SINGLE PHASE MELTING MACHINE

1. INTRODUCTION
1.1Overview
Induction heating is the process of an electrically conducting object by
electromagnetic induction, through heat generated in the object by eddy current
An induction heater consist of an electromagnet, and an electronic oscillator that
passes a high frequency alternating current through the electromagnet. The rapidly
alternating magnetic field penetrates the object, generating electric current inside the
conductor called eddy currents. The eddy current flowing through the resistance of the
Material heat by joule heating. In ferromagnetic material like iron, heat may also be
generated by joule heating .In ferromagnetic (and ferromagnetic ) materials like iron
,heat may also be generated by magnetic hysteresis losses. The frequency of current
used is depends upon the object size , material type, coupling (between the work coil
and object to be heated ) and the penetration depth.
An important features of the induction heating process is that the heat is
generated inside the object itself, instead of by an external heat source via heat
conduction. Thus objects can be heated very rapidly. In addition there need not be any
external contact, which can be important where contamination is an issue. Induction
heating is used in many industrial process, such as heat treatment in metallurgy,
Czochralski crystal growth and zone refining used in the semiconductor industry, and
to melt refractory metals which require very high temperatures. It is also used in
induction cooktops for heating containers of food; this is called induction cooking.

Dielectric heating:
Dielectric heating, also known as electronic heating, RF (radio frequency)
heating, and high-frequency heating, is the process in which a radio frequency
alternating electric field, or radio wave or microwave electromagnetic radiation heats a
dielectric material. At higher frequency, this heating is cause by molecular dipole
rotation with in the dielectric heating. Best example is Oven.

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Resistance heating:-
Electric resistance heating is defined as “the heat produced by passing an
electric current through a material that preferably has high resistance.” As the current
passes through the material, ohmic losses (I2R losses) occur. These losses cause the
conversion of electrical energy into heat.
Electric resistance heating is defined as “the heat produced by passing an
electric current through a material that preferably has high resistance.” As the current
passes through the material, ohmic losses (I2R losses) occur. These losses cause the
conversion of electrical energy into heat Inductance. Along with the capacitor and
resister ;inductor are one of the 3 passive linear circuit elements that make up
electronic circuit .inductors are widely used in alternating current (AC) electronic
equipment ,particularly in radio equipment they used to block ac while allowing dc to
pass; inductor design for these purpose.

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History
The basic principle involved in induction heating was discovered by Michael
Faraday as early as 1831. Faraday's work involved the use of a switched DC supply
provided by a battery and two windings of copper wire wrapped around an iron core. It
was noted that when the switch was closed a momentary current flowed in the
secondary winding, which could be measured by means of a galvanometer. If the
circuit remained energized then the current ceased to flow. On opening the switch a
current again flowed in the secondary winding, but in the opposite direction. Faraday
concluded that since no physical link existed between the two windings, the current in
the secondary coil must be caused by a voltage that was induced from the first coil, and
that the current produced was directly proportional to the rate of change of the
magnetic flux.[6]
Initially the principles were put to use in the design of transformers, motors and
generators where undesirable heating effects were controlled by the use of a laminated
core. Early in the 20th century engineers started to look for ways to harness the heat-
generating properties of induction for the purpose of melting steel. This early work
used motor generators to create the medium frequency (MF) current, but the lack of
suitable alternators and capacitors of the correct size held back early attempts.
However, by 1927 the first MF induction melting system had been installed by EFCO
in Sheffield, England.
At around the same time engineers at Midvale Steel and The Ohio Crankshaft
Company in America were attempting to use the surface-heating effect of the MF
current to produce localized surface case hardening in crankshafts. Much of this work
took place at the frequencies of 1920 and 3000 Hz as these were the easiest frequencies
to produce with the equipment available. As with many technology-based fields it was
the advent of World War II which led to huge developments in the utilization of
induction heating in the production of vehicle parts and munitions.[7]
Over time, the technology advanced and units in the 3 to 10 kHz frequency
range with powers outputs to 600 kW became common place in induction forging and
large induction hardening applications. The motor generator would remain the
mainstay of MF power generation until the advent of high voltage semiconductors in
the late 1960s and early 1970s.

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Early in the evolutionary process it became obvious to engineers that the ability
to produce a higher radio frequency range of equipment would result in greater
flexibility and open up a whole range of alternative applications. Methods were sought
to produce these higher RF power supplies to operate in the 200 to 400 kHz range.

Development in this particular frequency range has always mirrored that of the
radio transmitter and television broadcasting industry and indeed has often used
component parts developed for this purpose. Early units utilised spark gap technology,
but due to limitations the approach was rapidly superseded by the use of multi-
electrode thermionic triode (valve) based oscillators. Indeed, many of the pioneers in
the industry were also very involved in the radio and telecommunications industry and
companies such as Phillips, English Electric and Redifon were all involved in
manufacturing induction heating equipment in the 1950s and 1960s.

The use of this technology survived until the early 1990s at which point the
technology was all but replaced by power MOSFET and IGBT solid state equipment.
However, there are still many valve oscillators still in existence, and at extreme
frequencies of 5 MHz and above they are often the only viable approach and are still
produced.[8]

Mains frequency induction heaters are still widely used throughout

manufacturing industry due to their relatively low cost and thermal efficiency
compared to radiant heating where piece parts or steel containers need to be heated as
part of a batch process line.

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Figure 1.1 Block diagram of Single Phase Melting Machine.

The basic block diagram of our project is shown above. In block diagram
the content are power supply, filter, inverter, oscillator, heating coil, inductor. Through
power supply DC power is provided to filter filter convert the pulsating DC into
constant DC then inverter again convert the DC supply into AC supply and this supply
is provided to oscillator circuit oscillator provide the high frequency to the operating
coil and due to magnetization effect metal is heat in the coil and inductor is used for
avoid change in current.

• Power supply unit :

Power supply unit includes transformer and rectifier circuit. Here we used
step down transformer to convert 230v ac supply into 12v ac . supply is transfer from
transformer to rectifier circuit .Rectifire converts AC supply into DC supply.

• Filter section:

Filter section consist of capacitor. Capacitor is used to filter the Ac ripples

from the output of rectifier .

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• Inverter and oscillator section:

The ripple free DC coming from the capacitor is given in the inverter
section. Inverter converts dc into ac . MOSFET is switching device. MOSFET
generates high frequency ac supply required for heating the work piece.

• Working coil :-

Working coil is made up of insulated copper having number of turns .as the
number of turns of coil decreases heating in a work piece will increases.

• Inductor :-

Inductor is used to avoid any change in current passing through the

operating coil of induction heater change in current in coil is avoided to keep eddy
current loss constant throughout the work piece.

Summary of the thesis

An induction cooker normally operates at high frequency and it consists of two
major elements: Power Inverter and Heating Coil. In an induction cooker, an AC
supply is rectified to DC and then DC is used to generate a high frequency AC source
through high frequency inverter. This high frequency current produces a high
frequency alternating magnetic field through an induction coil. Placing a cooking pan
close to the induction coil induces eddy current on the pan. As a result of which, heat
energy is produced on the surface of the pan. The internal resistance of the pan is
another essential parameter which causes the generation of heat as per Joules effect.
Thus, it is the pan itself and not the cooker that heats up and cooks the food. To design
the energy efficient induction cooker, proper selections of high frequency inverter and
semiconductor switch are important.
The resonant inverter consists of resonant circuit and it delivers maximum
power to the load at resonant frequency. Mirror inverter, which is developed from a
modified half bridge series resonant inverter, is used in the present thesis as it offers
reduced switching losses for the power-devices. Also it possesses attractive
possibilities for high frequency operations. Moreover, higher efficiency, lightweight,
overall simplicity in terms of inverter control, protection and maintainability of mirror
inverter have made it very attractive. In the present thesis, high frequency mirror
inverter-fed induction cooker has been analyzed in three ways. Firstly, analytical
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expressions have been developed for different modes of operation. In the next case, it
is simulated through P-SPICE software and finally experiments have been carried out
with a real model.
A comparative study has also been made among the various semiconductor
switches in terms of switching and conduction losses through PSPICE-based computer
simulations and real time experiments. The material, shape and size of the heating coil
of the cooker affect the resonant frequency, Q-factor and efficiency of the inverter.
Thus, it is necessary to optimize the physical parameters of the cooker so as to
maintain the under-damped condition for R-L-C load circuit and to get the maximum
benefit of it. In the present thesis, physical parameters such as operating frequency, AC
resistance and inductance have been calculated analytically considering type and size
of wire, number of strands, number of spiral turns, and number of twists per feet of
heating coil.
Theoretically determination of AC resistance is seen to be complicated and
need to solve complex mathematical equations for achieving the value of AC
resistance. This AC resistance of the heating coil is also determined using a genetic
algorithm tuned neural network. Results have been compared with a well known
analytical method.Finally, one prototype model has been fabricated and experiment
has been carried out with different temperature set.
An induction heater is a key piece of equipment used in all forms of induction
heating. Typically an induction heater operates at either medium frequency (MF) or
radio frequency (RF) ranges.[1]
Four main component systems form the basis of a modern induction heater the
control system, control panel, or ON / OFF switch; in some cases this system can be
absent the power unit (power inverter) the work head (transformer) and the heating
coil (inductor) Radio frequency (RF) induction generators work in the frequency range
from 100 kHz up to 10 MHz. Most induction heating devices (with induction
frequency control) have a frequency range of 100 Hz to 200 kHz. The output range
typically incorporates 2.5 kW to 40 kW. Induction heaters in this range are used for
smaller components and applications such as induction hardening an engine valve.[5]
MF induction generators work from 1 kHz to 10 kHz. The output range
typically incorporates 50 kW to 500 kW. Induction heaters within these ranges are
used on medium to larger components and applications such as the induction forging
of a shaft.[1]
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Mains (or supply) frequency induction coils are driven directly from the
standard AC supply. Most mains-frequency induction coils are designed for single
phase operation, and are low-current devices intended for localised heating, or low-
temperature surface area heating, such as in a drum heater.

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2. LITERATURE REVIEW

In the national steel policy recently announced by the Govt. of India, it

is expected that FDI in the steel industry along with domestic investment will take
place in large integrated steel plants. So, all the focus and of the steel policy is on the
Primary Steel Sector while completely ignoring the Secondary Steel Sector.(1)
Induction melting furnaces in India were first installed to make stainless steel from
imported SS Scrap. But in years 81-82 some entrepreneurs, who were having small
size induction furnaces making stainless steel, experimented in making mild steel from
steel melting scrap, they succeeded. More firms in northern India produced steel
(Pencil Ingots) by using 500 kg to 1 tonne induction furnaces.
The power consumption was found to be about 700 kWh/tonne, which
was nearly 100 units less than EAFs. Bigger size Induction furnaces were then
installed first in North India and then in other states of India. By 1985-86, the
technology of making mild steel by Induction Furnace route was mastered by Indian
Technicians. Induction furnace manufacturers saw the potential and started
manufacturing bigger size/capacity furnaces. By 1988-89 period 3 tonne per charge
induction furnaces were installed (became standard) all over India. The chemistry of
melt was adjusted by adding mill scale, if opening carbon of bath was more. Good
quality of steel melting scrap was used. In 1991-92, the Government license and
control on steel making and rolling was removed. Then more induction furnaces were
installed all over India. The use of sponge iron made it possible to adjust chemistry of
melt. Thus good quality of Mild Steel pencil ingots are being produced with no tramp
elements.(3)
H.K.Jung has designed the optimal inductive coil in the induction heating
process of A356 (ALTHIX) alloy billets of 76 mm diameter and 90 mm length to
reduce the temperature gradient of the billet and to obtain a globular microstructure
was theoretically proposed and tested by reheating experiments. The optimal reheating
conditions to apply the thixoforming process were investigated by changing the
reheating time, holding time, holding temperatures, the capacity of the induction
heating system, and adiabatic material size. This study shows that, the larger the pellet
size, the better the multi-step reheating, and the heating time and the capacity of the
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induction heating system must be increased. In case of the three-step reheating process,
the final holding time is the most important factor and 2 min is suitable to maintain a
globular microstructure.
The analytical technique has been developed by Dae-Cheol Ko et al.[3] in
order to investigate the behavior of semi-solid material considering induction heating
of the workpiece. The induction heating process is analyzed using the commercial
finite element software, ANSYS. The finite element program, SFAC2D, for the
simulation of deformation in the semi-solid state is developed in the present study. The
behavior of semi-solid material is described by a viscoplastic model for the solid phase
and by Darcy's law for the liquid flow. Simple compression and closed-die
compression processes considering induction heating are analyzed. To validate the
effectiveness of the proposed analytical technique, the results of simulation are
compared with those of experiment. A general automatic optimization procedure
coupled to a finite element induction heating process simulation has been developed by
Y. Favennec et al. [5] The mathematical model and the numerical methods are
presented along with results validating the model. The first part of this paper presents
the direct induction heating mathematical model, the related main numerical choices
and especially the ultra-weak coupling procedure. The general optimization problem is
then presented with the full detailed transposition of the ultra-weak coupling procedure
for the adjoint problem. Numerical results provided at the end prove the efficiency and
robustness of the adjoint model in optimizing induction heating processes.
Double-channel induction furnaces are used extensively in many
processing industries due, mainly, to their relatively low operating costs. However,
thermal stresses in the refractory lining caused by high temperatures during the loading
cycle can cause erosion of the lining and premature inductor failure. J.I. Ghojel
developed a such a tool using a thermal modelling software and unidirectional axial
channel flow speeds of the melt that are estimated from analysis based on the first-law
of thermodynamics. This analysis reduces the cost, complications and uncertainties
associated with coupled multiple field analysis approach. The results of the analysis
show reasonable correlation with reported flow data and a comprehensive set of
scenarios can be devised on the basis of the developed approach to simulate start-up,
transient operation and steady state operation of double-channel induction furnaces.

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3. Components of project

1) Transformer:-

Electrical power transformer is a static device which transforms electrical

energy from one circuit to another without any direct electrical connection and with the
help of mutual induction between two windings .it transforms power from one circuit
to another without changing its frequency but may be different voltage level .

There are two types of transformer according to voltage level

• Step up transformer
• Step down transformer
Here we used step down transformer to convert 230v mains supply to 12v . A
step down transformer is a type of transformer , which converts a high voltage (230v )
At the primary side to a low voltage(12v) at the secondary side. The primary winding
of a step down transformer , has more turns than the secondary winding.

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Basic working principle of transformer :

The working principle of transformer is a very simple .it depends upon faradays law of
electromagnetic induction . actually, mutual induction between two or more winding is
responsible for transformation action in an electrical transformer

2. Bridge rectifier:-

Function:-

A bridge is an arrangement of four or more diodes in a bridge circuit

configuration, which provides the same output polarity for either input polarity. It is
used for converting an alternating current (AC) input into a direct current output. A
bridge rectifier provides full wave rectification from a two wire ac input, therefore
resulting in lower weight and cost when compare to a rectifier with a three wire input
from a transformer with a center tapped secondary winding

54

Working:

When input ac signal is applied across the bridge rectifier , during the positive half
cycle diode D1, D3 are forward biased and allows electric current while the diodes D2,
D4 are reverse biased and blocks electric currents. On the other hand , during the
negative half cycles diodes D2 and D4 are forward biased and allows electric current
while diodes D1 and D3 are reverse biased and blocks electric current .
3. Filter capacitor

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Filter capacitor are capacitors used for filtering of undesirable frequencies. They are
common in electrical and electronic equipment, and cover a number of application.

1) Glitch remove on direct current power rails.

2) Capacitors used after a voltage to further smooth dc power supplies.

Film capacitor:-

A film capacitor is a capacitor that uses a thin plastic film as dielectric. They
are relatively cheap, stable over time and have low self inductance and ESR, while
some film capacitors can withstand large reactive power values.Film capacitor are
capacitor which used thin plastic film as the dielectric. This film is made extremely
thin using a sophisticated film drawing process. Once the film is manufactured, it may
be metallized or left untreated, depending on the needed properties of the capacitor.
Electrodes are then added and the assembly is mounted into a case which protect its
from environmental factors.

They are use in many applications because of their stability, low inductance
and low cost. There are many types of film capacitor, including pollyster film,
metalized film, polypropylene film, PTFE film and polystyrene film. The core
difference between this capacitor type is the material used as dielectric, and the proper
dielectric must be chosen according to the application.

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4. Inductor
An inductor, also called a coil , choke or reactor ,is a passive two terminal electrical
component that store electrical energy in a magnetic field when electric current flow
through it. And inductor typically consist of an insulated wire wound into a coil around
a core

When the current flowing an inductor changes, the time varying magnetic field
induces a voltage in the conductor ,describe by Faradays law of induction. According
to Lenz’s law, the direction of induced EMF opposes the change in current that created
it. As a result, inductor oppose any the change in current through them.

An inductor in characterized by its inductance, which is the ratio of the voltage

to the rate of the change of the current. In the international system of unit(SI),the unit
of inductance is henry name for 9th century American scientist joseph henry .in the
measurement of magnetic circuit, it is equivalent to wb/amp .inductor have value that
typically range from 1micro henry to 20 henry .many inductors have magnetic core
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made of iron or ferrite inside the coil , which serves to increase the magnetic field.
5. MOSFET:-

The metal-oxide-semiconductor field-effect transistor (MOSFET, MOS-FET,

or MOS FET) is a type of field-effect transistor (FET), most commonly fabricated by
the controlled oxidation of silicon. It has an insulated gate, whose voltage determines
the conductivity of the device. MOSFET having N channel region between source
and drain is known as N channel MOSFET .It is a 4 terminal device, the terminal are
gate, drain and source and substrate body. The drain and source are heavily dooped N+
region and the substrate is P type . The current flow due to flow of the negatively
charged electrons, that’s why it is known as N channel MOSFET.

When we applied +ve gate voltage the holes present beneath the oxide layer
experiences repulsive force and the holes are push downwords into the bound.
Negative charges which are associates with the accepter atoms. The +ve gate voltage
also attract electrons from N+ source and drain region into the channel thus electron
reach channel is form, now if a voltage is applied between source and drain. The gate
voltage control the electron concentration in the channel N channel MOSFET is
preferred over P channel MOSFET as the mobility of electrons are higher than holes.

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4. Circuit Diagram

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4.1 Basic principle

A source of high frequency electricity is used to drive a large alternating current
through a coil. These coil is known as the work coil. The passage of current through these
coil is generates a very intense and rapidly changing magnetic field in the space within the
work coil. The work piece to be heated is placed within these intence alternating magnetic
field.
Induction heating is the process of heating an electrical conducting object (usually a
metal) by electromagnetic induction, through heat generated in the object by eddy currents.
An induction heater consist of an electromagnet, and an electronic oscillator that passes a
high – frequency alternating current (AC) through the electromagnet. The rapidly alternating
magnetic field penetrates the object, generating electric current inside the conductor called
eddy currents. The eddy currents flowing through the resistance of the material heat it by
Joule heating. In ferromagnetic (and ferrimagetic) materials like iron, heat may also be
generated by magnetic hysteresis losses. The frequency of current used depend on the object
size, material type, coupling (between the work coil and the object to be heated)and the
penetration depth.
An important feature of induction heating process is that the heat in generated inside
the object itself, instead of by an external heat source via heat conduction.Thus object can be
heated very rapidly. In addition there need not be any external contact, which can be
important where contamination is an issue. Induction heating is used in many industrial
processes, such as heat treatment in metallurgy, czochralshik crystal growth and zone
refining used in the semiconductor industry, and to melt refractory metals which require
high temperatures. It is also use in induction cooktops for heating containers of food; this is
called induction cooking

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5. Operation:-

The principal of induction heating is explained with the help of set-up shown in fig. The
metallic job called charge is kept within the alternating magnetic field . When alternating
voltage is supplied across the job coil , as shown in fig. an alternating current start flowing
in the job coil. This current produces an alternating magnetic field. The metallic job placed
in this field cuts the alternating magnetic flux and produces an induced EMF given by,

e={-N (dΦ/dt) Where N is the number of turns in the job coil

Φ is a magnetic flux

(dΦ/dt) is the rate of change of flux

The alternating current produced by induced emf e, are known as eddy currents. These eddy
currents will be responsible for generating the required amount of heat . In fact ,the heat
produced will be in the form of eddy current losses. As the supply frequency is increased the
eddy current losses will increased which will cause more amount of heat to be produced .

Thus for a large amount of heat, high frequency AC is use .skin effect which is also
dependent on the value of frequency, has an important bearing on the process of induction
heating.

Eddy current losses can be expressed by equation We=KF^2B^2V

From above equation it is clear that the watt losses in the form of heat produced is directly
proportional to

(i) The square of supply frequency

(ii) The square of maximum flux density.
(iii) Volume of the object.

The supply frequency has another important effect of depth of penetration of the heat due to
skin effect . in case of charge being magnetic in nature , another component of loss called

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the hysteresis loss is responsible for the total heat generated hysteresis losses given by

Wh=k’.Bm^1.6 V.f

From above equation it is seen that the hysteresis loss varies in proportion to the supply
frequency1.6 power of maximum flux density and volume of the core. An important point to
note is that hysteresis loss take place only up to the curie temperature above this temperature
this loss doesn’t exist because the magnetic properties vanish this losses only take place in
the case of magnetic materials.

Some of the salient points regarding induction heating are given as follow :

1. For a given flux density, frequency ,and resistivity ,the heat input per unit volume
depends on the value of permeability. This means that magnetic materials will get heated up
faster than non magnetic materials.

2. For a given material the depth of heat penetration depends on the supply frequency
.hence it can be controlled by changing frequency .
3. For a given material and frequency the heat input per unit volume depends on the
flux density .thus, the temperature can be controlled by changing no of turns in the coil used for
induction heating .

4. For the given flux density and depth of heat penetration , the heat input per unit
volume depends on the resistivity of the job. Thus material with a high value of resistivity
can be heated in lesser time as compared to the material with low resistivity.

5. Intensity of magnetic field depends on current ,number of turns and core material
.magnetic material heats up faster than non magnetic material because both eddy current and
hysteresis loss occurs in them while in non magnetic material only eddy current loss occurs
.however ,at temperatures above curie point ,the property of magnetism is lost hence, both
magnetic and non magnetic materials are heated equally .

6. Induction heating is generally used for melting , annealing, hardening ,brazing and
soldering of metals .for melting purpose generally mains frequency is used but for forging

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,annealing and deep surface hardening process high frequencies in the rang 0.5 -4Khz are
required for achieving greater efficiency . for brazing and soldering purpose or for hardening of
vary thin and small steel pieces etc., higher frequencies in the rang of 100 Khz to 1Mhz are required
.

For low frequency heating, ac power directly from mains at 50hz may be used, whereas for
high frequency heating a frequency converter device has to be used . some of the frequency
converter devices in use are the motor- alternator set(for 960,3000 or 9600hz), the mercury
pool frequency converter (for 1khz ) , the spark gap converter (50 hz to 200 khz )and the
electronic heater for (300khz to 1mhz )

The use of electric power from direct ac mains at 50 hz is limited for annealing and shaping
operation of steel tubes . the motor alternator sets may be used for induction heating purpose
. mercury pool frequency converters may be used to produced a frequency of about 1khz .
these methods were used in the past for medium frequency heating purpose .

The spark gap converters is device which works on the principle of an oscillating consensor
.the condenser discharges through a spark gap. Spark gap converters are used for high
frequency eddy current heating . electronic heaters are generally employed for very high
frequency heating . they are generally used in induction furnaces meant for very high
temperature heating .

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Control system
The control section monitors all the parameters in the load circuit, the
inverter and supplies switching pulses at the appropriate time to supply energy to the
output circuit. Early systems featured discrete electronics with variable potentiometers to
adjust switching times, current limits, voltage limits and frequency trips. However, with
the advent of microcontroller technology, the majority of advanced systems now feature
digital control.
The voltage-fed inverter
The voltage-fed inverter features a filter capacitor on the input to the
inverter and a series resonant output circuits. The voltage-fed system is extremely popular
and can be used with either SCRs up to frequencies of 10 kHz, IGBTs to 100 kHz and
MOSFETs up to 3 MHz. A voltage-fed inverter with a series connection to a parallel load
is also known as a third order system. Basically this is similar to solid state, but in this
system the series connected internal capacitor and inductor are connected to a parallel
output tank circuit. The principal advantage of this type of system is the robustness of the
inverter due to the internal circuit effectively isolating the output circuit making the
switching components less susceptible to damage due to coil flash-overs or
mismatching.[16]
The current-fed inverter
The current-fed inverter is different from the voltage-fed system in that it
utilizes a variable DC input followed by a large inductor at the input to the inverter bridge.
The power circuit features a parallel resonant circuit and can have operating frequencies
typically from 1 kHz to 1 MHz. As with the voltage-fed system, SCRs are typically used
up to 10 kHz with IGBTs and MOSFETs being used at the higher frequencies.[17]

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6. Conclusion
Both hybrid inverter and mirror inverter topology have been tried in high frequency
induction cooker. It has been observed that hybrid inverter can be selected for high power
multi-zone induction cooker and mirror inverter can be chosen for low to medium power
single/multi zone induction cooker. Mirror inverter, which is developed from a modified
half bridge series resonant inverter, is used in the present work as it has offered reduced
switching losses for the power-devices and possesses attractive possibilities for high
frequency operations. A comparative study has been made among the three semiconductor
switches IGBT, MOSFET and GTO in terms of switching and conduction losses through
PSPICE- based computer simulations and real time experiments on a hybrid resonant
inverter. It is seen that the current through the heating coil using GTO & MOSFET in the
hybrid resonant inverter circuit, doesn't have equal positive and negative peaks.
Hence, rms current will be less. So heating effect will also be less as compared to
IGBT. The GTO-based topology requires the arrangement of sending a negative gate pulse
through the gate terminal of GTO in order to turn it off, which enhances the circuit
complexity. For a frequency range of above 50 kHz, MOSFET will be a better option due to
its high switching speed, low switching and conduction losses. Among all the
semiconductor switches, IGBTs found more suitable in the frequency range of 1 kHz to 50
kHz for domestic induction cooker as it has low turn-ON ohmic resistance and in-built gate
isolation.
Also it has high input impedance and low on state conduction losses. Besides,
IGBTs have higher current densities than comparable bipolar transistors and simpler gate-
drive requirements. They also provide substantial benefits to a host of higher-voltage and
high-current applications.

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6.1 ADVANTAGES OF INDUCTION

1) Very high heating rates with less amount of oxidation and sealing can be obtain

2) It is possible to heat small parts of surface of metal piece instead of heating

the entire piece .

3) The portion of the surface to be heated can be controlled without much wastage of
heat.

4) It is possible to heat a job in a special atmosphere, vaccum , inert , gas etc.

5) Automatic control of temperature can be achieve .

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6.2 Applications

Induction heating allows the targeted heating of am applicable item for applications
including surface hardening, melting, brazing and soldering and heating to fit. Iron and its
alloy responds best to induction heating, due to their ferromagnetic nature. Eddy currents
can, however be generated in any conductor, and magnetic hysteresis can occur in any
magnetic material. Induction heating has been used to heat liquid conductors (such as
molten metals) and also gaseous conductors (such as a gas plasma-see Induction plasma
technology). Induction heating is often used to heat graphite crucibles (containing other
materials) and is used extensively in the semiconductor industry for the heating of silicon
and other semiconductors. Utility frequency (50/60HZ)induction heating is use for many
lower cost industrial applications as inverters are not required.

Furnace

An induction furnace uses induction to heat metal to its melting point. Once molten,
the high frequency magnetic field can also be used to stir the hot metal which is useful in
ensuring that allowing additions are fully mixed into the melt. Most induction furnace is
consist of a tube of water, cooled copper rings surrounds a container of refractory material.
Induction furnace are used in most modern foundries as a cleaner method of melting metals
than a relavatory furnace or a cupola.

Welding

A similar, smaller- scale process is used for induction welding. Plastics may also be
weld by induction, if they either doped with ferromagnetic ceramics or by particles. Seam
of tube can be welded this way. Current induced in a tube run along the open seam and heat
the edges resulting in temperature high enough for welding. At this point the seam edges are
forced together and the seam is welded.

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Brazing

Induction brazing is often used in higher production runs. It produce uniform results
an is very repeatable. There are many industrial equipment where induction brazing is used.
For instants induction is used for brazing carbide to shaft.
Hardening
Induction hardening is a form of heat treatment in which metal part is heated by
induction heating and then quenched. The quench metal undergoes a martensitic
transformation, increasing the hardness and brittleness of the part. Induction hardening to
selectively harden area of apart or aasembly without affecting the properties of the part as
hole.

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7. Final Circuits:

1. Capacitor Bank Circuit

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2. Capacitor Circuit

3. Connector

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4. Coil

5. Capacitor Circuit

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6. Final Circuit

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7.1 Scope for future work:

The present work can be extended in many ways, some of them are mentioned below.
1. Computation of inductance using soft computing technique: In the present study only the
AC resistance was computed using soft computing based approaches. The same can be used
for inductance calculation and simultaneous computation of AC resistance and inductance
both.
2. Design of an induction heating unit for hyperthermia treatment:The induction heating to
ferromagnetic implants (Ferromagnetic Induction Heating: FIH) has been developed for the
purpose of selective hyperthermia on deep-seated tumors. The induction heating unit is
composed of radio frequency generator (500KHZ, 6-12KW) and circular applicator (60 cm
in diameter). Ferromagnetic particles are suspended in tenacious polysaccharide solution
which is injectable through needle into the cavity of tumor or cancerous cell with
subsequent exertion of induction heating for a limited time period. After a certain range of
temperature rise in the ferromagnetic particle surrounded in the tumor or cancer area, serum
GOT and GPT transiently elevated more than 3 times to that of before heating. There are
extensive degeneration and necrosis of liver tissue or cancerous tissue because of high
localized heat generation. Thus the magnetic fluid for hyperthermia treatment using
induction heating process can provide well therapeutic effect with minimal damage of
peripheral tissue.
3. Design of an induction heater for curing of organic coating:
Induction heating is used to cure organic coating such as paints on metallic substrates,
generating heat within the substrate and minimizing the tendency for formation of coating
defects. A typical application is the drying of paint on sheet metal.
4. Design of an induction heater for sintering of carbides:
Induction heating is widely used in sintering of carbide performs because it can provide
the necessary high temperature (2550˚C) in a graphite retort or susceptor with atmosphere
control. Other performs of ferrous and nonferrous metals can be sintered in a similar manner
with or without atmosphere protection.

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Reference
Books referred

1 ) industrial electronics and control by S. K. Bhattacharya and S. chatterjee

2 ) industrial and power electronics by G. K. Mittal

You Tube Resources

1 ) https://youtu.be/4holxPmfZrmyoutu.be

2)https://yarbans.com/wpcontent/uploads/2017/10/induction-heater-in-12v.jpg

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