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Induction heating offers several advantages including fast start-up, energy savings, and high production rates due to efficient heat generation within the workpiece. The process relies on alternating magnetic fields to induce eddy currents, with heat generated primarily through Joule heating and magnetic hysteresis loss in ferromagnetic materials. Key components of the induction heating system include the inverter, induction coil, and matching transformers to ensure optimal power transfer and efficiency.

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Uday k
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3 views

induction_12

Induction heating offers several advantages including fast start-up, energy savings, and high production rates due to efficient heat generation within the workpiece. The process relies on alternating magnetic fields to induce eddy currents, with heat generated primarily through Joule heating and magnetic hysteresis loss in ferromagnetic materials. Key components of the induction heating system include the inverter, induction coil, and matching transformers to ensure optimal power transfer and efficiency.

Uploaded by

Uday k
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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 Advantages of Induction Heating

 Fast start-up & Quick heating


 Energy Savings – can be turned off often as restarting
is quick
 Efficient as heat is generated inside the workpiece
 Non-contact, heated material not contaminated
 High Production rates
 Ease of automation and control
 Quiet, safe and clean environment
 Low maintenance
 Less scale loss
Working Principle of Induction Heating
 Work-coil acts like primary of transformer and generates alternating magnetic
field
 Workpiece acts like single turn shorted secondary and eddy currents flow in the
workpiece
 Induction heating has two mechanisms of energy dissipation for heating
 Joule heating
 Heat power due to eddy currents induced in conducting material placed
in changing magnetic field
 Ф=μoIcnπ ro2, E = -N(ΔФ/Δt), R= ρl/A, P= E2/R
 Sole mechanism of heat generation in Non-magnetic materials like
aluminium, copper, stainless steels, carbon steel above Curie
temperature
 Primary mechanism in ferro-magnetic materials below Curie
temperature ( eg carbon steels )
 Magnetic hysteresis loss
 Secondary mechanism in ferro-magnetic materials below Curie
temperature ( eg carbon steels )
Block Diagram of Induction Heating System

Inverter

 Induction Coil design as per the heating requirements of the load


– Depth of Heating => frequency
– Temperature & Duration => Wattage => current, voltage
– Shape => Inductance
 Load Matching

 Capacitor to correct Coil Inductive Reactance and get unity power factor at

resonance frequency
 Matching Transformer for isolation and matching with standard voltage

levels
 Inverter for frequency control – typically square wave voltage, sine wave

current due to load resonance


 Line Rectifier for power / voltage level control. Also incorporating Line Power

Factor Control to ensure near unity Line Power Factor


Max Impedance at fr Min Impedance at fr

Rp – work coil resistance


Rs – secondary eddy current path resistance
in workpiece reflected to primary
Xlp – work coil reactance
Xls – secondary eddy current path reactance
in workpiece reflected to primary
Xlg – secondary air gap reactance between  Under no-load only power to overcome
coil and workpiece reflected to primary leakage losses is drawn from the supply.
P= I2 x(Rp +Rs)  When a lossy work-piece Rs is inserted in
the work-coil the system is damped and
draws power from the source
Impedance Matching
 Work-piece and Work-coil takes large current while Power Source
(Inverter) typically operates at higher voltage and low current.
Matching is done using
 Step-down Transformer
 Auto-transformer, LCL tank
 Coil inductance is matched by Capacitor at resonant frequency to
give unity power factor and maximum heating power to the workpiece
 Inductor coil 100kW, 40V, 10,000A ,10KHz
 Power Source 100kW, 440V, 350A, 10KHz
 Use isolation transformer 440:40 ie 11:1
 Current drawn from the Power Source = 10000/11 = 909A beyond
capacity of source
 Addition of Capacitor in load circuit to achieve unity power factor
would result in a current requirement of 100KW/440V = 227A
 A huge current flows through the work-coil and capacitor but inverter has to supply only
relatively low current
 Placing the Capacitor nearest to the work-coil reduces the circulating currents in the system

- reduces transformer VA
 Placing the Capacitor in the Primary of the transformer - reduces capacitance and capacitor

current but increases the transformer VA


 Capacitor are specified in KVAr

KVAr = VI = V2/(XLx1000) = (2xπxFxCxV2)/1000


 Active Transformers

 only active power transferred from primary


 Decrease current through the semiconductors
 Reactive Transformers
 Both Active and reactive power transferred from Primary
 Used for low impedance inductors – capacitance and capacitor
current is reduced

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