Multi-Domain Design Optimization of dv/dt Filter for SiC-Based Three-Phase Inverters in High-Frequency Motor-Drive Applications

High slew rate of the line voltage (dv/dt) has been a concern for power inverters based on the emerging wide bandgap switching devices, such as silicon carbide (SiC) MOSFETS. Particularly, for SiC-based power inverters feeding electric machines interconnected with long cables, there could be more severe insulation stress on the stator windings in electric machines, due to the higher dv/dt output from the SiC inverters. Compared to the conventional lower voltage electric transportation applications (e.g., 270 V dc), higher dc bus voltage of 500-600 V can dramatically reduce cable weight and systematic copper losses, hence improve the power density and efficiency of power converters. However, high dc bus voltage further increases the dv/dt level in the converter ac line voltages. Driven by the necessity of developing SiC inverters with 500 V dc bus in electric transportation applications while attenuating the dv/dt stress to a low level, this paper presents a multi-domain design approach for dv/dt filters that comprehensively considers the constraints in electrical, magnetic, and thermal domains. Experimental results based on a 75 kW SiC inverter are provided to verify the efficacy of this design approach.