Resonant inverter power and coil parameters determination for metal surface hardening

In this paper, a design of a resonant inverter is conducted with the induction coil system for induction surface metal hardening. Considering a sample metal rod made out of AISI 1038 material, we propose to determine the required power size of the inverter and the induction coil specifications, which would enable to deliver the necessary heat to achieve the appropriate hardening profile. In this approach, the system operates in the medium resonant frequency range of 1-30 kHz, and with a penetration depth spanning from 0.5-1. The approach combines a 2D numerical analysis for eddy currents losses determination in the first stage, followed by an electrical circuit analysis to account for the magnetic and electrical aspects of the system. To demonstrate the effectiveness of the approach, a comparison is performed between the predicted and the experimental performances using a low power prototype for induction hardening applications.

[1]  K. Jirasereeamornkul,et al.  A high efficiency of a Class-D resonant inverter high power factor for induction heating multi-coils hardening application , 2013, 2013 IEEE 10th International Conference on Power Electronics and Drive Systems (PEDS).

[2]  Mutsuo Nakaoka,et al.  High Efficiency Discrete Pulse Modulation Controlled High Frequency Series Load Resonant Soft Switching Inverter for Induction-Heated Fixing Roller , 2006 .

[3]  S. B. Dewan,et al.  Starting problems associated with a transformer coupled load in a series inverter , 1988 .

[4]  Mohammad Hossein Tavakoli,et al.  Influence of workpiece height on the induction heating process , 2011, Math. Comput. Model..

[5]  J.M. Espi,et al.  Design considerations for transformerless series resonant inverters for induction heating , 1997, Proceedings of Second International Conference on Power Electronics and Drive Systems.

[6]  Bilel Meziane,et al.  Open-loop control of full-bridge resonant inverter for induction metal surface heating , 2014, IECON 2014 - 40th Annual Conference of the IEEE Industrial Electronics Society.

[7]  H. Zeroug,et al.  Efficient digital adaptive control for full-bridge series resonant inverter for surface metal heating , 2014 .

[8]  L. C. Meng,et al.  Variable turn pitch coils design for heating performance enhancement of commercial induction cooker , 2012 .

[9]  N. Tsopelas,et al.  Influence of Some Parameters on the Effectiveness of Induction Heating , 2008, IEEE Transactions on Magnetics.

[10]  T. Todaka,et al.  Designing of suitable construction of high-frequency induction heating coil by using finite-element method , 2005, IEEE Transactions on Magnetics.

[11]  Oscar Fernandez,et al.  Design and implementation of a 120A resonant inverter for induction furnace , 2013, 2013 IEEE International Autumn Meeting on Power Electronics and Computing (ROPEC).

[12]  Eiji Sekiya,et al.  Application of High-Frequency Induction Heating Apparatus to Heat Treatment of 6061 Aluminum Alloy , 2011 .

[13]  Enrique Maset,et al.  Improving the Reliability of Series Resonant Inverters for Induction Heating Applications , 2014, IEEE Transactions on Industrial Electronics.

[14]  Soe Sandar Aung,et al.  Design Calculation and Performance Testing of Heating Coil in Induction Surface Hardening Machine , 2008 .

[15]  Nistor Daniel Trip,et al.  Considerations on the analysis of an induction heating system , 2014, 2014 11th International Symposium on Electronics and Telecommunications (ISETC).

[16]  Xiaoguang Yang,et al.  Simulation of induction heating device with double inductors for continuously heating up steel bars , 2008, 2008 World Automation Congress.