A Compact Integrated DM-CM Filter with PCB Embedded DC Current Sensor for High Altitude High Current Applications

This paper presents a novel multi-turn solution for integrated DM-CM filter used in DC-fed motor drive system. The proposed solution is targeted for high-current and high-altitude applications by stacking multiple PCB(s) and interconnects. A ladder network is proposed to realize the multi-turn solution, while edge plating is proposed for filter grounding. A Printed Circuit Board (PCB) based Active Magneto Resistive sensor (AMR) is embedded within the PCB dielectric to measure DC side current. PCB based feedthrough connection is implemented to improve DC filter attenuation characteristics at high frequency. Challenges pertaining to partial discharge (PD) free operation, high current and grounding of the filter are discussed. The filter and enclosure are tested in a high-altitude chamber for partial discharge. The integrated AMR sensor is tested using Silicon Carbide (SiC) enabled three level inverter under open loop RL load tests. The proposed structure is highly competitive compared to the state-of-the-art technologies and is recommended for low weight requirements.