pcu, is I2R and is straightforward, if the skin effect is minimal.
The iron loss, Pfe, is calculated from core manufacturers' data. Gap loss, Pg, is
independent of core material strip thickness and permeability.

INDUCTOR DESIGN STEPS

1 Design Spec

VL

230

Inductance

Line Current

IL

10 A

Line Frequency

50 Hz

Current Density

Efficiency goal

ef

0.045 H

300 A/cm2
90 %
Iron
Powder

Material
Magnetic

permiability

um

1200

11

Flux Density

Bac

1.4 Tesla

Window
Utilisation

Ku

0.4

Temp Rise Goal

Tr

60 C

Calculate Apparent
2 power Pt
Pt = VA = VL*IL

2300 A

3 Calculate Area Product

AP

AP = VA*10^4/
(4.44*Ku*f*Bac*J)

616.68811
67 cm4

Select Core
Iron Powder Core
EI228
core Material
Magnetic Path Length

MPL

34.3 cm
2844 g

Mean Length Turn

MLT

32.7 cm

Iron
Area

Ac

31.028 cm2

Window Area

Wa

24.496 cm2

Area product

Ap

760.064 cm4

Coef

Kg

288.936 cm5

Surface Area

At

1078 cm2

12

Material P

Winding Length

Lamination E

8.573
5.715

Calculate Number of
5 Turns

6 Inductance Required

Calculate required
7 airgap

lg

lg = (0.4piN2Ac10-4/L)
- (MPL/um)
lg

Calculate Fringing flux

8 F

Calculate New number

9 of turns

N1

N1=sqrt(lg*L/0.4piACF
10-8)

238.50255
9 turns

0.045 H

0.4640422
87 cm

1.3006997
51

202.96670
27 turns

203

10 Calculate flux density

Bac = VL*10^4/
(4.44*N1*Ac*f

Bac

1.6451150
76 Tesla
13

11 Calculate Bare wire area

Awl

0.0333333
33 cm2

Awl=IL/J

Select wire from Wire

12 table
AWG
14

Aw

0.02 cm2

uOhm/c
m

uOhm/c
82.8 m

Calculate Winding
13 Resistance
R=MLT*N1*uOHm*10
-6
R

0.5495445
26 Ohms

14 Calculate Copper Loss

PL = IL2 * RL

PL

54.954452
56 W

Calculate Watts per

15 kilogram
W/K =
0.000557*f^1.68*B^1.8
6
w/k

1.3654455
33 Ohm

14

16 Calculate Core Loss

Pfe =w/k *Wtfe

Pfe

0.9230411
8 W

Pg

55.624748
48 W

PL

111.50224
22 W

17 Calculate Gap Loss

Pg = Ki*E*lg*f*B2

18 Calculate Total Loss

sum of losses

19 Calculate surface area watt density

psi = PL/At

psi

0.1034343
62 watts per cm2

Tr

69.075759
95

Calculate the
20 Temperature rise
Tr = 450*psi^0.826

Calculate Window
21 utilisation
Ku = N1*Aw/Wa

0.1657141
6 watt
15

16

INDUCTOR WINDING DETAILS

210

3
2

20
0

Inductor
Termination

Winding Arrangement

WINDING DETAILS
N
o.

Winding
no.

Terminals

No Wire Insulation
of
gauge between
turn SWG winding Layers
s

1&2

200

14

Remarks

Nil
(Varnishing
Required)

Tapping 3

210

14

17

Core Details : EI 225

CORE DIMENSIONAL DETAILS

18

19

WIRE TABLE

20

SIMULATION CIRCUIT:

Figure 4: Inverter and Filter Simulation Circuit

21

SIMULATION RESULTS:
Without Filter:

Figure 5: Inverter Output Without Filter

22

With Filter:

Figure 6: Inverter Output With LC Filter

23

REFERENCES:
[1] Miss. Sangita R Nandurkar , Mrs. Mini Rajeev ,Design and Simulation of three
phaseInverter for grid connected Photovoltic systems,Proceedings of Third Biennial
National Conference, NCNTE- 2012, Feb 24-25
[2] COLONEL WM. T. MCLYMAN, Transformer and Inductor Design Handbook
Third Edition, ISBN: 0-8247-5393-3
[3] www.mag-inc.com
[4] www.epcos.com
[5] www.arnoldmagnetics.com

24