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INTRODUCTION
4344
---
-- -
Line A.C.
POWER
OSCILLATOR
SOURCE
MATCHING
NETWORK
LOAD
Feedback
OSCILLATOR
WORK COIL
MAGNETIC
FIELD
>
CURRENT
(EDDY CURRENT)
Work Piece
(0.00035Inch Thick
Foil)
[Aluminum
Source Current
Applied To These
Terminals
%
y:d;+?
n
):t
L W o r k Coil Assembly
INDUCTION
HEATINGSYSTEMANALYSIS
Vacuum Tube Oscillator Analysis
4345
RI
LL
L; = Lp -
Ri
w2MiS(Ls+ LL)
(R, + R ~ +) w ~~ ( L +
, L~)'
= Rp i-
(R,
u2M;,(R,
+ RL)
R; = Ri
+ w2LI2
L; = L;
(2)
(3)
R'"
(4)
EQUIVALENT CIRCUITS
(6)
V x E = -jwB
(7)
V * B = O
(8)
V - D = O
(9)
4346
E(x, Y , t )
Re
[JW,
y) exp ( j u t ) ]
(10)
pH
(1 1)
(12)
B = V x A .
This relation follows from (8) and the results of Helmholtz's theorem. Substituting (13) into (7) yields
V
(E
+ jwA) = 0 ,
(14)
+ j u A = -VV,
(15)
VV.
(16)
(17)
This equation is simplified further by imposing the Coulomb gauge condition (which is needed to uniquely specify A ) :
V.A=O.
The resulting equation is
V 2 A - jpuuA = puVV.
(18)
(19)
v 2 v= 0.
(20)
Equations (19) and (20) are equivalent to (6)-(9), and, in
where
J,,,,,
(21)
= -uVV.
In the work piece, there is an induced current density denoted by J e d d y , but there is no source term. The appropriate equation for this region is
V 2 A - jpuwA = 0
(22)
with
Jddy = -juuA.
There are no conduction currents in air
(19) simplifies to
(23)
(U =
0), and so
V 2 A = 0.
(24)
where J ( x , y, t) is the physically measurable current density given by J ( x , y, t) = Re [J(x, y) exp ( j w t ) ] . Accordingly, (25) can be rewritten as
I(?) =
workcoil
Re [ -juuA exp ( j w t ) ] dS
____
4347
Work Pjece
(Foil not lo scale]
Work Coil
Source Current
Applied To These
Terminals
Cross-section of
Rlght-Hand %de 01
Aluminum Foil
(Work Piece]
Cross-section 01
Right-Hand Side
Of COll
Fig. 7 . Right-hand side of axisymmetric representation of the work coilwork piece system.
4348
tance, yielding
L -
10
sallspace
CL dv.
Equations (29) and (30) were applied to the work coilwork piece described above for a variety of frequencies
and configurations. The computed and measured values
of RL and LL are compared in the next section.
F i g . 9. F l u x plot forf = 384
kHz
RESULTS
Oscillator Simulation
\
I
I
I
(e,)
0 Hz
is given by
PT
QL =
Z2(t)RLdt
where, by assumption, Z(t) = Io cos (wr) and T i s the period of one cycle. However, energy is dissipated in both
the work coil and work piece. The energy dissipated per
cycle in these two components is given by
Q =
s,'ls
Jzdv
workcoil U
Jzdv
workpiece U
where
Re [J(x, y,
z ) exp (jut)]
and
1[i
Io
workcoil
(JIzdv
U
workpiece
-1 JdI 2 v ]
(29)
L O A D V O L T A G E VS.
100.
LOAD V O L T A G E V S .
250. I
INCH1
I
cn
50
60.
40.
2
W
'
D
5
INCHI
I
150.
100.
20.
50.
0.00
y4
0.00
50
T I M E ISPACING=0.085
200.
80.
cn
c
4349
-20.
-40.
0
-60.
-150.-
-80.
'
100.
0,000
.00002
.00006
.00004
T I ME
LOAD V O L T A G E V S .
.00008
-200.-
-250.
0.000
.00002
'
I
.00010
I I I
.00004
T I ME
SECONDS I
T I M E ISPACING=0.045
250.
INCH1
.00006
.00008
.00010
I SECONDS I
T I M E ( C O I L ONLY
NO F O I L 1
600.
1
-
400.
in
F
d>
200.
0.00
+
d
, ~200.
0
J
0
0
J
'
-250.
0.000
.00002
.00004
.00006
.00008
I
.OOOlO
T I ME ISECONDS I
-400.
600.
0.000
I
.00002
.00004
T I ME
.00006
.00008
.00010
SECONDS 1
Fig. 11. Plots of load voltages versus time for load conditions in which no
heating occurred. Top: Coil-to-foil spacing was 0.015 in. Bottom: Coil-tofoil spacing was 0.045 in.
Fig. 12. Plots of load voltage versus time for load conditions in which
heating occurred. Top: Coil-to-foil spacing was 0.085 in. Bottom: Coil-tofoil spacing was infinite (no foil).
The impedance of the load depicted in Fig. 3 was computed and measured at room temperature for several different spacings and frequencies. The work piece is a
0.00035-in-thick aluminum foil (a = 3.88 * lo7 mho/m)
and the work coil, which is rectangular, consists of two
turns of copper wire (a = 5.8 * lo7 mho/m). The wire
has a 0.060 in diameter, and there is a 0.080 in spacing
between the two turns. The work coil measures 3 in on a
side (defined by the outermost wire). For the axisymmetnc approximation, the radii to the center of the inner and
outer wire were 1.53 and 1.67 in, respectively. They were
computed based on keeping the area subtended by the axisymmetric coil equal to that of the rectangular coil.
Four different load conditions were analyzed corresponding to the four cases studied in the oscillator simulation described above. The first condition (no heat) was
with a foil-to-work coil spacing of 0.015 in and an operating frequency of 450 kHz. The computed values of resistance and inductance are RL = 0.269 Q and LL = 0.153
pH, which compare to measured values of RL = 0.344 Q
and LL = 0.189 pH.
The second condition (onset of heating) was for a fre-
4350
CONCLUSIONS
The behavior of an induction heating system can be accurately predicted from first principles using a combination of nonlinear circuit analysis and the impedance predicting capability of finite element analysis. The
technique, as described in this paper, has been successfully applied to several induction heating configurations.
I
APPENDIX
AMPEREXMODEL8867 TUBECHARACTERISTICS
ANODE VOLTAGE(V1
ANODE VOLTAGE ( V )
4351
ANODE VOLTAGE ( V )
APPENDIXI1
MACSYMA PROGRAMMING
SESSIONTO SOLVEFOR 12, I , , I4
load('[egan.modeli]osmdint.mac");
(C3) values;
03)
(U)
vl;
(D4)
((3)
v2;
05)
((33) v3;
4352
(C12) di3:part@art(dlO,l),Z);
(D12) DI3DT = - (LP (- MSF V601- LF V301)
('MSF2 -LFLS)
MPF' V301
+ LSMPF')
(C13) di4:part@art(dl0,1),3);
(D13) DI4DT = - (LP (- LS V601- MSF V301) + mp52 V601 + MPF MPS V301
+ W S MSF - Is MPF)V2Ol)/(LP (MSF' - LF LS)- MPF MPS
2
MSF+ LF MPS'
+ LsMPF2)
((214) fortran(di2);
DI2DT = WS*(MSF*V601+ LF*V301) +MPP(-LS+V601-MSF*V301) + (MSF**2-LF
1 *LS)*K?Ol)/(LP*(MSF**2-LF*LS)-2*MPF*MPS*MSF
+ LF*MPS**2 + LS*MPF**2
2)
((215) fortran(di4);
+(MPS*MSF
DI4DT = -(LP*(-LS*V601-MSF*V30l)+MPS**2*V601+MPF*MPS*V301
-LS*MPF)*V2Ol)l(LP*(MSF**2-LF*IS)-2*MF'F*MPS*MSF+ LF*MPS**2 + L S M P
2 FO.2)
(CU) load('[egan.modelilosmdintt.mac");
(C17) a l ;
(D17) DDDT = - (LP (- MSF V601- LF V301) + MPF MPS V601+ MPF' V301
+ (LF MPS - MPF MSF) V2Ol)/(LP (MSF' - LF IS)- MPF MPS
2
MSF+ LF MPS'
+ IsMPF2)
(C18) a2:
(Dl8) V301 = I3 (RS + RL) + DI3DT LL
(C20)solv~[al,a21,~di3dt,v3011~;
@20) [[DI3DT = ((LP MSF - MPF MPS)V601
+LPMSF2(I3RS+I3RL)+LFMPS2(I3RS+I3RL)+LSMPF2(I3RS+I3RL)
+ LF LPLS (- I3 RS- I3 RL) + MPFMPSMSF(- 2 I3 RS- 2 I3 RL))
/(LPMSF2-2MPFMPSMSF
(C21) di3:part@art(dZO,l),l);
(D21) DI3DT = ((LP MSF - MPF MPS) V601 + (MPF MSF - LF MPS)V201
(-
I3 RS - I3 RL))
+ L F M P S 2 + (LS + LL)MPF'-LFLPLS-LFLLLP)
((22) v3vOl:part@art(d20,1),2);
(D22) V301= ((LLLP MSF - LL MPF MPS) V601+ (LL MPF MSF - LF LL MPS) V201
+LPMSF2~3RS+I3RL)+LFMPS2(I3RS+I3RL)+ISMPF2(I3RS+I3RL)
+ LF LP IS (- I3 RS - I3 RL) + MPF MPS MSF (- 2 I3 RS- 2 I3 RL))
/(LPMSF2-2MPFMPSMSF
(C23) fortran(di3);
((24) fortran(v3vOl);
V301 = ((LL*LP'MSF-LL*MPF*MPS)+VGOl+ (LL*MPF*MSF-LF*LL'MPS)*V201+ LP
1 *MSP*2*(I3*RS+ 13*RL)+WMPS**2*(IS*RS+ I3*RL) +LS*MPF**2*(I3*RS+
2 I3*RL) +LF*LP*LS*(-13*RS13*RL) + MPPMPS*MSF*(-2*13*I*I3*RL))/
3 (LP*MSF**2-2*MPFaMPS*MSF+
IPMPS**2 + (Ls+ LL)*MPF**2-LF*LP*SLF*L
4 L*LP)
APPENDIX
I11
ACSL PROGRAM
program owillator simulation ( cle-Dyne A501 no foil
constant rl=o.o41 ~ B p u i v a d resistance"
L
constant I1 =7.90.47 $"equivalent load inductance"
constant cp =4.73e-O9 $"tank capacitor"
constant rp=O.78 ("tank inductor resistance"
constant 1p=47.7e-O6 $"tank inductor"
constant m = 0.017 $"seeonday inductor resistance"
constmt 1s=2.5147 Yseeondary inductor"
constant rf= 0.25 $"fedback inductor resistance"
constant If= 15.54e-06 $"feedback inductor"
constant cfl = 1.$"feedback coupling capacitor"
constant rml= l . l l e + 0 3 $"grid meter series inductor resistance"
constant lm = 3.6e-03 $"grid meter series inductor"
constant cml= 1.07e-10 $"grid meter aeries capacitor"
constant cm2 = 1.oe-08$"grid meter shunt capacitor"
constant rm2= 1.0 $"grid meter resistor"
constant kps = 0.83 Vprimarylmndary coupling"
constant kpf=0.58 $"primary/feedback coupling"
constant kst=0.0 $"seeondary/feedback coupling"
constant rg=4oooO.O $"series gate resistor"
constant cg= 1.Oe-09 $"aeries gate capacitor"
constant i2ic=O.O $"tank inductor current initial condition"
constant i3ic=O.O $"secondary inductor current initial condition"
constant i4ic=O.O $"feedback inductor current initial condition"
constant i5ic=0.0 $"grid meter series inductor current initial cond"
constant vcpic=O.O $"tank capacitor voItage initial condition"
constant vc 'c 0 0 $"series gate capacitor voltage initial condition"
constant vcRiclO.0 $"grid coupling capacitor voltage initial cond"
constant vcmlic=0.0 $"meter series capacitor voltage initial cond"
constant vcmZic=O.O $"meter shunt capacitor voltage initial cond"
constant vO1 =O.O $"ground reference"
constant vbs = -8.k+ 08 $"plate/cathode bias voltage ramp slope"
table
ipt,2,10,13/-800.0,0.0,100.0,200.0,~.0,400.0,500.0,~.0
,...
700.0,800.0,5000.0,0.0,125.0,260.0,375.0,500.0,750.0,1000.0 ,...
15w.0,2OOO.0,3000.0,4000.0,5000.0,...
0.00,0.00.0.00,0.00,0.00,0.00,0.00,0.00,0.00,0.00 ,...
0.00,0.00,0.00.0.00,0.00,0.01,0.01,0.02,0.03,0.04 ,...
0.00,0.00,0.22,0.50,0.50,0.64,0.64,0.82,0.82,0.90,...
0 00 000022 0 50092 1 2 2 1 3 0 150 150 1 Eo,...
0 ~ ~ ~ 0 ~ ~ ~ 0 ~ 2 4 ~ 0 ~ ~ ~ 0...~ 9 8 ~ 1 ~ 4 8 ~ 1 ~ ~ ~ ~ ~ ~ ~ 2 8 ~ 2 ~ 6 4 ~
0.00.0.00,0.24,0.56,1.00,1.sO,2.00,2.58,3.20,3.~
,...
0.00,0.00,0.26,0.60,1.08,1.60,2.14,2.72,3.38,4.00,...
0.00,0.00,0.27,0.64,1.14,1.66,2.22,2.82,3.50,4.20,...
0.00,0.00,0.31,0.68,1.18,1.74f.36,3.00,3.76,4.44 ....
0.00.0.00,0.33,0.76,1.26,1.80,2.44.3.16,3.92,4.60 ,...
0.00,O.OO 0 39,O.M 138 2 00,2.62,3.36,4.10,4.82 ,...
0 00 0 00'048 0 95'1'50f:12 2 80,3.52 4 28 5 OO,...
0~00~0~00~0~sO~1~09~1~66,2.26~3~00,3.74~4~50~5~20/
tablei 269/-800000500.0600.0.700.0 ,...
O..:.
800.0
h . 0 4% 0
600.0'750 0'1OOO b lsbd.0 2bOO.O,.._
0.OOO:0.odo:0.01iob,0.0&,0.~,0.072~,...
0.OOO 0 OOO 0 00120 0 02900 0 OM00 0 06300....
0.000'0'000'0~00130'0'oo2so'0~03OOO~0~0~00,...
0.OOO'O:OOO'O 00144'0'00264'0 00400 0 01700....
0.000~0.OOO~0~00152~0~00272~0~oo44a~0~00,...
0.OOO 0 OOO 0 00160 0 00276 0 00500 0 00800,...
a.0
O.OOO'O'OOO'000148'0'00261'0~~'0'0016,...
0.000:0:OOO:0:~:0~001~~0~~92~0~00732,...
0.OOO.0.OOO.0.00016.0.00100,0.00200,0.00476/
constant tJ3top=1.044
nsteps nstp = loo00
cinterval cint=2.0e-07
minterval mint = LOe-20
algorithm ialg= 1
initial
pi =4.0*atan(l.O)
mps = kps*qrt(lp*ls) $"primarylsecondary mutual inductance"
mpf =kpPaqrt(lp*lf) S"primary1feedback mutual inductance"
msf= Wsqrt(ls*lf)
$"secondary/feedback mutual inductance"
ooId =0.0
b l d = 0.0
ipold=0.0
igold =0.0
pavint=O.O
Igmavi=O.O
ipavi = 0.0
end $"of initial"
derivative
vb = vbs*(ramdO.O)-ramp(5.0e-06))
V601=v6-v01
v301=v3-vOl
V201=V2-v01
vbOl =vb-vOl
dvcfl.vcflic)
l n !%2E
vcml= integ(dVcm1,vcmlic)
d v c d = i7/cm2
vcm2 = intag(dvcm2,vdic)
dvcg=ilO/
veg= inw&,vcgic)
il= ipi2
...
DI2=(MPS*(MSF*V601 +LF*V301)+MPF*(-LS*V6Ol-MSF*V3Ol)+(MSF**2-LF
*Ls)lmOl)l(4P*(MSF**2-LF.LS)-2*hPF*MPS*MSF
+ LF*hPS**2 + LS*MPF**2)
12= integ(di2,dic)
4353
4354
k =&g(di4,i4ic)
di5= (v9-vlO)flm
i5= inydi5,i5ic)
i6=i4-1 16
i7 = i5 + i6-18
ilO=i i9
i8 = (vkvb)/rm2
i9 = (v8-vll)lrg
vp=vl-vb
Vl=dl+VCD
v2=vl '2. *
V3 =Vi; + (ieL*LP*MSF-LL*MPF*MPS)*V~l+
(LL*MPF*MSF-LF*LL*MPS)*VZOl+
LP ...
*MSF**2*(I3*RS+ 13")
+WMPS**2*(I3*RS+ I3*RL) +LS*MPF**Z*(I3*RS+ ...
I3*FU.) + LF*LP*LS*(-I3*RS-I3*RL) + MPF*MPS*MSF*(-Z*I3*R2*13*~))/...
(LP*MSP*2-2*MPF*MPS*MSF+
LF*MPS**2 + &3! + LL)*MPF**Z-LF*LP*LSLF*L...
T.*T.P\
;42~i3*rs
v5 =vdi3*rl
v6=v7 + i4.d
v7 =v8 +vcfl
v8 =vb +vcml + vcm2
~9 = v a i 5 * m i
v10 =vb +vcm2
vii=v8-vq
vg= v l 1-vb
mv= inted(i3**2)*rl.0.0)
&hedule &t :xp. -vb-vp
~ t @ ~ ~ p o r . i 2 . @1oooO.O)
.
d
i imt
s$v-pold)/(t-told)
pold = p v
I= (iav-igold)/(t-told)
igold = i p v
ipavi = (ipav-ipold)/(t-told)
ipold = ipav
told =t
end $"of pavint"
end $"of discrete"
end
ACKNOWLEDGMENT
The authors would like to thank J. Sproul, who provided careful and invaluable guidance in the preparation
of this manuscript. The authors would also like to thank
Dr. L. F. Pizziconi, whose comments led to significant
improvements to the text.
REFERENCES
[ l ] E. J . Davies and P. G. Simpson, Induction Heating Handbook.
London: McGraw-Hill, 1979.
[2] S. Zinn, S. L. Semiatin, I. L. Harry, and R. D. Jeffress, Elements of
Induction Heating: Design, Control, and Applications. Palo Alto,
CA: Electric Power Res. Inst., 1988.
[3] G. M.Chute and R. D. Chute, Electronics in Industry, 4th ed. New
York: McGraw-Hill, 1971.
[4] "MACSYMA," developed by M.I.T. Lab. for Computer Science/
Mathlab Group, Cambridge, MA for NASA, Office of Naval Research, U.S.Department of Energy, and U.S. Air Force.
[5] Advanced Continuous Simulation Language. Concord, MA: Mitchell and Gauthier Associates, 1986.
[6] W. H. Hayt, Jr. and J. E. Kemmerly, Engineering Circuit Analysis,
2nd ed. New York: McGraw-Hill, 1971.
[7] Z. J. Cendes and A. Konrad, Elecrric Machine Modeling and Power
System Constraints in Electric and Power Problems: The Mathematical Challenge, A. M. Erisman, K. W. Neves, and M. H. Dwarak-
[lo] D. H. Lowther and P. P. Silvester, Computer-Aided Design in Magnerics. Berlin: Springer-Verlag. 1986.