An accurate measurement method to extract the common mode (CM) and the differential mode (DM) noise source impedances of a switched-mode power supply (SMPS) under its operating condition is developed and validated. With a proper premeasurement calibration process, the proposed method allows extraction of both the CM and the DM noise source impedances with very good accuracy. These noise source impedances come in handy to design an electromagnetic interference filter for an SMPS systematically with minimum hassle.

This paper presents a design methodology for a high power density converter, which emphasizes weight minimization. The design methodology considers various inverter topologies and semiconductor devices with application of cold plate cooling and LCL filter. Design for a high-power inverter is evaluated with demonstration of a 50 kVA 2-level 3-phase SiC inverter operating at 60 kHz switching frequency. The prototype achieves high gravimetric power density of 6.49 kW/kg.

Based on a two-probe measurement approach, the noise source and noise termination impedances of a switched-mode power supply (SMPS) under its normal operating condition are measured. With the accurate noise source and noise termination impedances, an electromagnetic interference (EMI) filter can be optimally designed. A practical example of the design of an EMI filter to comply with a regulatory conducted EMI limit using the proposed procedure is demonstrated and compared with the cases, where the noise source and noise termination impedances are not taken into account, or coarse estimates of them are considered. Although all approaches allow filtered SMPS to pass the regulation limits, designing EMI filters with the accurate noise source and termination impedances leads to optimal component values and avoids overdesign.

To achieve high power density, increasing the switching frequency of the power converter has become a trend. The LCL filter is a major contributor of the overall weight of a high-power-density converter (HPDC), especially the inverter-side inductor, which requires to suppress higher frequency harmonic contents at the inverter side. This paper describes a comprehensive design flow of the LCL filter for a 50-kW, 60-kHz two-level silicon carbide (SiC) inverter for high-power aerospace applications with space constraint and harsh ambient temperature environment. To meet the space constraint requirement and reduce the inductor size, specific design attention is made on a customized amorphous cored inductor with a comprehensive study on the relationships of inductor weight, core width, and total surface area with respect to air gap length. To overcome the harsh ambient temperature environment, a liquid cooling system of the amorphous cored inductor is also described.