Comparison of New Multilevel Inverter Topology with Conventional Topologies Used for Induction Heating System

In this article, a comparison of innovative multilevel inverter topology with standard topologies has been conducted. The proposed single phase five level inverter topology has been used for induction heating system. This suggested design generates five voltage levels with a fewer number of power switches. This reduction in number of switches decreases the switching losses and the number of driving circuits and reduce the complexity of control circuit. It also reduces the cost and size for the filter used. Analysis and comparison has been done among the conventional topologies (neutral clamped and cascade H-bridge multilevel inverters) with the proposed inverter topology. The analysis includes the total harmonic distortion THD, efficiency and overall performance of the inverter systems. The simulation and analysis have been done using MATLAB/ SIMULINK. The results show good performance for the proposed topology in comparison with the conventional topologies.

Development of the design of a new working section cooled by a dispersed coolant flow for a stand with induction heating

The paper presents a description of the design of a new working section cooled by a dispersed coolant flow for a stand with induction heating. The choice of the material of the working area and the method of spraying has been substantiated. The first commissioning experiments were carried out in a stationary cooling mode, with the parameters of the coolant p = 1.7 · 105 Pa, G = 3.8 · 10-3 kg/s.

Optimal control for a phase field model of melting arising from inductive heating

<abstract><p>Due to its unique performance of high efficiency, fast heating speed and low power consumption, induction heating is widely and commonly used in many applications. In this paper, we study an optimal control problem arising from a metal melting process by using a induction heating method. Metal melting phenomena can be modeled by phase field equations. The aim of optimization is to approximate a desired temperature evolution and melting process. The controlled system is obtained by coupling Maxwell's equations, heat equation and phase field equation. The control variable of the system is the external electric field on the local boundary. The existence and uniqueness of the solution of the controlled system are showed by using Galerkin's method and Leray-Schauder's fixed point theorem. By proving that the control-to-state operator $ P $ is weakly sequentially continuous and Fréchet differentiable, we establish an existence result of optimal control and derive the first-order necessary optimality conditions. This work improves the limitation of the previous control system which only contains heat equation and phase field equation.</p></abstract>

Low-temperature induction heating of flat metal objects in a traveling electromagnetic field

The article discusses possible options for a low-temperature induction heating system (LTIHS) of flat metal products in a traveling electromagnetic field. The problem of calculating eddy currents, active and reactive powers induced in a heated flat object, as well as electromagnetic forces acting on the object moving it in a given direction, is posed and solved. A mathematical model has been developed that takes into account the dependence of the influence on the main parameters of the electromagnetic field of the following factors: geometric dimensions of the air gap between the poles of the magnetic circuit and the heated flat body; the longitudinal edge effect caused by the open circuit of the magnetic circuit of the inductor, as well as the transverse edge effect associated with the appearance of the longitudinal components of eddy currents in a heated flat object. The solution of particular problems of LTIHS in one- and two-dimensional formulation allows them to be simplified and to perform calculations for various design variants of induction heating devices with a traveling electromagnetic field, using a one-dimensional model that explicitly takes into account the features of electromagnetic processes in the systems under study.

Design of an electromagnetic induction steam generator device based on air source heat pump

Aiming at the current problems of coal-fired boilers and electromagnetic induction steam generators for environmental pollution and high energy consumption, this article combines air source heat pumps and electromagnetic induction heating technology, and at the same time carries out the structure of the condensate tank and electromagnetic induction steam generator. Redesign. Through trial production and experimentation of the prototype, the results show that compared with traditional coal-fired boilers and separate electromagnetic induction heating technology to generate steam, this device not only achieves energy saving and environmental protection, but also the stability of the steam outlet temperature and the amount of steam generated. Compared with the use of electromagnetic induction heating alone, it has increased by 20%. It can be seen that the use of air source heat pump’ electromagnetic induction heating technology to generate steam saves energy and increases the amount of steam generated.

Application and schemes of induction preliminary heating in magnetic-pulse treatment of metals

The features of the processes of magnetic-pulse processing of metals in traditional schemes of technological processes of modern industrial production are highlighted. The work is a brief description of the state, application, and also proposed induction pre-heating schemes in industrial magnetic-pulse processing of metals. A method for increasing the efficiency of performing specified production operations is considered. The use of preheating leads to a significant improvement in the quality of production operations while reducing energy consumption. New directions of magnetic-pulse processing of metals are noted, implying the transformation of the natural repulsive forces of the metal of the processed object into the forces of magnetic-pulse attraction with a decrease in the operating frequencies of the acting fields. A significant decrease in operating frequencies makes it possible not only to go from repulsion to attraction, but also to go from working with ferromagnetic metals to non-ferromagnetic ones. For example, it becomes possible to attract aluminum blanks. Examples of the use of induction heating of metal blanks in modern industry are given. Various devices used for these operations, offered on the modern market, by both domestic and foreign manufacturers, are considered. The physics of Lenz-Joule heat release is described, the result of which is the induction heating of conductors by Foucault currents in the external electromagnetic field of the instrument. Schemes are proposed for the practical implementation of preliminary induction heating during magnetic-pulse processing of metal blanks, allowing the use of both autonomous devices for exciting eddy currents and a stationary connection, for the same purpose, of an additional source of electricity. As a result of the work, the possibility of increasing the efficiency by increasing the plasticity of the metal when heating the workpiece, as well as possible limitations of the described technology associated with an increase in the active resistance of metals with an increase in the Lenz-Joule heat release is noted.

Design of an universal source for semi-automatic ac welding and induction heating

This paper proposes a circuit solution and a power source control algorithm for semi-automatic AC welding with improved energy and weight-size characteristics. A distinctive feature of the designed source is the absence of an input rectifier: welding is carried out with a high-frequency alternating current. That has made it possible to significantly reduce power losses in the source, as well as provide the possibility of implementing induction heating by connecting an inductor to the source output. Another distinctive feature of the designed source is an increased power factor and a reduced level of higher harmonics of the current consumed. The power factor of the described source reaches 0.94 against 0.5÷0.7 for sources equipped with a conventional rectifier with capacitive smoothing. The designed source's composition includes a power supply system for the wire feed drive with speed stabilization due to positive feedback on the motor current. That has made it possible to ensure the stable operation of the drive in a wide range of speeds. A model has also been developed of a flux wire welding torch containing a feed drive and a coil with a wire (up to 100 mm in diameter), placed, in order to reduce the size, in the handle of the torch. In addition to the welding function, the source makes it possible to solve the tasks related to induction heating and/or hardening of small parts; to that end, a compact inductor is connected to its output. Tests of the source showed the feasibility of the proposed ideas and circuit solutions. The dimensions of the source are 190×107×65 mm; weight, 1.4 kg; output current, up to 120 A. The proposed technical solution enables the construction of small-sized, lightweight, universal, easy-to-use power supplies for semi-automatic welding with the option of induction heating