EMI-RFI filters are used to reduce electromagnetic interference generated by variable frequency drives and servo drives which when installed inside automated machinery create RF disturbances at high frequencies that affect other electrical devices such as nearby machinery, PLCs, sensors or PCs.

EMI and RFI both refer to unwanted electromagnetic signals that can interfere with electronic devices, while EMC refers to the ability of electronic devices to function properly in the presence of electromagnetic interference.

There are some tests that can be used to evaluate the effectiveness of an EMI filter in reducing electromagnetic interference in your design such as conducted emission testing ,radiated emission testing,Component testing etc...

Yes, Leakage current and Voltage drop has to be taken into consideration while designing EMI Filters . Series inductance will have voltage drop and parallel capacitance will have leakage current . The Voltage drop and the Leakage currents are intentional effect that have major contribution in the Filter performance.

"There are certain filters which are designed for PCB Mountable application . A simple way to have a filtering circuit in the PCB could be the combination of capacitors and inductors at the input stage. But this can only give basic protection and may not be able to provide advanced protection and insertion loss like a well designed EMI filter "

The impact of an EMI filter on a circuit's power consumption or efficiency depends on the type of filter used. Generally speaking, EMI filters can reduce the amount of power used by a circuit, as they reduce the amount of interference entering the circuit. However, the use of EMI filters can also reduce the efficiency of a circuit, as they may limit the amount of power that can be delivered to the circuit.

power loss can be a cause of Electromagnetic Susceptibility (EMS), but it can be mitigated through the use of backup power systems and proper grounding and shielding techniques.

There are some limitations by using EMI filters which includes Size and price .other alternative might be design level optimization.

Based on the application ,filters are designed to withstand high temperature ,schock and vibration by choosing the potting component .

optimizing the cost of an EMI filter without sacrificing performance requires a careful balance between the design, materials, manufacturing process, and testing. By carefully considering these factors, it is possible to create an effective EMI filter that meets performance specifications at a reasonable cost.