Government Polytechnic, Jalgaon

▪ Program :- Diploma in Electrical Engineering

▪ Scheme:- I
▪ Semester and Academic Year :- EE5I (2019 -20)
▪ Course :- Capstone Project Planning
▪ Course code :- CPP ( 22050)
▪ A Project Report on :-

▪ Title :- Induction Heater

✓ Submitted by :-

Sr..no Enrollment number Name of Student Signature

01 1700180220 Nagardhane Prasad Samadhan
02 1700180229 Wankhede Yogita Ravindra
03 1700180236 Patil Prajakta Digambar
04 1700180237 Khatik Aadil Shakil

Guided by :- Shri J.K. Pandit Sir

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 GOVERNMENT POLYTECHNIC, JALGAON
ELECTRICAL ENGINEERING DEPARTMENT
Annexure A

CERTIFICATE

This is certify that Mr./Ms........................................................................................................

From...................................................................College having Enrollment No.......................
has completed Report on the problem definition/semester V project report / Final
Project Report having title ......................................................................................................
...............................................................................................................................................
in group consisting of .......... persons under the guidance of the Faculty Guide.

Project Guide CPP Incharge Head of Department

Shri A.S.Zope Sir

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 GOVERNMENT POLYTECHNIC, JALGAON
ELECTRICAL ENGINEERING DEPARTMENT
Annexure A

CERTIFICATE

This is certify that Mr./Ms........................................................................................................

From...................................................................College having Enrollment No.......................
has completed Report on the problem definition/semester V project report / Final
Project Report having title ......................................................................................................
...............................................................................................................................................
in group consisting of .......... persons under the guidance of the Faculty Guide.

Project Guide CPP Incharge Head of Department

Shri A.S.Zope Sir

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 GOVERNMENT POLYTECHNIC, JALGAON
ELECTRICAL ENGINEERING DEPARTMENT
Annexure B

Portfolio for Self Directed Learning for Major Project Work

Name Of Student:....................................................................................................................
Semester:.................................................. Programme/ Branch:...............................................
Roll Number:................................
Title of Project:........................................................................................................................
...............................................................................................................................................
Name and Designation of Project Guide:...................................................................................
Name of Polytechnic:...............................................................................................................

GOVERNMENT POLYTECHNIC, JALGAON

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 ELECTRICAL ENGINEERING DEPARTMENT
Annexure B

Portfolio for Self Directed Learning for Major Project Work

Name Of Student:....................................................................................................................
Semester:.................................................. Programme/ Branch:...............................................
Roll Number:................................
Title of Project:........................................................................................................................
...............................................................................................................................................
Name and Designation of Project Guide:...................................................................................
Name of Polytechnic:...............................................................................................................

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 Acknowledgement
In the present world of competition, there is a race of existence in which these are
having will to come forward succeeds. Project is like a bridge between theoretical and practical
working.
First of all, we would thank the supreme power-the Almighty god who is obliviously
the one who is always guided us and make us interested to work for this project, without his
grace this project could not become a reality
Thanks to Dr. Shri. M. V. Ingle, Sir Principle of government polytechnic, Jalgaon for
giving us an opportunity to do our project works in Government Polytechnic, Jalgaon. We are
feeling oblige in taking the opportunity to sincerely thank to Shri.A. S. Zope, Sir HOD of
electrical department and special thank to our project guide Shri. J.K.Pandit, Sir for providing
us an opportunity to embark on this project. We are greatly indebted to them for bringing us up
with proper guidance and active encouragement.
We also express my gratitude to all the staff members of electrical department for
their generous attitude and friendly behavior
At last but not the least, I am thankful to all my team members for their co-
operation and active participation during project work and also for their consistent hard work in
making the project sheets
I have no valuable words to express my thoughts, but my heart is still full form
favours received from every person.

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 Abstract
The technology within engineering has to carry out variety of innovative that answer
and social solve economic and environmental problems. The water heater by magnetic
induction is a new device that is proposed to heat the water carrying steel pipe for heating
water. The project is characterized by its advanced technology used, reliability, Sustainability
and controlled operation. The heating technology consumes less technical electrical energy than
the energy than the resistance based heater thereby creating new areas of energy efficiencies
and energy conservation.
The main component is the high frequency generation circuit from which high
frequency AC current is passed through the coil to generate a high Alternating flux which links
to the work piece to produce eddy current losses. As the frequency is very high, the losses
occurred becomes high, hence large amount of heat is generated inside the work piece itself.
This heat energy is utilized to heat water in our project. It should be noted that the element
which is to be heated should be magnetic material and must be a good conductor of heat. Thus,
for making this project successful one, proper planning is done and accordingly the work shall
be executed.

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 Chapter 1 –
PART A- INTRODUCTION –
Energy conservation is the reduction or removal of unnecessary or unwanted energy use.
Individuals and companies are called as direct consumers of energy may need to conserve energy
so as to reduce energy expenses and promote economic security.

It is the practice of reducing the quantity of energy used. It may be attained through
efficient energy use; in this case, energy use is decreased at the same time getting a same outcome
as a result, or by reduced consumption of energy services. It is one of the easiest processes to help
the globe by means of pollution in addition to make use of natural energy.

It may result in Increase of financial capital, better environmental results, national

security, personal security, Human comfort.

In the past, a steady investment into research for process heating and related topics such
as combustion has contributed in development of innovative technologies that have resulted in
substantial improvements in energy efficiency of industrial processes. Major strides could be
made towards reducing energy use and reducing Green House Gas (GHG) emissions to meet the
national goals.

For contribution in energy conservation we are focusing on induction heating by

considering its features like

✓ Improved process efficiency.

✓ Localized, constant and precise heating.
✓ Temperature control.
✓ Energy saving.
✓ Possibility of integration into production lines.
✓ Best quality and yield/performance.
✓ Pollution free, fast and secure technology.
✓ Improved working environment

In this project which is titled as induction heating as its name suggests ,it deals with heating
technology by induction principle using high frequency generating circuit that produce alternating
current and this currents links magnetically by induction with work piece.

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 By considering the energy conservation need and the industrial conventional heating systems,
we preparing model for induction heating. Also considering the problem of hostel students that
they don’t get hot water especially in winter season.
As shown in block diagram of our project, the high frequency generating circuit passes
current form coil and by induction principle eddy current losses are takes place in work piece.
This heating of work piece is very quick and efficient.

Pulse generating circuit produces firing angle pulse of desired amplitude and time period to
make switching process hence heating process more accurate and precise.
Buffer circuit amplifies the signal of pulse generating circuit and provides output to the driver
circuit. Driver circuit is nothing but the triggering circuit of mosfets which provides isolated
output signal to gates of both mosfets.

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 Two Mosfet are connected in half bridge inverter whose output goes to L-C resonating circuit
which makes process free of harmonics and unwanted losses. Then finally output goes to the
heating coil.
As shown in below diagram, water is passed from tank through this coil from pipe made up
of suitable material. Due to hot pipe water also become hot and can be used to complete our
desired task. Induction heating has numerous application but up to working coil all circuitry and
blocks are same.
Below sections explain about 5th semester work in detail.

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 CHAPTER 1
PART B- BACKGROUND OF INDUSTRY AND USER
BASED PROBLEMS -
In industries there many processes which could not be possible without introducing heating.
Hence Industrial heating is considerable topic.
❖ Industrial Process Heating Overview –
Industrial process heating operations are responsible for more than any other of the
manufacturing energy demand. There are a wide range of process heating unit operations, and
associated many equipment, that are to achieve important materials transformations such as
heating, drying, curing, phase change, etc.
This are fundamental operations in the manufacture of most consumer and industrial major
products including those made out of metal, plastic, rubber, concrete, glass, and ceramics.
Energy is supplied from a diverse range of sources, and includes a combination of electricity,
steam, and fuels such as natural gas, coal, biomass and fuel oils.

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Heating applications or processes in industries -

• Annealing / Heat Treating-

Process annealing is used to treat work-hardened parts made from low-carbon steels (<
0.25% carbon). Annealing can be used to stress-relieve or fully soften a part. A full
anneal allows the parts to be soft enough to undergo further cold working without
fracturing.
• Curing / Tempering-
Heaters are designed for curing or tempering applications. They can heat adhesive bonds
to curing or setting specifications.

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 • Drying-
Heaters are used to dry products or materials with in-process or batch operation.

• Melting-
Heaters are used to transform materials from a solid to a liquid state for further
processing (e.g., casting).

• OEM / Custom-
Heaters are designed as OEM modules and are designed to be embedded or installed in another
piece of equipment

❖ In 2010, process heating consumed approximately 330 TBtu of electricity, 2,290 TBtu of
steam, and 4,590 TBtu of mostly fossil fuels.
❖ Process heating technologies are generally designed around four principal energy types:
1. Fuel-based process heating technologies
2. Electricity-based process heating technologies
3. Steam-based process heating technologies
4. Hybrid process heating technologies.

❖ Recent advances and improvements in process heating systems Although no major

break-through technology additions have been made recently that have been adopted by
industry, modest contributions by the industry and supported R&D can be found in these
development areas-
1) Digital Control Equipment

2) Reduction of NOx Emissions

3) Improvements in Thermal Efficiency of Selected Processes.

4) Improvements in High Temperature Materials Availability.

5) Advancements in Enhanced Heat Transfer.

6) Introduction of a Few Improved Combustion Equipment Products and Burners.

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 ❖ Some major and some moderate advancement in process heating/combustion
technologies took place in :
• Reduction of Combustion Generated Nitrogen Oxides
• Development of High Temperature Silicon Carbide or Silicon Nitride Radiant Tubes
• Oscillating Combustion Systems
• Flameless combustion for high temperature processes
• Oxygen Enriched Air and Pure Oxygen Based Combustion
• Regenerative burners or combustion systems
• Flame Impingement Heating.
❖ Industrial Process Heating Overview –
Industrial process heating operations are responsible for more than any other of the
manufacturing energy demand. There are a wide range of process heating unit operations, and
associated many equipment, that are to achieve important materials transformations such as
heating, drying, curing, phase change, etc.
This are fundamental operations in the manufacture of most consumer and industrial major
products including those made out of metal, plastic, rubber, concrete, glass, and ceramics.
Energy is supplied from a diverse range of sources, and includes a combination of electricity,
steam, and fuels such as natural gas, coal, biomass and fuel oils.
In 2010, process heating consumed approximately 330 TBtu of electricity, 2,290 TBtu of steam,
and 4,590 TBtu of mostly fossil fuels.
Process heating technologies are generally designed around four principal energy types:
1. Fuel-based process heating technologies
2. Electricity-based process heating technologies
3. Steam-based process heating technologies
4. Hybrid process heating technologies.
• By concluding and interpreting from all above collected data and from this four, we
selected electricity based heating process which is Induction Heating.
• Along with this such induction heater can be used in home also instead of lpg gas whose
sourses are depleting day by day.
• Also use of L.P.G. and other heating sources leads to many accidents and pollution.

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 Chapter 2
Part A- literature survey for problem identification-
➢ From the previous chapter part B we are now got familiar with the problems and
industry background.
We selected, collected and used required information and knowledge to solve the
problem we identified.
We tried to consider ethical issues related to project suitability.as we identified the
problem we find out the causes behind that and suggested possible solutions. Collected the
relevant data accordingly.
Before deciding the project /selection of project, we thought alternatives which should
have emphasis on integration experimental, experimental learning, real world problem solving.
We tried to select the project topic which fulfills the course outcomes and learning
outcomes.
We considered topics by ensuring about time availability, resources, tools, components
required availability. Also considered such one for which expertise is available for guidance,
technology, software is available
For selection of this project title we made survey in industries, referred various books, web
articles and essential papers.
The topics were –
a) Rectifier.
b) Solar powered auto irrigation system.
c) Contactless tachometer.
d) Wireless power transfer.
e) Automatic light intensity controller.
f) Converter circuits.
g) Induction heating.
From this we selected induction heating beacause, from the surveys and literarure survey we
found that there is really a need of induction heating over against of conventional huge
unwanted energy consuming methods.
Conventional heating methods have difficulty in relative to maximizing thermal efficiency,
minimizing emissions, and optimizing uniform heat transfer.

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From all the data we collected ,we found that induction heating has many advantages over using
other methods.

➢ why we selected Induction Heating –

It has features like,
▪ Improved process efficiency
▪ Localized, constant and precise heating
▪ Temperature control
▪ Energy saving
▪ Possibility of integration into production lines
▪ Best quality and yield/performance
▪ Pollution free, fast and secure technology
▪ Improved working environment
• Increase current programs and journal articles that support health

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• Where on the other hand, conventional heating methods have difficulty in relative to
maximizing thermal efficiency, minimizing emissions, and optimizing uniform heat transfer.

• We also visited Shivam industry located in MIDC which makes induction heating based
daily life machineries and similar food preparing machineries which can be used in hotels
or small scale industries.
• Material to which we are going to provide heat –

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 Chapter2 ,Part B - Specifications
In the circuit we planned to make, involves –
The arrangement of different circuitry and various working parts is as shown in
below figure. We will mount all this on bakelite sheet of required thickness and of
size near 2 feet by 3 feet.

As given in introduction above the working of different block will happen and in
this manner high frequency will get generated and further L-C tank circuit will help
to remove unwanted distortions from output.

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FIG. PULSE GENERATOR

FIG. DRIVER CIRCUITRY

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 ❖ RESOURCES USED –
Sr Compone Specification Photos Quantity
No nts
1 IC SG3525 a) 8v To 35v Input Voltage 1
b) 100 Hz To 400khz Oscillator
Range
c) Operating Temperature Range
0 To +70◦C

2 IC 7815 a) Fixed Output 2

b) B)+15v Output Voltage
c) 1.5A Output Current
d) Input Voltage 17.7V To 35V
DC.
3 IC 7805 a) Input Voltage 40V 1
b) Operating Temperature -30◦C
To 85◦C,
c) Internal Short Circuit Current
Limiting.
4 IC 74LS04 a) Supply Voltage 4.5V To 5.5V 1
b) Operating Temperature -55◦C
To 125◦C
c) Output Current Up To 4ma
5 IC TLP250 a) Input Threshold Current 5ma 2
b) Supply Current 11ma
c) Output Current 10-35 V
d) Switching Time 1.5µs

6 Capacitor a) 0.1µf 3
s b) 1000µf, 35v 3
c) 100µf,25v 3
d) 0.01µf 1
e) 2200µf, 50V 2

7 Resistors a) 1KΩ 3
b) 10KΩ Variable Resistor (Pot) 2
c) 100Ω 1
d) 10KΩ 1
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8 Diode a) Maximum Recurrent Peak 12
Reverse Voltage 1000V
b) Maximum RMS Voltage 700V
c) Operation And Storage
Temperature Range -65 To
175◦C
9 Power a) IRFP250 2
MOSFET

10 Transform a) 230/15V 2
er b) 230/5V 1

11 Coil a) Toroid Core Inductance Coil 1

Wire Wound

12 PCB a) Epoxy Glass 4

13 Patch a) Specific Rating 1

Chord

14 Base a) Used Bakelite Sheet 1

Sheet

15 Battery a) 24v 1

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16 cables a) Single stranded cables As per
requireme
nt

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 Chapter no.- 3 Proposed detailed methodology of solving
the identified problem with acton plan -
Different methods that can be used for heating are-

As per the identified problem in our college campus i.e. in Government Polytechnic
Jalgaon which is unavailabity of hot water to hostel student especially in winter season,
there is a strong necessity to provide solution for that.

Home solving these problems in a proper fashion through correct methods and
procedure will not only help in fulfilling the objective the project but also made the
project in better way.

❖ How to solve the problems of unavailabity of Hot water?

To solve this problem heating of water should be done there are various techniques employed to
heat the water.

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 Some of the company used water heating is as follows:

a) Heating through conduction method

b) Heating through convection method.

c) Heating through radiation method.

A) Heating through conduction method:- 1.Induction Heating Systems

Induction heating uses electromagnetism to heat the conductive components of a part.
Induction heating is accomplished by running an electric current through an induction coil
which produces an electromagnetic field. When steel or iron components are placed within that
field, they resist the electrical flow, creating energy and heat in the process.
Induction heating can be a very effective and efficient use of energy and quickly heat up
components, however, the products need to be shaped so that a coil can apply the power
properly. When used during a preheating or post heating process, it can dramatically cut down
production times, allowing for greater efficiency and product throughput

2.Convection Air Heating Systems

Convection systems use either gas burners or electric elements to heat air in an internal
recirculation system. With gas-fired systems, gas (natural or liquid) is fed into a burner, and the
heat from that is distributed evenly throughout the unit with a fan. With electric systems,
heating elements are used instead of a burner.
Convection air heating systems are the most common heating methods we use since the level of
heat they produce is easily controlled, allowing for consistent results across the board.

3.Infrared Heating Systems

Infrared (IR) heating uses various wavelength light emitter panels to radiate energy based
on the intensity of the heating required for the parts being processed. IR panels used can be
made from sheathed elements, quartz panels or lights to UV wavelength lamps. The use of IR
heaters is ideal when the radiant light energy can reach the part surface.
An advantage of IR heating is it’s often faster than convection heating if only surface heating of
the part is required.
Infrared heating can be used in curing powder paint, epoxy, and polyester resin. In addition, it
can also be used to pretreat other types of coatings.

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 4.Resistance Power Heating Systems
Resistance heating is a direct heating of a part or product that can have power applied to it.
Examples of resistance heating are electric motor and transformers that allow the part to act as a
resistor. Applying various amounts of power to the part based on its resistance will determine
the amount of time it will take to heat a part by this method. Resistance heating in electric
motor applications is somewhat the opposite of induction heating where the conductive steel is
heated. In resistance heating, most often the copper winding is what is directly heated, which
then conducts the heat to other parts of the product that are in contact with it.

5.Combinations of Heating Methods

Can engineer custom heating systems, including furnaces, industrial ovens, and other
thermal systems, with any of these technologies, either on their own or in combination for
reduced heating times and optimal processing times.

In induction heating, high frequency generation is the most important favor. For
this project circuit is basically divided into four categories as per the operation,

I. Driver circuit

II. Buffer circuit

III. Inverter circuit

IV. Power circuit

➢ FROM ALL MENTIONED HEATING METHODS WE SELECTED
INDUCTION HEATING METHOD

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 Action plan –what is next ?

• How to construct the circuit in proper way?

This is the most frequent question arising in done any project. Hence, it needs action
plan to do so.

Action plan is a planning done which lists the steps to be taken in order to achieve a
specific goal.

• The action plan and steps taken to successfully complete our project are as
follows:-

1) List out the components acquired

2) Estimate the opportunity cost required.

3) Do market survey for best quality and economical component.

4) Present the market survey in front of Project-Guide.

5) Purchase the components with the consult of project guide.

6) Do pre-mounting, testing to ensure the circuit is functioning properly or not.

7) Search for PCB printing shops with low cost and good quality printing.

8) Place the PCB printing order.

9) Mount the components of circuit on PCB board by soldering.

10) Conduct testing on circuit.

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11) Troubleshoot the problems if occurring any and do rectification of errors with
the help of project guide.

12) Do final testing of circuit.

13) Search for pleasant, attractive, strong enough and nice appearance of
fabrication.

14) Provide fabrication and submission.

This is the action plan which is to be followed for the smooth functioning and
constructing the project.

In this semester (EE-5I), we have required up to the 'pre-mounting testing' step

find ourselves favorite that the circuit that the fortunate that the circuit is a
functioning properly.

In the next semester i.e. in EE-6I we are going to do the major works which the
PCB printing, marketing, testing and providing proper fabrication.

Thus, by following the action plan, it will help us in making our project an
extraordinary one.

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 ❖ References

1. From various books of Induction Heating:-

I. Induction Heating
Author: - a) Valery Rudnev
b) Don Loveke
c) Raymond.L.Cook
Publisher: - a) CRC Press
II. History of Induction heating and melting:-
Author: - Airfred Muhlbauer
Publisher: - Vulkan
Publication Date: - 01-12-2008

III. High frequency Induction heating:-

Author: - Frank W. Curtis
Publisher: - Lindsay Publication
Publication Date: - 01-01-1987

2. From Internet Source:-

I. Through Different Worker
Sr.No. Websites Link
1 Wikipedia https://en.m.wikipedia.org/wiki/inductionheating
2 Elproeus.com https://www.elprocus.com/induction-heating-
principle-and-its-application
3 Comsel.com https://www.comsel.co.in/multiphysics/induction-
heating
4. Research and survey • Inspirations and Aspirations: The
papers of U.S.A. Sustainability Strategy. (May, 2006).
• Paper articles on Urgent energy
conservation steps needed. (January,
2009)

4. Slideshare.com Power point presentations –

1.Induction Heating Fundamentals
By ,Brett Daly , Marketing Specialist at Ambrell
Corporation
Published on Jun 11, 2014
2.Induction heating applications
Published on Mar 16, 2015
3.Electrical Heating 01-03
Published on Nov 21, 2012

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 By, Vijay Raskar , MBA-Operation (Electrical
Engineer) at Electrical engineering

II. By watching you tube videos:-

a) Links:-
1) https://youtube/-V5Hg2zfLjS
2) https://youtu.be/0v:-sArhmkl
3) https://youtu.be/TFcv0xg3A-Y
4) https://youtu.be/I0a17Wdk4M

3. From student who got training from the industry related to induction heating technology:-
Industry: - Shivam electrimechnical
Address: - M-144, MIDC Area 425001
Student: - a) Pushpak R. Pawar (EE-5I)
b) Gajanan G. Warpade (EE-5I)
c) Poonam S. Pawar (EE-5I)

4. from Concerned Project Guide:-

Guide name: - Shri. J. K. Pandit, Sir
Designation: - Lecturer, Government Polytechnic Jalgaon,
Electrical Department (M-TECH)

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