ISSN: 2394-6881

International Journal of Engineering Technology and Management (IJETM)

Available Online at www.ijetm.org
Volume 2, Issue 2, Page No. 115-120

Full Bridge Inverter for Induction Heating applications with PFC Control
1 2
Lekshmi.M, Manjunatha.S
1
Associate Professor, Dept. Electrical & Electronics Engineering, Acharya Institute of Technology, Bengaluru, Karnataka.
2
M.Tech (Power System Engineering), Dept. Electrical & Electronics Engineering, Acharya Institute of Technology, Bengaluru, Karnataka.
Manjunatha.mtps.13@acharya.ac.in
lekshminair@acharya.ac.in

ABSTRACT
Induction Heating (IH) provides contactless, fast, and efficient heating of conductive materials. It is becoming one of the
preferred heating technologies in industrial and medical applications among other applications, due to its advantages
when compared with other classical heating techniques. Commercial Induction Heating (IH) systems are based on a dc-
link resonant converter which supplies high frequency currents (20-49 kHz) to an inductor, which heats up the induction
cooktops. Different topologies have been developed on the basis of current source and voltage source inverter. Recent
developments in switching schemes and control methods have made the voltage-source resonant inverters widely used
in several applications that require output power control. In resonant converters, maximum output power and efficiency
occurs at the resonant frequency, and the switching frequency is increased to reduce the output power. A high
frequency soft-switching PWM inverter with PFC (Power Factor Correction) function suitable for consumer IH cooking
appliance is presented in this paper. The proposed system is composed of a soft switching chopper based boost PFC
converter with passive snubber and phase shifted PWM controlled full bridge ZVS high frequency inverter. In order to
meet the utility AC grid current harmonic regulation, a simple PFC control technique with discontinuous current method
is introduced.
Index Terms: Induction Heating (IH), resonant converter, PWM, ZVS, & PFC.

INTRODUCTION: boost with PFC functional soft switching chopper and a

Induction Heating (IH) provides contactless, fast, and
efficient heating of conductive materials. It is becoming
one of the preferred heating technologies in industrial
and medical applications among other applications, due
to its advantages when compared with other classical
heating techniques such as flame heating, resistance
heating, or traditional ovens or furnaces.
However, as the switching frequency becomes higher, the
effective resistance of metallic materials, such as stainless
steel and iron, becomes too large so as to supply
sufficient heating power. To adapt, there are many
approaches such as changing over the resonant
components of the inverter and operating frequency,
effective using of the third harmonic currents of the high
frequency output current, etc. Furthermore, it is
important to correspond with the utility AC grid current
harmonic regulations of various countries.
In this paper, a phase-shifted soft switching high
frequency inverter with a boost PFC function is proposed
for consumer cooking and processing appliances. The
phase-shifted full-bridge inverter with ZVS and ZCS legs.
The feasible operating characteristics of the proposed
power system using IGBTs and Diodes are evaluated and
illustrated on the basis of the experimental results.
Induction heating system
Fig. 1 shows the block diagram of single phase IH system.
A high frequency inverter supplies high frequency current
to a planer-working coil, then induced eddy currents
directly flow into the pan or vessel on the basis of
Faraday’s electromagnetic induction law. In accordance
with this principle, the IH method is able to realize high
thermal conversion efficiency. In the meantime, in case of
a multi-coil type IH system assembly, it is preferable to
control the output power of each coil under constant
frequency, because of a rising beat sound from the
operating frequency differences between mutual
inverters. This means the constant frequency power
regulation method is indispensable for IH systems.
Furthermore, to reduce input utility AC grid current
harmonics, PFC converter stage is connected to meet
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proposed system consists of two power stages, a voltage regulations.

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Lekshmi.M, IJETM Volume 2 Issue 2 Page No. 115-120

Lekshmi.M, et al. International Journal of Engineering Technology and Management (IJETM)

Figure 1: A block diagram of IH heating system using power electronics circuit.

Figure 2: Proposed phase-shifted soft switching high frequency inverter with boost PFC converter.

Circuit description of high frequency soft switching
inverter with boost pfc converter
Fig. 2 represents the circuit configuration of the proposed
high frequency power supply composed of a soft-
switching phase-shifted PWM inverter (HF-INV) with
boost PFC converter. This circuit topology consists of a
boost PFC stage comprising low pass filter Lf and Cf, boost
inductor L1, switching device Q1 with its lossless snubber
inductor L2 and lossless snubber capacitor C1, C2,
intermediate DC smoothing capacitor C0 and so on.
Additionally, the high frequency inverter stage comprises
ZVS side switching devices Q2 and Q3, lossless snubber
capacitor Csn, ZCS side switching devices Q4 and Q5 and
lossless snubber inductor Lsn. The induction heated load
with working coil is described as L0& R0 with a series
capacitor CS. In addition, the commercial AC oriented
lower frequency current components through the
working coil is designed to be eliminated by intermediate
the proposed circuit is 60 kHz. High frequency output
power to the IH load can be
Regulated by controlling the phase shift angle ø of the
high frequency inverter stage, as well as intermediate DC
voltage VCo , which can be controlled by the boost PFC
converter stage mentioned in the following subscripts.
A. Operation principle of boost pfc converter
The primarily connected voltage boost PFC converter
stage has two functions. One is power factor correction
of the total system with discontinuous current mode
operation; the other is the additional output power
regulation by boosting intermediate voltage VC. This
circuit stage includes 10 operating modes during one
switching period, as shown in Fig. 3. Switching device Q1
operated under ZCS turn on by lossless snubber inductor
L2 and ZVS turn off by lossless snubber capacitor C1.
Moreover, boost inductor current iL1 is controlled under
discontinuous current mode (DCM) with constant duty
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DC smoothing capacitor C0. The switching frequency of cycle D in this case.

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Lekshmi.M, et al. International Journal of Engineering Technology and Management (IJETM)

Figure 3: Circuit Waveform for PFC boost converter stage

Operating principle of phase-shifted high frequency inverter stage

Fig. 4 explains the circuit operation principle of the soft switching phase-shifted PWM inverter stage. This circuit includes
10 operation modes during one switching period.

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Figure 4: Circuit waveform of phase-shifted PWM inverter stage

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© 2014 IJETM. All Rights Reserved.

Lekshmi.M, et al. International Journal of Engineering Technology and Management (IJETM)

Switching devices Q2 and Q3 in the current lagging leg

operate under the conditions of ZVS & ZCS turn on and
ZVS turn off by the lossless snubber capacitor Csn. On the
other hand, switching devices Q4 and Q5 in the current
leading leg operate under ZCS turn on assisted by lossless
snubber inductor Lsn and ZVS & ZCS turn off. The high
frequency output power is regulated by the phase shift
angle ø as shown in this Fig.4.
Prototype experimental studies
Steady state performance
To verify the performances of the proposed IH system, an
experimental prototype was built. The circuit parameters
of the prototype are listed in Table I. Switching device; Figure 6: Voltage and current waveforms of Phase-shifted high
IGBTs in the inverter stage, are trench gated 2 in 1 frequency inverter switches Q2
module (Semikron SKM100GB12T4), on the contrary,
Semikron SKM200GB12T4 is selected for the boost PFC Fig. 5 and 6 show the experimental waveforms of the
converter stage. Furthermore, discreet diodes are proposed circuit with the stainless steel pan, when the
secreted for D6, D7, D8 and D9 to reduce the switching duty cycle of the PFC converter stage D =0.28 and phase
losses and current/voltage spikes derived from recovery shift angle ø = 62.5 degrees. In this condition, the
current of the diodes. intermediate DC voltage is 402 V, and input power is 2.5
kW. Fig. 5 illustrates the operating waveforms of the
Experimental Circuit parameters boost PFC converter. From this Fig., boost switch Q1
Items Symbols Value turns on under the condition of ZCS and turns off under
Utility AC side Voltage Vin 200V the ZVS condition. Observed voltage and current ringing
Utility AC side Frequency fin 50Hz may be mainly caused by the stray inductance in the
Switching Frequency fsw 20kHz hand-made circuit construction. The manufacture-based
Filter Capacitance in Utility AC robust circuit design may be able to solve this problem.
Cf 5uF From Fig. 6, it is clear that IGBT switching devices Q2 in
side
Boost Inductance Lf 860uH the current lagging leg turns on under ZVS and ZCS turn
Lossless Snubber Inductance L1 28uH on, and ZVS turns off as an effect of lossless snubber
Lossless Snubber Capacitance C1 2uH capacitor Csn. Additionally, Q5 in the current leading leg
turn on under ZCS condition with the assistance of
Lossless Snubber Capacitance C2 47nF
lossless snubber inductor Lsn, and ZCS & ZVS turn off. As
DC Filter Capacitance C0 3900uF
a result, switching losses in each IGBT is dramatically
Lossless Snubber Inductance Ln 2uH
decreased.
Lossless Snubber Capacitance Csn 10nF
Power Factor Compensation
Cs 32nF
Capacitance

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Figure 5: Voltage and current waveforms of PFC converter switch Q1 Figure 7: Utility AC grid voltage and boost inductor current
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Lekshmi.M, et al. International Journal of Engineering Technology and Management (IJETM)
Figure 8: Utility AC grid voltage and current
Fig. 7 & 8 depicts the experimental waveforms of the
utility AC grid current controlled by the PFC stage under
discontinuous current mode operation when the duty
factor D=0.28 and phase shift angle ø =62.5 degree.
In this condition Input power is 2.5kW with load. An
envelope curve of the boost inductor current iL1 is settled
by a utility AC grid voltage as shown in Fig.7. In this
operation, iL1 is controlled under discontinuous current
mode with constant duty cycle D. Fig.8. Indicates the
relations between the utility AC grid voltage vin and the
grid current iin. To satisfy the harmonic regulations
perfectly, active duty control of the PFC switch S1 may be
necessary.
B. Simple PFC control using PLL
This paper propose a simple PFC control method using
PLL to meet harmonic regulations perfectly, by injecting
the third harmonic element into a fundamental modulate
signal of PFC switch S1 as shown Fig.9. This method
injects the reversed phase third harmonic element into
fundamental modulate signal of PFC switch S1 to cancel
the third harmonics, which is included in utility AC grid
current iin. This control method is only necessary the zero
cross signal of utility AC grid voltage by PLL. Amplitude of
third harmonic element AS, which is injected into
modulate signal S1 can be decided using α as shown
Fig.9. Here, α can be described with fundamental current
harmonic if, third current harmonic ith and a target
current value of third harmonic element ita as follows: α
= (ith-ita) / (if)
Each current value of if and ith is found by experimental
results as follows: if =18.5 A and ith =3.04 A. In this case,
a target value of third harmonic current ita is set as 1.20
A, α is calculated α=0.1 from above equation.
© 2014 IJETM. All Rights Reserved.
Figure 9: Principle diagram of simple PFC control; injected reversed
phase third harmonic element into modulation signal of PFC switch
S1
Conclusion
In this paper, a novel circuit topology of a utility
frequency AC converted to high frequency AC power by
employing a boost PFC converter stage and phase-shifted
PWM high frequency inverter and its control procedure
was proposed for consumer induction heating appliances.
Its operating principle and unique features were
presented, along with a phase-shifted PWM and boost
chopper based on an intermediate voltage control
scheme. The proposed high frequency IH power
conditioning system, which can heat various metallic-
cooking items, could reduce the switching losses
generated in IGBTs and diodes. The steady state
operating performances were experimentally illustrated,
which include high frequency power regulation. In
addition, proposed simple PFC control method, which
injects reversed phase third harmonic element into
fundamental modulate signal of PFC switch can
effectively reduce the harmonic elements of the utility AC
grid current.
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© 2014 IJETM. All Rights Reserved.
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