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1174
Absfruct-Theinductionheating
of circularferromagneticplates is
studied to predict power levels under various excitation conditions. A
detailedandaccurate
analysisbased on auniquenoninteraction
approximation is presented. A lumped parameter transformer model
is developedwith the nonlinearequivalentdisk
resistance expressed
as a function of the terminal variables in the system. The transformer
model is applied to predictoperating characteristics. Experimental
results are presented to justify the theoreticalmodel.
I. INTRODUCTION
MAGNETICS, VOL.
and secondary plate as shown in Fig. 1 for the circular geometry. Basu and Srivastava [3] have elucidated two approaches
to theproblem:thecoupled
circuit approachand the field
theory approach. They found the latter approach was more
accuratefor force calculations involvingnonmagneticdisks
with very close coupling. At large coil-diskseparations (>1 cm,
coil radii between 5 and 15 cm), both approaches were equally
acceptable. Later, Adler [4] used the field theory approach to
studythe arrangement of Fig. 1 with a magnetic plate. He
included a treatment of the effects of the
magnetic material
nonlinear permeability on power predictionsunder various
excitation conditions. However, he was unable to offer conclusive experimentaljustificationfor
his approachand did
not allude to the broader class of problems.
In this paper the coupled circuit and field theory approaches
are combined to develop a lumped-parametertransformer
model which greatly simplifies the understanding of the complex interactions present inaninductionheating
system,
giving greater physical insight into the operatingand design
ofsuch systems. The circular geometryofFig.
1 with a
magnetic plate is studied here, but the techniques developed
Secondary disk
r
,o,
Fig. 1. Coil and disk arrangement in an induction heating system.
&(r, z) = poNl^,a
where Jl(kr) is the Bessel Function of order 1 and argument
kr, i is the current in a coil of radius a, and r, z are the radial
and axial coordinates withthe origin at the coil center.Because
of cylindrical symmetry, only the circular component of the
vector potential needbe considered.
In the second case, half the medium (above or below the
coil) has apermeability p and again zeroconductivity. By
appropriate use of theboundaryconditiononthe
magnetic
field intensity, andassuming p >> p o , we obtain
J,
Jl(ku)Jl(kr)e-kZdk.
(3)
A,,
where w is the exciting frequency (rad/s). If J,(p) is the complex amplitude of the eddy current density at the surface of
the disk ata radius p, thenconsideration of thePoynting
vector at the disk surface shows that an equivalent rms current
so the presence of the magnetic half-plane doubles the field.
(J,(p)/2)6 dp flowsinan annular segment of width dp and
In an induction heating system suchas that shown in Fig. 1, thickness 6 and givesrise to the same absorbed power in the
the magnetic coupling between'the primarycoil and secondary disk [SI. Since we have assumed the disk is semi-infinite in
conductingbody givesrise to eddycurrents which flowin
the axial direction, case two applies to the equivalent currents
coaxial circular paths and produce secondary vector potential
so that the amplitude at the disk surface of the vector potential
fields. The eddy currents will be opposite in direction to that due t o the eddy current is
of the primary coil current. The above solutions for the vector
potential fielddue t o a current carrying coil
will apply here for
theprimary coil.If we nowdecompose the secondary disk
co
A"(r, z) = poia
Jl(ka)Jl(kr)erkz dk
(2)
1176
so (1 1) becomes
iw
1
Js(r)Jl(kr)r d r = -jopooNZrna- J1(ka)e-kz
k
A(r, z ) = poNIma
J1(ka)J1(kr)e-kz dk
B=VXA
J,= UE.
d f k
(10)
+-
1-
Jl(ka)Jl(kr) e-kz dk
f(k)=
J, (kr)rdr
(1 2)
1- 1-($
Jl(kr)rdr
J,(k'a)Jl(k'r)k'dk'
lW
Js(r)Jl(kr)rdr
d
dx
- &(x) =&(x)
-.&(x)
X
we obtain
1 +-
f i k
B,(r) =
"Falw
Jl(ka)Jo(kr)
edkzk
dk
1177
Jl(ka)J,(kr) emkzk dk
Jo
Js(r) = -
JO
J1(ka)J1(kr)
e-kz
dk.
IV. TRANSFORMER
MODEL PARAMETERS-CIRCUIT
THEORY APPROACH
The lumped-parameter transformer model for the induction
heating system of Fig. 1 is shown in Fig. 2. Re is the resistance
of the primary coil with correction made for high frequency
operation. R D is the equivalent disk resistance obtained from
the decomposed disk. L , is themagnetizinginductanceof
the primary coil and Ll is the leakage inductance. A hollow
conductor is used fortheprimary coil forthepurposesof
forced convection cooling. The various parameters are calculated as follows.
A. Coil Resistance R e
The dcresistance of a hollow conductoris
Re dc =
N2na
u,2na, A
where a is the mean coil radius (Fig. l), a, is the mean radius
of the hollow conductor, N the number of turns, a, the conductor conductivity, and A the conductor thickness. The ac
resistance isderived fromthePoyntingvectorby
assuming
an equivalentcurrent inan equivalentthickness 6 , the skin
depth, as before, so that
Re ac
Re dc
-=-
'
A
6'
B. Disk Resistance R D
For an annular segment of width dr at a radius r, the equivalent rms current asusedin
(5) can be obtainedfromthe
Poynting vectoras
271r
dR = a6 dr
where 6 is a function of p, which is evaluated at a radius r
from the flux level given by (21) and ( 2 2 ) and the normalized
magnetization curve.
The
average
power
absorbed in the
TRANSACTIONS
IEEE 1178
segment is then
Ieq
71
dP = -(JS(r))'6r dr.
20
(28)
C. Coil Self-lnductance L,
The self-inductance of the primary coil is given by the sum
of the magnetizing and leakage components
L , = Ll t L,.
(3 2)
D. Magnetizing Inductance L ,
If Lz is the secondary inductance, then
tance is
M = d G .
(33)
A mutualinductanceformula
distribution (18).
(34)
is obtainedfromtheflux
E. Leakage Inductance Ll
This is simply
L,=L,-L,.
( 35 )
(37)
1179
HEATING OF CIRCULARFERROMAGNETICPLATES
40
Innerdiameter
I.D. = 3.175mm
Wall thickness
A = 0.762mm
Copper conductivity oc = 5 . 9 x l O ' m m ) - '
20
io
I
I
i1
1.0 1.2
1.4 1.6 r
O+
d
'
@)
Fig. 4. Experimental system. (a) Coil conductordimensions.
overall dimensions.
(b) Coil
B(Wb/m2)
TABLE I
CALCULATED
A N D MEASURED
PARAMETERS
FOR A COIL-DISK
SEPARATION
OF 2 cm
Paranletcr
LS
'
P.xi
0.0
10
20
40 60
80
LL
Q
?
/I* '
I
I
100
200
400 600
1000
2000
Lm
6000 10000
H(A-T/m),pr
Calculated
Measured
86.9 pH
92.5 pH
43.1 uti
50.5 ut1
43.8 pH
42.0 vti
20 m
Ec(dc)
25
ni R
A
5.9 5.85.7 -
[L
5.6 5.5 -
.-
5.4-
u)
5.3r
" 1I
E 5.2
5.1
0
5
10
1
15
1
1
1
1
20
25
30
35
I p (Arms)
"
1
'
40 45
50
55
1180
1400
1200 1000 -
Measured
Calculated
800 -
6oo
800
"
"
rnlr,,lntmi
" U 1 U ' ~ "
600 -
400
200 0
400
10
15
20
25
30
200 -
35
b
1.5 2.0 2.5 3.0 3.5 4.0
0 1.0
Ip(N
Z(cml
in p and then fall off. However, these power levels are impractical. On theother hand,fortransformer
steel such as
that used by Adler [4], y reaches its maximum at approximately 160 Atlm which in our case corresponds to the flux
levels at 1000 W disk power. In Fig. 5 for cold-rolled steel,
p reaches its maximum at 600 At/m. Thus it is vitally important that the correct curve is chosen if valid predictions are
to be made for equivalent resistance and power.
Equation (30) gives the power dissipated in the disk. Substituting (23) and (4) into (30) shows that PD is a function
I,, X , and o. The variation of PD with I, is reflected in the
terminalcurrent I p . Using the terminal variables I p and Vp
determined fromthe
phasor diagram, the disk absorbed
power is
PD
= VpIp
COS
6 - R,
dc
I;.
(38)
10
15
20
L
25
f(kWz)
Thus we can calculate all quantities of interest in terms of the Fig. 10. Disk power as afunction of frequency; Zp = 20 A rms,
lumped-parametertransformer model using the coupled cirz = 2 cm.
cuitapproach, with I,, and flux distributions found by the
field theory approach.
Figs. 8, 9, and 10 show experimental and theoretical curves
for PD as a function of I,, z , and f. The results show excelpD(w)
lent agreement exceptfor discrepancies at large z . This is
1400 due to convergence problems with the series used to evaluate
the integrals involving
Bessel
functions (21)-(23), where
1200 increased number of terms for increasing z were not used in
1000 the computer program; the convergence was tested only at
z = 2 cm. Phase angle measurements were made by displaying
800 voltage andcurrenton
an oscilloscope, 2' was the greatest
600 accuracy obtainable in this way. The phase anglewas in the
72"-75"range where a 2" change could cause errors of 10
percent. At high power levels, resistance changes in the disk
at high temperatures were not accounted for. However, this
does not introduce large errors since both I p and Po are
proportional to fi(Section IV-B). Hysteresis losses are also
neglected.
In thenoninteractionapproximation,
the eddycurrents
Fig. 11. Disk power as a function of primary coil current; a2 = 1.2 a,
were derived directly fromthe fluxdistribution.
On this
z = 2 c m , f = 1 0 kHz.
IEEE TRANSACTIONS
MAGNETICS,
ON
MAG-15,
VOL.
NO. 3, JULY
1181 1979
VI. CONCLUSION
As mentioned in theIntroduction,the
system wehave
studied is a relatively simple one where the field equations
could be reduced on onedimension or in some cases two.
However,thelumped-parametertransformermodel
is completely generalandonlyrequiresthe
field distributionsfor
coils of various geometries, most of which have been treated
in the literature [8]. The model is a powerful tool whereby
more complicated geometries could
be handled by adopting
the same techniques developed here. In general, the correlationbetweenexperimentaland
analytical results was quite
good over a verywiderange
ofexperiments.Thenoninteractionproved to beinvaluable in solving thecomplex field
equations without affecting the integrity or generality of the
analysis.
Themodelcould
be improvedby closer attention to the
errorsourcesoutlined in the discussion ontheexperiments.
We confinedour studies to one material, butany material,
for which a B-H curve and conductivity are available, could
be studied. Extension to rectangular or solenoidal geometries
would be relatively easy. Also asingle-frequencysinusoidal
excitationsource was used, but again themodel is general
enough to be adapted to square-wave orotherexcitation
studies.
REFERENCES
W. C. Moreland 11, Theinductionrange:Itsperformanceand
development problems, IEEE Transaction on Industry Applications, vol. IA-9, Jan./Feb. 1973.
P. H. Peters, A portable cool-surface induction cooking appliance,
IEEE Transactions on Industry Applications,vol. IA-10, Nov./Dec.
1974.
S. Basu and K. D. Srivastava, Electromagnetic forces on a metal
disk in an alternating magnetic field,
IEEE Tmnsactions on Power
Apparatus and Systems,vol. PAS-88, no. 8, August 1969.
M. S. Adler, A field-theoretical approach to magnetic induction
heating of thin circular plates, IEEE Transactions on Magnetics,
vol. MAG-4,pp. 1118-1125,December 1974.
J. D. Ryder, Networks, Lines and Fields. New York:Prentice
Hall, 1955, pp. 437-442.
P. Morse and H. Feshback, Methods of Theoretical Physics. New
York McGraw-Hill, 1953, chapter 6 , part I.
W. G. Hurley, Induction heating of circular ferromagnetic plates,
M.S. thesis, Massachusetts Institute of Technology,December
1975.
Bulletin of the Bureau of Standards, vol. 8, no. 1, U.S.Government Printing Office, January 1912.
Letters
INTRODUCTION
The region external to the two infinite length pole pieces separated
by a gap of half length b as shown in Fig. 1 can be conformally mapped
onto the upper half complex w = u + iT plane by the implicit SchwarzChristoffel transformation [4]
z/b =
[,/x
d x + arcsin (l/w)],
(1) in