Integrated EMC Filter PLC Interface Common Mode Choke

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Solution Overview

Problem

Existing DC-AC inverters face challenges in integrating electromagnetic compatibility (EMC) filtering and power line communication (PLC) interfaces, leading to increased size and cost due to the separate components required for filtering AC output power and coupling PLC signals.

Innovation Solution

An integrated EMC filter with a PLC interface is designed, combining common mode choke windings for EMC filtering and differential mode windings for PLC, allowing for simultaneous filtering and signal coupling, thereby reducing physical space and production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate EMC filter and PLC transformer components are used, then EMC filtering and PLC signal coupling functions are achieved, but the inverter size and production cost increase

Engineering Contradiction:

ImproveEMC filtering and PLC signal couplingVSAvoidinverter size

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent combines the EMC filter and PLC transformer into a single integrated component that performs both functions simultaneously. The common mode choke windings serve dual purposes: filtering EMC noise and coupling PLC signals, eliminating the need for separate components and reducing overall inverter size.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated component is designed to perform multiple functions: EMC filtering through common mode rejection and PLC signal coupling through differential mode operation. This multi-functionality allows a single component to replace what would traditionally require separate dedicated components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate EMC filter and PLC transformer components are used, then EMC filtering and PLC signal coupling functions are achieved, but the production cost increases

Engineering Contradiction:

ImproveEMC filtering and PLC signal couplingVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By merging the EMC filter and PLC transformer into one integrated component, the patent reduces the total number of parts that need to be manufactured, assembled, and tested. This consolidation simplifies the manufacturing process and reduces production costs while maintaining both filtering and communication functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The universal design that performs both EMC filtering and PLC coupling in a single component reduces bill of materials costs and assembly complexity, directly impacting production cost reduction while ensuring both functions are reliably performed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Volume of stationary object

If an integrated EMC filter with PLC interface is used, then the inverter size and cost are reduced, but the design complexity increases

Engineering Contradiction:

Improveinverter sizeVSAvoidintegrated filter design

Core Design Contradiction:

Volume of stationary objectVSDevice complexity

Solution Approach 1:

The integrated component is designed with distinct winding sections: common mode windings for EMC filtering and differential mode windings for PLC coupling. This segmentation of functions within a unified structure allows the complex multi-functional component to be designed and analyzed in manageable parts.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The integrated solution effectively reduces the size and cost of inverters while maintaining compliance with EMC standards and enabling efficient PLC communication, enhancing overall system performance.

Implementation Method 1

An integrated electromagnetic compatibility (EMC) filter and power line communication (PLC) interface is provided. The integrated EMC filter/PLC interface comprises a common mode choke having a first plurality of windings and a second plurality of windings

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The first plurality of windings on the common mode choke provide an EMC filter for filtering the AC output power from a DC-AC inverter. The second plurality of windings on the common mode choke provide a PLC interface for coupling a PLC signal to and from the AC output

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10367408B2Electromagnetic compatibility filter with an integrated power line communication interface

Publication Date: 2019.07.30 ENPHASE ENERGY INC

AI summary

An embodiment of the present invention is directed to an integrated electromagnetic compatibility (EMC) filter and power line communication (PLC) interface. The EMC filter and PLC interface comprises a first filter winding and a second filter winding configured as a common mode choke; and a two-part winding on the common mode choke, wherein the two-part winding comprises (i) a first winding coupled proximate the first filter winding and (ii) a second winding coupled proximate the second filter winding, wherein the first winding and the second winding have an equal number of turns, and wherein phasing of the first winding is reversed with respect to the second winding.