The advent of wide-bandgap (WBG) devices like silicon carbide (SiC) MOSFETs has resulted in a paradigm shift toward high-density and high-efficiency integration of power electronics systems. This being the result of relatively high switching frequencies (>10 kHz) compared to conventional Si IGBT counterparts, which reportedly can minimize the size of passive components such as DC-link capacitors and line harmonic filters. Unfortunately, with faster switching speeds and high slew rates, the common-mode (CM) and differential-mode (DM) conducted emissions interference (EMI) noise is worsened. The effects are manifested at the utility interface with grid-tied applications (three-phase rectifiers or back-to-back converters) in the form of high CM and DM emissions, total harmonic distortion (THD) and current harmonics. While at the motor end, long cable and bearing/leakage current effects are prevalent. As such, typically bulky passive filters are recommended to comply with industry regulations and allow safe and reliable system operation, which can be detrimental on the overall system power density. Hence, it is imperative to minimize the filter volume/weight contribution to fully utilize the benefits of WBG power converters. As an added feature, modular filter building block (FBB) configurations inspired by the building block nature of power electronics converters are needed to address scalability to higher power levels (through interleaving or paralleling) without the need for significant filter redesign. As such, for grid-tied applications (AC-DC converters), the interleaving of parallel converters adopted to achieve superior harmonic attenuation for grid-side currents at the expense of low harmonic filter volume. Therefore, interleaved converters are explored in Chapters 2 and 3. However, to block inter-channel circulation, additional use of coupled inductors (CI) can outweigh the benefits of interleaving. Therefore, modular FBB architectures with unique methods to handle circulating currents are proposed. At the same time, the FBB is designed to meet power quality and EMI limits for any given number of channels, up to the maximum number of channels, N, allowed at the point of common coupling (PCC). Consequently, a qualitative and quantitative comparison of FBB candidates is performed, and the indirectly coupled FBB using a secondary loop interconnection is proposed as a viable modular FBB candidate. Correspondingly, for DC-AC inverters, modular filters can be realized using a masked impedance and decoupling approach. The test case being a DC-fed motor drive for aircraft propulsion systems. Techniques, such as optimized parallel RC dampers to reduce the peak bearing current and CM/DM magnetic integration of a DC side filter with an embedded DC current sensor and embedded decoupling path with gate driver for high frequency commutation, are implemented to reduce the overall weight of the system. The challenges with low temperature rise margin due to high ambient temperature and low peak Partial Discharge Inception Voltage (PDIV) are addressed. In addition, a novel pulse with modulation (PWM) scheme is proposed to further enhance the bandwidth of the proposed AC filter, specifically targeted to reduce the peak bearing current and improve the specific power and motor lifetime. A negative consequence of high-density filter integration is the impact of self and mutual parasitic couplings of filter sub-components on filter attenuation, which is studied on a back-to-back converter system (AC-AC). Simplified lumped models that are representative of the high frequency filter behavior are developed to desensitize the impact of individual filter sub-components. Thereafter, unique winding and placement techniques are proposed to compensate for the impact of self and mutual parasitic couplings on the noise spectrum. Overall, this work presents potential FBB topologies for varying modes of power conversion (AC-DC, DC-AC, and AC-AC), ultimately aimed at reducing the volume/weight of the system. Methods to minimize the passive component volume/weight from the point of view of topology, magnetic integration, and PWM techniques are discussed, while the implications of a high-density integration at high frequency is presented. Generalized practical design guidelines are formulated to aid in accurate high-density filter design for WBG converters. / Doctor of Philosophy / With the ever-increasing use of switching converters, either AC-DC, DC-AC, or DC-DC converters, electromagnetic interference issues can affect the overall system performance, which necessitates the use of filters. This is especially true with more and more point-of-load applications (parallel converters in charging stations, industries, and residential loads), distributed energy sources (solar power, wind power, and battery storage systems), and primary sources (power plants) being integrated together into a super grid. Similarly, transportation applications (electric vehicles, more-electric aircrafts) demand strict filtering requirements, due to the prime importance of reliability. Therefore, three-phase power quality and EMI filters are an integral part of any power conversion system, from low to high power applications. First, novel techniques to address the scalability and modularity of filters with parallel converters are considered (grid-tied application), where the benefits of interleaving and challenges in circulating current mitigation are addressed. The idea is simply to design one filter that can be used with any given number of converters running in parallel, which promotes rapid manufacturability to meet the ever-increasing demand. Thereafter a highly integrated and optimized filter structure is demonstrated for a traction inverter used in aerospace propulsion. Challenges pertaining to compact filter design are addressed, and new methods are proposed to overcome some of the critical issues that come with high-altitude operation, such as reliability, high temperature, and partial discharge-free operation. Lastly, the effect of non-idealities on filters that can lead to deteriorated performance is explored. As such, solutions to compensate for these effects are proposed and verified. Clearly, there is a need to optimize filters as well, minimizing their volume and weight contribution within a power converter. This aspect is considered throughout the work where design guidelines are proposed to optimize the given filter topology, filter parameter selection, and form factors for different applications, ranging from AC-DC converters to DC-AC traction motor drives.

La diminution drastique des temps de commutation des convertisseurs MLI, due aux technologies émergentes comme le SiC (Carbure de Silicium), engendre un nombre important de phénomènes hautes fréquences dans les moteurs électriques notamment des tensions inter-spires et des courants de paliers. Ces travaux portent sur l'établissement d'un modèle impédant prédictif, valable sur une large bande de fréquence, fournissant les valeurs des tensions et des courants dangereux pour les moteurs. Pour cela, une maquette à échelle réduite a été étudiée dans un premier temps pour comprendre les phénomènes et offrir un cas simplifié de modélisation. Un bobinage en circuit imprimé a été fabriqué à cet effet. Un modèle de ligne a été développé et offre des résultats satisfaisants en prenant en compte les effets dus à la montée en fréquence. La même démarche de modélisation a été adoptée dans le cas du moteur réel dans la suite des travaux. Des campagnes de mesures sur un moteur instrumenté ont permis d'observer la propagation des ondes dans le bobinage. Une bobine a également été instrumentée pour offrir un accès au potentiel de chaque spire. Un modèle présenté dans la littérature a été approfondi en proposant une méthode d'identification des paramètres à partir de quelques points de mesures. Ce modèle sert de comparaison avec le modèle prédictif établi à la fin de ces travaux. La dernière partie de ces travaux s'intéresse à la modélisation du même moteur de traction. Un modèle de ligne dont les valeurs de paramètres ont été issues de calculs analytiques ou de simulations numériques a été réalisé tout en évitant d'avoir recours à des mesures. Ce modèle a donc un comportement prédictif puisque les données d'entrées sont pour la plus grande majorité uniquement géométriques. Il donne accès aux valeurs de tensions dans le bobinage et à l'amplitude des éventuels courants de paliers. Ce modèle peut alors servir d'outil d'aide à la conception des machines électriques en montrant les conséquences des choix de géométries. / In PWM converter, emerging technologies, like Sic and GAN, tend to decrease the rise time commutation which increases the occurrence of high frequency phenomenon such as bearing currents and voltage between coils. In this thesis, we aim to develop a predictive model able to give the currents and voltages amplitudes of those parasites. To simplify the understood of the phenomenon, a mock-up was built. It consists of a winding coil in a flexible PCB which represents the wave propagation in a real winding. Therefore, a first model was developed taking into account the effects produced by an increasing frequency. The model gives good results. It will be used in the real traction motor. Measures on a modified motor allowed observing the wave propagation across the coil. Those measures results will be compared to our motor model ones. A model found in the literature has also been studied. For this model, we built a parameters identification method based on several measurement points. This model will also be a compared to our motor model. The last part of this work explains the method used to build the predictive model. A line model is used to give an access to the winding. All parameters have been found with analytical formulations or with numerical simulations to avoid the use of measures. This model gives an access to a voltage between coils and to bearings currents. It can be used during the conception of motor to predict those problems.

Bearing currents are not all the same. Under certain circumstances and special use cases classic bearing insulations are not sufficient anymore to prevent bearing currents due to the operation of frequency converters. Additional corrective measures have to be implemented to reduce the source of bearing currents the common mode current. The usage of nanocrystalline tape wound cores shows high effectiveness. As part of a big field study with more than 50 large drive trains in the primary industry, the damaging mechanics of bearing currents are examined under real conditions. Of exceptional high interest is the influence of disturbances which can hardly be simulated in the laboratory. Additional to the shielded motor cable parallel installed functional potential equalization cables applied multiple times have almost no effect in regard to reducing the bearing current. With an optimal installed functional potential equalization system more than 95 percent of the common mode current can flow back through the motor cable shield to the converter. The disturbance impact in the field can influence the voltage over the bearing that breakthroughs are favored but also reduced.

Electric machines are widely used in for instance the automotive industry in electric vehicles and in wind turbines. The electrical machines have mechanical bearings as an integral part used to transmit power and load. In addition, the main function includes reducing friction between interacting surfaces. However, it is one of the most failing machine elements in these machines. To improve operational sustainability and reduce maintenance costs, understanding bearing failure mechanisms under electrical influence is important. One of the main reasons of bearing failure is linked to high frequency power switches typically used to enhance electric machines’ efficiency. The increase in switching rate induces more frequent common mode voltage fluctuations making the system vulnerable to bearing currents. A small voltage difference of a few ten volts can induce significant electric stress on the bearing depending on the lubricant film thickness and related tribological parameters. The electric charge build-up leads to electric current conduction (arc discharge which happens when the voltage exceeds the breakdown voltage) ultimately damaging the bearing. There are different mitigation strategies which are used to restrict bearing currents through grounding or using completely insulative bearings such as ceramic ones. However, at the moment, there are no satisfactory solutions and there is a need for efficient and economical solutions to the problem. On the other hand, various filters are used to reduce the amplitude and its frequency of bearing currents, but they only partly solve the problem. Similarly, the insulative surface coatings provides high electrical resistance but start acting as capacitors. At a sufficiently high voltage difference, the current passes through the system. Therefore, mitigation strategies are still being explored to improve system performance and service-life. To understand the bearing discharge activity and electrical breakdowns, an electrified ball bearing rig is developed with the ability of testing different electrical properties of lubricants and running conditions. To be able to characterize the electrical properties of a bearing, two electrical circuits are designed. Experimental tests are carried out with PAO-15 and an electrical conductivity-enhanced PAO-15/P-SiSO lubricant with addition of ionic liquids. The influence of different tribological parameters such as rotational speed and viscosity are compared with respect to discharge activity. In addition, two fully formulated experimental oils are compared and evaluated in terms of their electrical performance. The bearing is found to be in different states showing electric-field dependent insulation breakdown ranging from resistive to resistive-capacitive to capacitive states. The electric characterization shows a difference between the boundary, mixed and full film lubrication regimes. Conclusively, the electrical behavior of a mechanical bearing is characterized experimentally to understand discharge problem and roadmap solution opportunities.

The technological advancement in electrical machinery represents the need to understand the lubricant behaviour in the electrical environment. As shaft voltages are unavoidable in electrical machinery, developing new grease formulations and studying their performance against electric loads is required. The thesis aims to design, develop, install and validate a novel test machine to study grease performance under the influence of electric currents. The system aims to supply damaging electric currents through the bearing, but that was not possible to accomplish due to miscalculations. The test machine is designed to carry out experiments using angular contact bearings. The experiments were performed with four greases, Lithium-complex and polypropylene-based, of high and low base-oil viscosity, respectively. The study compares the frictional moments and self-induced temperatures in the bearings with and without the influence of electric currents. Along with the frictional moment measurements, the lubricant film thickness was estimated using the “electrical-capacitance” method to monitor the status of the lubricant inside the bearing in real-time. The test machine is limited to speeds up to 3600 rpm, and the project lays out a foundation for research in film thickness estimation in rolling element bearings. As a part of the thesis, new slip rings were specified to facilitate the test machine to perform studies at higher speeds up to (17000rpm). / De tekniska framstegen inom elektriska maskiner representerar behovet av att förstå smörjmedlets beteende i den elektriska miljön. Eftersom axelspänningar är oundvikliga i elektriska maskiner krävs utveckling av nya fettformuleringar och studier av deras prestanda mot elektriska belastningar. Avhandlingen syftar till att designa, utveckla, installera och validera en ny testmaskin för att studera fettprestanda under påverkan av elektriska strömmar. Systemet syftar till att leverera skadliga elektriska strömmar genom lagret, men det var inte möjligt att åstadkomma på grund av felberäkningar. Testmaskinen är designad för att utföra experiment med vinkelkontaktlager. Experimenten utfördes med fyra fetter, litiumkomplex- och polypropenbaserade, med hög respektive låg basoljeviskositet. Studien jämför friktionsmomenten och självinducerade temperaturer i lagren med och utan påverkan av elektriska strömmar. Tillsammans med mätningarna av friktionsmomentet uppskattades smörjmedelsfilmtjockleken med hjälp av metoden "elektrisk kapacitans" för att övervaka statusen för smörjmedlet inuti lagret i realtid. Testmaskinen är begränsad till hastigheter upp till 3600 rpm, och projektet lägger en grund för forskning inom filmtjockleksuppskattning i rullager. Som en del av avhandlingen specificerades nya släpringar för att underlätta för testmaskinen att utföra studier vid högre hastigheter upp till (17000rpm).