Industrial Approach to Design a 2-kVa Inverter for Google Little Box Challenge

Uninterruptible power system, photovoltaics inverters, home appliances, motor drives, and automotive systems require highly efficient, reliable, and compact single-phase inverters. This paper presents different industrial design approach and experimental performance of high power density (100 W/in(3)) single-phase inverter with power output of 2 kVA that was presented for Google Little Box challenge. Multiple technical challenges were addressed, different methodologies described to achieve high power density and high efficiency reliable design. High power density was achieved by using the combination of optimized forced air cooled heatsinks, fully digital control, optimized component packaging, and by the introduction of a series active filter that enabled to reduce the size of dc bus capacitors. Low-loss high flux density magnetic materials such as Amoflux powder iron for power inductors and nanocrystalline magnetic materials for electromagnetic interference filter were also used. To minimize inverter switching losses, SiC devices operating at low switching frequency were adopted. Also, an innovative ground current control strategy is devised to minimize the ground leakage currents.