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5, MAY 2014
Abstract—This paper analyzes a high-power (100-kW) high- ticularly induction hardening, are repetitive processes with
frequency (50-kHz) voltage-fed inverter with a series resonant relatively low periods. This means that an induction heating
load circuit for industrial induction heating applications which is inverter can make several cycles per minute. Under these con-
characterized by a full-bridge inverter composed of isolated-gate
bipolar transistors and a new power control based on phase-shift ditions, the IGBT power cycling capability is one of the most
(PS) control. This power control circuit incorporates a load- important reliability items that relates directly to the lifetime
adaptive variable-frequency controller and automated blanking of the inverter. Since the failure mechanism depends on the
time management in order to allow the inverter to work in zero- IGBT ΔTj , we can improve the inverter reliability reducing the
voltage switching for all output power levels and load conditions. transistor losses or improving the thermal management [8].
An important improvement of the inverter reliability is achieved
by choosing an appropriate and novel switching sequence for This paper describes an induction heating system of 100 kW
the PS inverter. The results are verified experimentally using a and 50 kHz for industrial applications, which uses a novel
prototype for induction hardening applications. A comparative control scheme based on a PS IGBT full-bridge SRI that allows
study between the proposed and standard PS power control will us to improve its reliability significantly by increasing the
be made. lifetime of the IGBTs. To achieve this, the inverter should
Index Terms—Induction heating, phase-shift (PS)-modulated always perform zero-voltage switching (ZVS) operation and
inverters, resonant power conversion, zero-voltage switching the impact of the turn-off switching losses in the temperature
(ZVS). increase of the IGBT junction should be as low as possible. The
I. I NTRODUCTION inverter working frequency is automatically adjusted close to
the resonance frequency in order to allow a quasi-zero-current
solution, we must extend the switching cycle of the standard PS Fig. 5. Here, the transistors that have larger switching current
inverter so that the main branch will be alternately formed by are Q3 and Q4 , while the switching of Q1 and Q2 is relatively
Q1 and Q2 in one cycle and Q3 and Q4 in the next cycle. soft. The second period corresponds to the two columns on the
Fig. 5 shows the complete switching sequence of the mod- right of the figure.
ified PS inverter organized in four columns. The top of each Now, the switching are softer in Q3 and Q4 , and most of the
column shows the simulated waveforms of the output voltage losses are in Q1 and Q4 . Since the time of these cycles is much
vo and the output current io of the inverter and the four trigger smaller than the thermal time constant of the transistor modules,
signals of the gates of the IGBT transistors vg1 −vg4 . The the temperatures reached will be the same for all transistors.
steps of the switching sequence are identified by numbers. The Fig. 6 shows the switching sequence for the full output power
inverter schematics corresponding to each step are shown in regulation. Note that, now, the conditions in the first and second
the lower portion of the figure. The current-carrying devices periods of the oscillation are the same; therefore, the work of
are drawn with solid lines, and the voltage-blocking devices modified and standard PS inverters is the same.
are drawn with dotted lines. The direction of the current and The control circuit designed to implement this modified
the voltage polarity obtained at the end of each step has been PS inverter is a load-adaptive variable-frequency system [11],
expressed with arrows and ± signs. The first full period of the [12], [15] that must be able to perform ZVS under all operat-
oscillation corresponds to the first two columns on the left of ing conditions and generate the switching sequence discussed
2568 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 61, NO. 5, MAY 2014
V. E XPERIMENTAL R ESULTS
The prototype described in Section III is tested in order to
meet the industrial application requests. The four IGBTs of the
inverter (Eupec FZ600R12KS4) are rated at 1200 V and 600 A.
Tests made with this prototype allow us to make the validation
of the calculations and simulations and a comparative study be-
tween the proposed modified PS inverter and the standard one.
The inverter is fed by 540 V which is the average value of
the output voltage of a noncontrolled rectifier connected to the
three-phase 400-V 50-Hz utility power system used in Europe.
The maximum peak amplitude of the output current is rated
to 300 A. The experimental values of the components of the
output circuit are as follows: LL = 1.5 μH, CL = 6.7 μF, and
n1 = 7 : 1 (the turns ratio of T1). The value of LL includes the
inductance of the corresponding inductor and its connections
to the rest of the circuit. For long time tests, a water-cooled
Fig. 6. Switching sequence for full output power regulation.
dummy load is used. The equivalent resistance of the load is
47 mΩ. This load configuration represents a quality factor of
earlier. Fig. 7 shows the block diagram of the proposed control approximately ten which remained constant during all the tests.
circuit. Since the phase detector and the voltage-controlled The experimental resonant frequency of the output circuit was
oscillator (VCO) act like a phase-locked loop, the signal Q 50.2 kHz. The control circuit set automatically the switching
will be in phase with the inverter output current io . This square frequency between 50.5 and 60.5 kHz depending on the output
signal determines the rising slope of the trigger signal of the power regulation.
inverter main leg transistors and therefore defines its turn-on A photograph of the experimental implementation of the
switching. inverter is shown in Fig. 8. The red rectangles marked with
The delay block is used to advance this turn-on switching letter “A” represent the four IGBT modules, “B” and “C”
with respect to the zero cross of the inverter current such as that indicate the position of the dc-link and ac coupling capacitors,
represented in steps 5, 10, 15, and 20 of Fig. 5 or steps 3 and 6 respectively, and “D” shows the position of the snubbing ca-
of Fig. 6. pacitors. In this implementation, the equivalent capacitance of
The signal φ inputs the PS modulator to generate the signal each inverter switch CS , including the snubbing capacitor and
that defines the turn-on switching of the phase-shifted leg the output capacitance of the IGBT, is approximately 10 nF.
transistors of the inverter. The thermal management of the IGBT modules was carried out
The blanking time indicates the time interval between the by using water-cooled heat sinks. The experimentally measured
turn-off and turn-on switching of the transistors of the same thermal resistance from the transistor junction to the water
leg. The blanking time control circuit generates the signal that (ambient) is RthJA = 0.05 K/W. For all power measurements,
references the turn-off switching of all transistors of the inverter a calorimetric method was used [13].
taking into account the calculation of (5) in order to achieve Fig. 9 shows the experimental waveforms of the modified PS
ZVS operation such as that represented in steps 4, 9, 14, and inverter output vo and the current of the diode and the transistors
19 of Fig. 5 or steps 2 and 5 of Fig. 6. Analog circuits like of the main leg iQD1 and the phase-shifted leg iQD3 for full
a summer, a divider, a limiter, a peak detector, an arccosine output power (100 kW approximately) with a frequency of
calculator, and an amplifier carry out this calculation. 50.5 kHz. In this case, the modified and the standard PS inverter
The value of the switching frequency is obtained from the have the same behavior.
input of the VCO (supposing that it has enough linearity). Fig. 10 shows the same waveforms of Fig. 9 for 50% of
The values of the voltage of the dc link Vd and the equivalent the output power (50 kW approximately) with a frequency of
output transistor capacitance CS are included in the adjustment 52.2 kHz. Note that the hard turn-off commutations are alterna-
of the amplifier gain. tively present in both legs of the inverter.
The logic circuit collects all these signals to generate the Compare this waveform with that shown in Fig. 11 where
trigger signals that need a standard PS inverter. the inverter works like a standard PS control. Now, the hard
ESTEVE et al.: IMPROVING THE RELIABILITY OF SRIs FOR INDUCTION HEATING APPLICATIONS 2569
Fig. 15. Theoretical and experimental power losses and the increase of the
Fig. 12. Experimental waveforms of vo (CH1) and io (CH2) for 100% of the junction temperature of a transistor of the (green) main leg and (blue) phase-
output power. (CH1: 200 V/div; CH2: 100 A/div; time: 500 ns/div). shifted leg of the standard PS inverter and (red) of any transistor in the modified
PS inverter versus output power.
The green and blue traces represent the power losses of the
IGBTs of the main and phase-shifted legs, respectively, in a
standard PS inverter. The red trace indicates the losses of a
transistor of any leg of the modified PS inverter. Experimental
points are marked with squares and triangles. In the right
vertical axis are the calculated increase of temperature ΔTj of
the IGBT junction with RthJA = 0.05 K/W.
In order to know the impact of this result in the reliability
of the inverter, we need to move these data to the “power
cycling curve” of the IGBT’s manufacturer [14]. This curve
Fig. 14. Power losses of the transistor of the modified PS inverter versus indicates the expected number of on–off cycles of the device as
output power. a function of its junction temperature swing. Taking these data
for industrial modules based on IGBT4 working with Tjmax less
than 100 ◦ C makes it possible for us to draw Fig. 16, which
VI. C OMPARATIVE S TUDY
shows, in the left axis, the power capability of a transistor of
This section shows the significant impact of the results the standard PS inverter (blues trace) and of the modified PS
obtained using the modified PS inverter on the reliability of inverter (red trace) as a function of the output power. Note that
the system compared with those obtained using standard PS the minimum for the standard PS inverter is around 2 million
control. Fig. 15 illustrates, in the left vertical axis, the the- cycles and that for the modified PS inverter is almost ten times
oretical and experimental values of the power losses of one bigger.
of the four modules used in the inverter as a function of the In order to clarify this phenomenon, we can imagine an
output power. As the experimental points were obtained using industrial induction heating application where four pieces per
the calorimetric method applied to each power module, it is minute are treated. This means that after a year, there have
only possible to measure the sum of the losses of the diode been over 1.27 million cycles. According to this specification,
and the transistor included in each module. Since diode losses the right axis in Fig. 16 indicates the lifetime of the two types
are significantly lower than transistor losses, it is possible to of inverters. If the output power is around 60%, the expected
neglect them and assume that the experimental points obtained lifetime of the standard PS inverter is less than 20 months but
represent approximately the IGBT losses. the modified PS inverter will still be working after 14 years.
ESTEVE et al.: IMPROVING THE RELIABILITY OF SRIs FOR INDUCTION HEATING APPLICATIONS 2571
Enrique Maset (M’00) was born in Xàtiva, Spain, Agustín Ferreres was born in Sant Mateu,
in October 1965. He received the M.Sc. and Ph.D. Castellón, Spain, on November 26, 1963. He re-
degrees in physics from the University of Valencia, ceived the M.Sc. degree in physics and the Ph.D.
Valencia, in 1988 and 1993, respectively. degree in electronics engineering from the University
He is currently an Associate Professor with the of Valencia, Valencia, Spain, in 1993 and 1999,
Electronic Engineering Department, University of respectively.
Valencia, where he belongs to the Laboratory of For two years, he was a Power Electronics Re-
Industrial Electronics and Instrumentation. His main searcher with the R&D Department, GH Industrial.
research areas are space power systems and high- In 1995, he joined the Laboratory of Industrial Elec-
frequency and soft-switching conversion techniques tronics and Instrumentation, University of Valencia,
for industrial applications. where he is currently an Associate Professor.