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
