The performance optimization of the two-level, three-phase, grid-feeding, voltage-source inverter (VSI) is studied in this paper, which adopts an online adaptive switching frequency algorithm (OASF). A new degree of freedom has been added to the employed OASF algorithm for optimal selection of the weighting factor and overall system optimization design. Toward that end, a full mathematical formulation, including the impact of the coupling inductor and the controller response time, is presented. At first, the weighting factor is selected to favor the switching losses, and the controller gains are optimized by minimizing the integral time-weighted absolute error (ITAE) of the output active and reactive power. Different loading and ambient temperature conditions are considered to validate the optimized controller and its fast response through online field programmable gate array (FPGA)-in-the-loop. Then, the weighting factor is optimally selected to reduce the cost of the L-filter and the heat-sink. An optimization problem to minimize the cost design at the worst case of loading condition for grid-feeding VSI is formulated. The results from this optimization problem are the filter inductance, the thermal resistance of the heat-sink, and the optimal switching frequency with the optimal weighting factor. The VSI test-bed using the optimized parameters is used to verify the proposed work experimentally. Adopting the OASF algorithm that employs the optimal weighting factor for grid-feeding VSI, the percentages of the reductions in the slope of the steady state junction temperature profile compared to fixed frequencies of 10 kHz, 14.434 kHz, and 20 kHz are about 6%, 30%, and 18%, respectively.
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