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Hybrid LC Filter Electrical Design Considerations

Article  in  IEEE Transactions on Industrial Electronics · February 2012

DOI: 10.1109/TIE.2011.2157283

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 Hybrid LC Filter Electrical Design Considerations
Valentin Dzhankhotov, Juha Pyrhönen, Member, IEEE, Pertti Silventoinen, and Mikko Kuisma

Abstract—This paper continues the design considerations of a

novel type of passive filter called hybrid LC filter (HLCF). The fil-
ter is aimed at significant reduction in high-frequency differential
mode (DM) and common mode (CM) currents in speed-controlled
ac drives. A model of the HLCF is presented. Based on the model,
a transfer function of the HLCF is found. The HLCF behavior is
analyzed in frequency domain. A method for HLCF frequency-
domain behavior estimation with asymptotes is proposed. A com-
parison of the measured, simulated, and calculated results in
frequency domain is presented.
Index Terms—Common mode (CM), differential mode (DM),
filters, high-power drives, overvoltage.

I. I NTRODUCTION

P OWER electronic converter drives use, for the sake of

high efficiency, pulsewidth modulation (PWM), which re-
sults in sequences of high-voltage high-frequency steep-edged
pulses. Such a power signal contains a set of high harmonics,
which are not required for control purposes but, instead, cre-
ate harmful effects. Harmonics cause reflections in the cable
between the motor and the inverter, leading to faster winding
insulation aging [1]–[8]. Bearing failures and problems with
electromagnetic compatibility may also result [9]–[15].
Electrical du/dt filters provide an effective solution to prob-
lems caused by PWM, thereby increasing the performance and
service life of electrical machines. It is shown, for example, in
[1]–[3], [6], [16], and [17] that RLC filters effectively decrease
DM and CM noises leading to motor winding insulation break-
downs and bearings damages.
Foil chokes and film capacitors are among the most widely
used components in high-power applications. In actual applica-
tions, they can be placed in different parts of the cabinet. This
fact complicates the arrangement of the cabinet and decreases
the reliability of the system. In addition, the inductances of
connection wires may prevent filtration at high frequencies.
In [1], [2], [18], and [19], a new hybrid LC filter (HLCF) was
introduced. This filter uses the natural capacitance between the
turns of the foil choke based on integration of an auxiliary layer
into it (Fig. 1).
V. Dzhankhotov is with The Switch Drive Systems Oy, 53850
Lappeenranta, Finland, and also with the Department of Electrical Engineering,
Lappeenranta University of Technology, 53850 Lappeenranta, Finland (e-mail:
valentin.dzhankhotov@theswitch.com).
J. Pyrhönen, P. Silventoinen, and M. Kuisma are with the Department
of Electrical Engineering, Lappeenranta University of Technology, 53850
Lappeenranta, Finland (e-mail: juha.pyrhonen@lut.fi).
Fig. 1. Single-phase column of the proposed HLCF.
The main idea of the HLCF results from the fact that both
the foil choke and the film capacitors have the same roll
structure. Moreover, the capacitance between the turns (“in-
tracapacitance” often referred to an end-to-end capacitance) of
the foil inductors is the reason for the deterioration of choke
properties at high frequencies [20]. It is shown in [1] and
[2] that the proposed filter has a natural cancellation of the
intracapacitance. An HLCF may contain two or more foil layers
isolated from each other and coiled on a core. The core material
can be a ferromagnetic material, such as iron lamination, air,
or a suitable combination of them. In this paper, an air-cored
hybrid filter is observed. Therefore, no eddy currents are present
in the core. In iron cores, the eddy currents at high frequencies
should significantly affect the attenuation behavior of the filter.
Foils carrying the useful power signal, which are called the
main foils, are placed between the inverter and the motor cable.
The other foils, which are called auxiliary foils, may be con-
nected in star to create DM and CM noise paths. The star point
is then coupled to the dc-link midpoint to guarantee a traveling
path, particularly for the CM currents. There is a remarkable
capacitance between the main foil and the auxiliary foil.
The proposed LC filter can be a competitive solution for
modern power drives and offers advantages over the traditional
chokes and filters. It has good differential mode (DM) and
common mode (CM) noise attenuation properties. As a sin-
gle unit, the HLCF provides equal or better reliability, com-
pared with the filters based on separate components. Because
of the natural capacitance, no extra connections producing
high-frequency operation deterioration are required. The filter
works for both DM and CM, maintains its inductance at high
frequencies, and has good cooling properties because of the
air core letting cooling fluid flow easily. If needed, the low-
frequency inductance can be increased by ferromagnetic core
parts. The auxiliary foil also minimizes the intracapacitance of
the main foil [2].
The reliability of the HLCF can be assumed approximately
equal to or lower than the reliability of a foil choke. The voltage
stresses are higher in the HLCF than in a foil choke because
the auxiliary foil has a low potential; therefore, the electric
field strength is high between the main and auxiliary foils.
In conventional foil chokes, the insulation is significantly less
stressed because the potential differences between the turns are
rather small.
Usually, the current flowing through the capacitance of a
du/dt filter is considerably smaller than the current flowing
through the choke. Moreover, the losses depend on the current
squared. Thus, for both a conventional LC filter and the HLCF
capacitive chain, the losses are negligibly low. Therefore, both
types of filters can be described by an equal amount of losses,
which are quite close to the losses in a traditional air-cored
choke.
The disadvantage of the HLCF is the slightly more com-
plicated manufacturing technology when using present-day
fabrication facilities. However, rolling four layers (main foil,
insulation, auxiliary foil, and insulation), instead of two, si- Fig. 2. (a) Phase-to-phase voltage and (b) CM current in real drive. (Dark
solid line) With the HLCF. (Light solid line) Without the HLCF.
multaneously should not be too difficult. If the manufacturing
technology should be further developed, insulation bands in- tromagnetic compatibility. The topology proposed in [9] was
tegrated with auxiliary coil material might be possible. Then, implemented, and a wire connecting the filter star point to
coil manufacturing should not differ from present-day foil coil the dc-link midpoint was used. The measurements were made
manufacturing, except auxiliary foil connections. with a Yokogawa PZ4000 power analyzer, which provides a
The capacitors in three-phase passive power filters with measurement frequency bandwidth up to 2 MHz. Differential
separate components usually cost up to 50% of the inductor voltage probes Testec TT-SI9002 with a frequency bandwidth
price. The HLCF auxiliary foil can be made of a very thin up to 25 MHz were used for voltage measurements. A custom-
material because the CM currents are small. The amount of made Rogowski coil with an estimated frequency bandwidth up
insulation, however, is larger than in traditional foil filters to 5 MHz was used for the current measurements.
because thicker insulation layers must be used due to the high The HLCF increases the pulse rise time by a factor of 25
electric field strength. The price of the HLCF is expected to (from 0.12 to 3 μs) and decreases the du/dt rate by a factor of
be about 0%–25% higher than the price of the chokes in filters 20 (from 5200 to 260 V/μs), compared with the case without
based on separate components. filtering. Oscillations are explained by the fact that no damping
The main restrictions on the scalability of voltage and cur- elements were used, which underlines the LC nature of the filter
rent ratings are similar to those for foil-wound chokes. When under consideration. In addition, HLCF essentially decreases
increasing the voltage rating, special attention should be paid the CM noise with attenuation about 22 dB (from 6 to 0.5 A).
to the insulation properties. When increasing the current rating, This paper deals with the HLCF electrical design and model-
the current density in the main foil, as well as the insulation ing. Based on the model proposed in [1], the transfer function of
thermal properties, must be carefully considered. the HLCF is found. This function is used during the frequency
Fig. 2 shows measured phase-to-phase voltage and the CM behavior analysis to find the resonance frequencies of the
currents in a drive when tested with the HLCF or without it. HLCF. Finally, comparison of the measured, simulated, and
A 22-kW 400-V three-phase induction motor is driven by an calculated data is provided. Comparison shows the good degree
ABB inverter with a PWM switching frequency of 2.4 kHz. of the realism of the proposed model and the transfer function,
The motor is connected to the inverter by a 90-m symmet- as well as the effectiveness of the HLCF behavior prediction by
ric three-phase cable. The main parameters of the cable are calculations.
given as follows: the dc resistance at 20 ◦ C is 0.524 Ω/km,
the phase ac resistance at 50 Hz is 0.63 Ω/km, the phase
II. HLCF M ODEL
inductance is 0.26 mH/km, and the operating capacitance is
0.55 μF/km. The inductance of the HLCF main and auxiliary The lumped model of the HLCF is proposed in [1] and is
foils is Lm = La = 30 μH, and the capacitance between the proven with three prototypes. The model seems to be realistic
main and auxiliary layers is Cb = 140 nF. The cabinet was for both time and frequency (up to at least 100 MHz) domains.
manufactured of aluminum, which effectively guaranteed elec- This model is presented in Fig. 3.
Fig. 3. Lumped model of the HLCF.

The main foil with inductance Lm is coupled with the Fig. 4. Equivalent circuit for the matrix of the impedances.
auxiliary foil with inductance La through capacitance Cb and
this matrix corresponds to the number of independent circuits
mutual inductance M .
inside the main electrical circuit of the HLCF, whereas the num-
The stray self-capacitances (“intracapacitances”) of the main
ber of columns corresponds to the current in the independent
(Ci1 ) and the auxiliary (Ci2 ) foils are placed in parallel with
circuit with this number.
the inductances of the main and auxiliary foils. The ways of
The matrix of voltages B (2), shown at the bottom of the
inductances Lm and La , capacitance Cb , and intracapacitance
page, is written so that it indicates whether a voltage source
without auxiliary foil calculation are shown in [1] and [2]. It
exists in the independent circuit (by one) or not (by zero).
is explained in [2] that the intracapacitance of the main foil is
The number of rows again indicates the number of independent
effectively canceled by the auxiliary foil. Studies in [1] proved
circuits.
that earthing of the auxiliary foil reduces the intracapacitance
The next step is to find the inverse of matrix A and multiply
Ci1 approximately to 1/15th, whereas the intracapacitance
this inverse matrix by matrix B. The result of these operations
Ci2 may be assumed unchanged, and the magnetic coupling
contains the transfer functions of the currents in each indepen-
factor between the main and the auxiliary foils, even with
dent circuit, including current I2 , which creates output voltage
nonprofessional winding rolling, obtains values in the range
Uout across resistor Rout . Since the whole result is bulky,
c = 0.9−0.98.
it is skipped here. Instead, the transfer function Wout (s) =
(Uout (s)/Uin (s)) = (I2 (s)Rout /Uin (s)) is presented by
III. T RANSFER F UNCTION
Uout (s) a4 s4 +a3 s3 +a2 s2 +a1 s1 +a0 s0
To find a transfer function of the system with the mutual Wout (s) = = 5
inductance presented in Fig. 3 manually is not simple. Special Uin (s) b5 s +b4 s4 +b3 s3 +b2 s2 +b1 s1 +b0 s0
programs for the symbolic calculations can be used. In our case, (3)
we used the Maxima program currently developed by volunteer
contributors under the General Public License. where
The method of transfer function definition for the circuits
a4 = (M 2 − Lm La ) · (Cb + Ci2 ) · Ci1 Rout
with mutual inductance is presented in [21]. First, we have to
redraw Figs. 3 and 4, taking into account the voltage source a3 = 0
Uin with its internal resistance Rin , as well as a resistance Rout
a2 = [M Cb − Lm Ci1 − La (Cb + Ci2 )] Rout
representing a load.
Let us select four independent circuits inside the main circuit a1 = 0
and choose current directions in them, as indicated in Fig. 4.
a0 = − Rout
Now, we can write the quadratic matrix of the impedances A
as (1), shown at the bottom of the page. The number of rows in b5 = (M 2 − Lm La ) · Cb Ci1 Ci2 Rin Rout

⎡ ⎤
Rin + C1b s + 1
Ci2 s − C1b s 0 − C1i2 s
⎢ − C1b s 1
+ (Lm + La − 2M )s + Rout Lm s + M s −La s + M s ⎥
A=⎢ ⎣
Cb s ⎥
⎦ (1)
0 −Lm s + M s Lm s + C1i1 s −M s
− C1i2 s −La s + M s −M s La s + − Ci2 s
1

⎡ ⎤
1
⎢0⎥
B = ⎣ ⎦. (2)
0
0
Fig. 5. Asymptotic Bode plot of the HLCF (one phase). Range 1: low
frequencies. Range 2: intermediate frequencies. Range 3: high frequencies.
Range 4: frequencies over the working range of the HLCF.

b4 = (M 2 − Lm La )
· {[(Ci1 + Cb )Ci2 + Cb Ci1 ] Rin
+ [(Ci2 + Cb )Ci1 Rout ]}
b3 = (M 2 − Lm La ) · (Ci2 + Cb ) Fig. 6. Equivalent circuits of the HLCF across the frequency domain (a) at
low frequencies, (b) intermediate frequencies, and (c) high frequencies.
− (Lm Ci1 + La Ci2 )Cb Rin Rout
pacitance Cb and auxiliary foil inductance La , but not the main
b2 = 2M Cb Rin − Lm · [(Ci1 + Cb ) · Rin + Ci1 Rout ] foil inductance Lm . Anyway, the equivalent circuit presented in
− La · (Ci2 + Cb ) · (Rin + Rout ) Fig. 6(a) seems to be reasonable for the design.
At intermediate frequencies [Fig. 6(b)], capacitance Cb be-
b1 = −(Lm + Cb Rin Rout ) comes dominant, and the current flows through the auxiliary
b0 = −Rout . foil. The inductance of the auxiliary foil prevents damping
since its impedance at intermediate frequencies is quite large.
However, in accordance with Lenz law, the current in the
IV. T RANSFER F UNCTION A NALYSIS auxiliary foil creates a current of the opposite direction in the
main foil. This is the same as mutual inductance placed into
Let us consider the HLCF behavior across the frequency
the main foil with the polarity reversed relatively the applied
range from 0.1 Hz to 0.1 GHz. Now, let us think that Rin = 0,
voltage Uin (s). This coupling through the mutual inductance
Rout = ∞, and Lm = La = L.
becomes dominant at frequency
An asymptotic Bode plot is presented in Fig. 5. The fre-
quency ranges are chosen conditionally and related to the 1 1
fres2 =  =  . (5)
resonance frequencies of the HLCF. 2π (La − M )Cb 2π (L − M )Cb
At low frequencies, the inductance of the main foil Lm
provides the lowest impedance. The current in the main foil is After frequency fres2 , the attenuation slope becomes about
zero because Rout = ∞. The current in the auxiliary foil is neg- 0 dB/dec. The level of attenuation at the intermediate fre-
ligible because the capacitance Cb provides large impedance. quencies increases with the mutual coupling between foils.
Therefore, a low-frequency voltage applied at the input terminal Implementing (5) to Fig. 5, we can see that the higher the
appears without changes at the output terminal. Along with mutual inductance between foils is, the better the attenuation
the frequency increase, capacitive coupling via Cb becomes at intermediate frequencies will be.
dominating [Fig. 6(a)]. It happens at frequency From low to intermediate frequencies, components Ci1 , Ci2
in (3) can be replaced with zero. Then, the transfer function
1 1
fres1 = √ = √ (4) becomes
2π La Cb 2π LCb
(L − M )Cb s2 + 1
after which the attenuation increases with the slope Wout (s) = . (6)
LCb s2 + 1
−40 dB/dec.
It is interesting to mention that, according to the transfer At high frequencies, the impedance provided by the capaci-
function, a low-frequency resonance takes place between ca- tance Cb is negligible [Fig. 6(c)]. However, the intracapacitance
Fig. 7. Obtaining the Bode plots with an HP 4194a frequency analyzer.
of the main foil Ci1 worsens the attenuation. The effect of the
intracapacitance of the auxiliary foil Ci2 is negligible. Starting
at frequency
1
fres3 =  (7)
2π (L + M )Ci1
the attenuation falls down with the slope 40 dB/dec.
Finally, at frequency fres4 , a new resonance takes place,
and the attenuation becomes 0 dB/dec. To find this frequency,
the denominator of (3) should be equated to zero, assuming
capacitance Cb to be infinite. Then, the following equality can
be obtained:
(L2 − M 2 ) · Ci1 · s4 + L · s2 + 1 = 0. (8)
Equation (8) gives
 are given as follows: height h = 80 mm and outside diameter
1 L + L2 − 4 · (L2 − M 2 ) · Ci1
fres4 = · . (9)
2π 2 · (L2 − M 2 ) · Ci1
To take into account that L2  4 · (L2 − M 2 ) · Ci1 , (9)
becomes
1 L
fres4 ≈ · . (10)
2π (L − M 2 ) · Ci1
2 foil inductance Lm = 126 μH, auxiliary foil inductance La =
Equation (10) indicates that the higher the mutual induc-
tance, the wider the frequency range of attenuation.
After frequency fres4 , the HLCF can be roughly described as
an intracapacitance of the main foil Ci1 .
V. M EASURED , S IMULATED , AND C ALCULATED R ESULTS
Inductance, capacitance, resistance, and Bode plot measure-
ments were performed with HP 4194a impedance and gain-
phase analyzer, which allows impedance measurement in the
frequency range from 100 Hz to 40 MHz and gain-phase
measurement in the range from 10 Hz to 100 MHz. For gain-
phase measurements, the analyzer comprises two precision
resistances: the input resistance is nonselectable Rim = 50 Ω,
whereas the output resistances can be selected whether Rom =
50 Ω or Rom = 1 MΩ. In real drive, output impedance is
usually more than 1 kΩ, whereas input impedance is relatively
small. Therefore, to prevent damping of the resonances in mea-
sured frequency responses, additional resistance Ria was added
in the test setup, as shown in Fig. 7, and the output resistance
Fig. 8. Investigated HLCF 75-A 400-V prototype with 410-mm diameter.
of the analyzer was chosen to be equal to Rom = 1 MΩ. The
value of additional resistor Ria = 1 Ω was selected to provide

small input resistance Rin = (Rim · Ria /(Rim + Ria )) = (50 ·
1/(50 + 1)) ≈ 1 Ω (calculated in accordance with Thévenin’s
theorem). It was also measured beforehand that resistance Ria
keeps stable values over the frequency range of 10 Hz–30 MHz.
One phase unit of the investigated HLCF prototype is shown
in Fig. 8. It was designed in accordance with recommendations
given in [1] and [2]: small height and large diameter lead
to low cost and price. Large diameter, however, complicates
the installation of the filter phase units. The filter one phase
unit dimensions (excluding terminals) for 75-A 400-V drive
Dout = 410 mm. In a real application, the phase units of such
an HLCF can be placed, for example, on top of each other, even
though the filter then becomes somewhat nonsymmetrical. The
filter is made of aluminum foils (the thickness of the main foil
is 0.5 mm and the thickness of the auxiliary foil is 0.1 mm)
that are separated by a 0.5-mm Nomex insulator. The measured
electrical parameters at 100 Hz are given as follows: main
126 μH, mutual inductance M = 124 μH, capacitance between
foils Cb = 158 nF, intracapacitance of the main foil (auxiliary
foil is not earthed) Ci1 = 0.15 nF, and intracapacitance of the
auxiliary foil Ci2 = 0.15 nF. In accordance with recommenda-
tion in [1], the intracapacitance of the main foil for simulation
is 1/15 of its measured value or Ci1 = 0.01 nF.
A comparison of measured, simulated, and calculated results
is given in Fig. 9. These results show that the measured and
simulated frequency responses are quite similar, particularly
in the frequency range up to 2 MHz. Measured resonances
are damped better than simulated resonances. This is because
only the dc resistances, not ac resistances, of the foils were
taken into account in the simulations. The distributed nature of
the HLCF is also not taken into account in the lumped model
used for frequency analysis. These facts explain the differences
between the measured and simulated responses at intermediate
and high frequencies. (The lengths of the foils of the prototype
are about 17 m, i.e., a transmission line effect can be expected.)
On the other hand, the lumped model simplifies significantly the
frequency behavior of the HLCF analysis given in Section IV.
Differences at frequencies higher than 2 MHz can also be

Fig. 9. Frequency response comparison. (Dark solid line) Measured.
(Dashed line) Simulated. (Light solid line) Calculated.
explained by the inserted impedances of the connection wires,
which were not taken into account in simulations.
The asymptotic frequency response in Fig. 9 is built using
(4), (5), (7), and (10). The simulated and calculated curves
presented in Fig. 9 are, in fact, derived from the same equation.
The differences between simulated and calculated plots are
explained by the fact that asymptotic response does not take
into account signal amplification (or attenuation) at resonance
frequencies.
It is evident that the asymptotic frequency response describes
the HLCF model behavior quite well. Such a simple approach
can be used, for example, in MS Excel or other similar pro-
grams for quick HLCF property estimation.
VI. C ONCLUSION
This paper has considered a new type of electrical filter
called hybrid LC filter, which can be used in power electronic
drives replacing traditional du/dt filters. Such a filter reminds
a conventional foil choke, but an additional auxiliary winding
is integrated between main winding turns. This winding can
be connected to a neutral potential of the drive. The proposed
construction allows transforming the internal stray capacitance
of the conventional foil choke into a useful capacitance, which
contributes to the DM and CM noises’ attenuation.
However, auxiliary foil integration complicates the HLCF
analysis since it creates essential mutual inductance, which
influences the filter frequency responses. In combination with
modern scientific software, nowadays, methods of the electric
circuits’ analysis provide extensive possibilities for the investi-
gation of the devices with mutual coupling.
Thus, HLCF has a complex representation in the frequency
domain. At low frequencies, the HLCF can be considered as
a simple LC filter. At intermediate and high frequencies, the
mutual inductance between the main and auxiliary foils plays a
very important role: the higher the mutual inductance, the better
the attenuation. Therefore, theoretically, the main and auxiliary
windings of the HLCF should be placed as close to each
other as possible. This is also desirable to increase the useful
capacitance between foils. However, in practice, the decrease
in the distance between the windings is limited by the voltage
stress applied to the insulation layer. Anyway, to provide the
best possible performance, the winding and insulation layers
should be coiled as tight to each other as possible.
The equations proposed in this paper are convenient for the
HLCF properties estimation with the asymptotic Bode plots.
With that, the transfer function of the HLCF proposed in this
paper can be used for the HLCF analysis in time and frequency
domains.
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Valentin Dzhankhotov was born in St. Petersburg,
Russia, in 1977. He received the Ph.D. degree
(control systems) from Saint Petersburg State Elec-
trotechnical University (LETI), St. Petersburg, in
2004, and the D.Sc degree (electrical engineering)
from Lappeenranta University of Technology (LUT),
Lappeenranta, Finland, in 2009.
In 2000, he became a Lecturer with the Control
Systems Department, LETI. In 2008, he became an
R&D Researcher with The Switch Drive Systems
Oy, Lappeenranta. In 2010, he became a Researcher
with the Department of Electrical Engineering, LUT. His current research
interests are high-power drives, particularly electrical filters and control.
Juha Pyrhönen (M’06) was born in Kuusankoski,
Finland, in 1957. He received the D.Sc. degree
from Lappeenranta University of Technology (LUT),
Lappeenranta, Finland, in 1991.
He became an Associate Professor of electrical en-
gineering with LUT in 1993 and a Professor of elec-
trical machines and drives in 1997. He is currently
Head of the Department of Electrical Engineering,
where he is engaged in research and development
of special electric motors and drives. His current re-
search interests include different permanent-magnet
synchronous machines, induction motors, and solid-rotor high-speed induction
machines and drives.
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Pertti Silventoinen was born in Simpele, Finland, in
1965. He received the D.Sc degree from Lappeen-
ranta University of Tecnology (LUT), Lappeenranta,
Finland, in 2001.
He became a Professor of applied electronics in
2004. He is currently Head of the Degree Program
in Electrical Engineering with the Department of
Electrical Engineering, Institute of LUT Energy. His
current research interests include power electronic
systems in various applications.
Mikko Kuisma was born in Finland in 1971. He
received the M.Sc. degree in electrical engineering
and control systems and the D.Sc. degree in elec-
tronics from Lappeenranta University of Technology,
Lappeenranta, Finland, in 1997 and 2004.
Since 1995, he has been a Research Engineer and
Lecturer with Lappeenranta University of Technol-
ogy, where he is currently an Associate Professor
of applied electronics. His research interests include
electromagnetic compatibility (EMC), power elec-
tronics, analog signal processing, and engineering
education. His recent research interests include EMC in power electronics,
signal processing in biosensors, and academic curriculum in higher education.