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DECEMBER 1996
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DECEMBER 1996
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Head
Bureau of Research and Consultancy
ITM,ShahAIam
SELANGOR
Our above research project has completed. Here enclosed 3 final project reports to BRC as
references. Thank you.
Your Sincerely
w/
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(Signature)
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ACKNOWLEDGEMENTS
We thank Allah (S.W.T) for offering us the strength to finish this project.
The success of this project can be related mainly to the hard work of the final
year project students in Electrical Engineering Department Peto Galim, Zulkarnain,
Norafidah and Ferry Syafrizal.
We hope that this report will be considered as a good start for researchers in the
field of electromagnetics and its application on devices.
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ABSTRACT
power loss in the form of heat. The heat is caused by a high frequency flux produced
from a controller. The later produce high frequency currents fed to an exciting coil.
The cooking vessel is usually placed on the top of a flat or inside a solenoidal
exciting coil. Eddy currents will flow on the surfaces of the ferromagnetic vessel
Two types of the high frequency H-bridge inverters are used to produce
magnetic field at 15 kHz and 38.4 kHz. A Resonant Inverter is also used to produced
Three types of exciting coils are used. The first type is a solenoidal, the second
is flat single concentric coil, while the third consists of small flat coils arranged in
different shapes to match the bottom of the vessel. Good comparison has been
achieved between the performance and efficiency of the three controllers.
IV
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CONTENTS
Page No
Chapter 1
Introduction
1.1 Inverters
.....................................................:...................,
......................................................................
26
28
Chapter 2
32
32
36
36
38
49
54
55
56
59
Chapter 3
67
68
69
71
-71
72
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73
73
73
74
75
..............
76
77
82
Chapter 4
92
92
93
94
96
99
100
101
103
105
110
111
111
113
115
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Chapter 5
122
References ..............................................................................
124
Appendix
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128
CHAPTER 1
INTRODUCTION
Conventionally hot plate is used to heat up the metal vessel. Induction heating
phenomena depends on the losses produced in a ferromagnetic materials known as
eddy current loss. These losses provide ohmic power loss and cause local heating.
The main
advantage of using this frequency is to prevent the stress on the power device during
switching. The technique also reduces the number of power switching devices used
which in this case eliminate the possibility of short circuit in any part of the
inverter circuit.
Many types of vessels are used as load with the exciting coil.
Ferromagnetic vessels such as stainless steel is the most suitable vessel material for
induction heating purpose [2]. Different kinds of coils are used to study the
performance of the resonant inverter circuit. Rasmussen, C.B.; Alvsten, B.; Dahl, J. (
1994 ) described a converter where both series and parallel resonant circuits are used.
In order to minimise losses switching is made to zero current ( ZCS ). The converter
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described which is suitable for commercial and domestic use as an induction cooking
power supply. A gate turn off thyristor ( GTO ) operating a gate assisted zero current
switched mode ( ZCSM ) in this circuit provides several advantages including high
operating frequency ( >40 kHz ), and good efficiency ( >95% ). The circuit makes
good use of the high GTO current and voltage ratings, and with a small change in
operating frequency can cope with a wide range of output powers and loading
conditions. Design and construction details are given for a 3.2 kW prototype inverter
based on the Philips TO3P packaged BTR59 GTO operating at around 40kHz.
induction heating not only special iron vessels but also non-magnetic and low
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various metal vessels were investigated, and the optimum characteristic of a high
frequency inverter were determined. The inverter has double-layer coils and two
resonance circuit capacitors. Proper coils and frequencies are automatically selected
through the detection of the vessel material. The induction range can also prevent
undesirable levitation of light aluminium vessels on the top plate by monitoring the
variation of the resonance frequency.
Hybrid Resonant a converter [5] describes both series and parallel resonant
circuits are used. In order to minimise losses, switching is made at zero current
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The presented concepts are verified with measurements resulting from a prototype
inverter running at 10 kW/400 kHz. This operation is important to protect the
switches from overvoltage stress. Identification of the cause of the stress and works
out options to tackle the overvoltage amplitude is discussed. It is found that the
parasitic of the MOSFET with a suitable gate drive may be utilised to aid lossless
turn off. When the operation is below resonance, the high switching speed imposes
heavy stress on the MOSFETs.
matching transformer is proposed [8]. In this inverter the power source is separated
from the resonant circuit during the resonant capacitor. This is due to the discharged
capacitor and a DC blocking capacitor which is connected in series to the load.
Furthermore, the operating frequency and the output current are controlled by means
of varying the oscillation cycle and the initial current to the resonant inductor.
gate bipolar
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explains the principle stating the concept and derives a simplified model to quantify
the important parameters that govern the start-up. The theoretical concept is verified
by experimental data demonstrating the start of such inverters.
The partial series-resonant power converter [11], previously used for DC-DC
capacitors to values between zero and the supply voltage. Three types of control are
investigated: constant switching frequency; constant turn-off" current; and a
combination thereof. The latter seemed to be the best. This circuit is only found
suitable for-loads in which the Q value is low while the temperature, of the workpiece
is below the Curie temperature.
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achieving output power regulation by means of both the swept-frequency method and
the PWM scheme. A simple IC-based triggering circuit has been developed which
can provide the required stable PWM signals in a range wide enough to achieve the
goal of control.
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1.1
Inverters
Inverters [15] are static circuits that convert power from a dc source to ac
power at a specified output voltage and frequency. Inverters are used in many
industrial applications. The following are some of their important application.
1.
2.
Induction Heating
3.
4.
In general, there are two types of inverters : voltage source inverter (VSI) and
current source inverter (CSI). Inverter is a converter which changes d.c input to a.c.
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output. The d.c. may be derived from a battery, in which case forced commutation
components are required for the power switches if they are thyristor, or it may be the
d.c. energy from the load being fed back into an a.c. supply, as when a.c. to d.c.
i
converters are operating in an inversion mode. The operating mode is now natural
commutation. In the voltage source inverter, the input is a dc voltage supply and the
inverter converts the input dc voltage into a square-wave ac output voltage source as
shown in Figure 1 .la. In the current source inverter the input is a dc current source
and the inverter converts the input dc current into square-wave ac output current as
shown in Figure l.lb.
+1
tJ
vsi
+
v
CSI
(b)
(a)
a stiff dc voltage supply, which can be a battery or the output of a controller rectifier.
Both single-phase and three-phase voltage source inverters are used in industry and
will be discussed here. The switching device can be a conventional thyristor ( with its
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During the positive half cycle of the output voltage, the switch S, is turned
On, which makes V 0 ~ +V/2 . During the negative half-cycle, the switch S2 is turned
On, which makes V0 = -V/2 . Waveforms of gate pulse ( i Bt and ig3 ) and output
voltage V0 are shown in Figure 1.2b. Note that prior to turning On a switch, the
other one must be turned Off, otherwise both switches will conduct and short-circuit
the dc supply. If the load is reactive, for example, a lagging power factor load, the
output current i0 lags the output voltage V0 , as shown in Figure 1.2c. Note that
during 0 < t < T/2 , V0 is positive; that is, either S, or D, is conducting during
this interval.
However, i0
conducting during this interval. The load current i0 is positive during t, < t < T/2 and
therefore S, must be conducting during this interval. The devices conducting during
various intervals of time are shown in Figure 1.2c. The feedback diodes conduct
when the voltage and current are of opposite polarities.
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D.
'gl
'82
V/2
V
S,
S,
D,
T/2
D,
S2 D 2
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The fall bridge configuration of the single phase voltage source inverter is
shown in Figure 1.3a. Switches S, and S2 are fired during the first half-cycle and
switches S3 and S4 are fired during the second half-cycle of the output voltage. The
(a)
T/2
-V
(b)
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'"'
t
V
A
. 4- D.
FW
L
R
(a)
D,
ie
D
'2 A
(b)
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circuit, and these can be operated to turn off the main thyristors S, and S2 . For
example, to turn Off the main thyristor S, at instant j ( prior to turning On the
other main thyristor S 2 ), the auxiliary thyristor S,A is fired. As a result, an
Vco are shown in Figure 1.5b. When S, is fired at cof 0 pole A is connected to
the positive bus of the dc supply, making VAO=V/2.
those of VAO , except that they are shifted by 120 . The line voltages are related to
the pole voltage as follows :
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(a)
[1.1]
[1.2]
[1.3]
The line voltages are graphically constructed as shown in Figure 1 .5b. These
voltages are quasi-square waves with 120 pulse width. They have a characteristic
six-tapped wave shape. The pole voltages can be written as :
[1.4]
[1.5]
VCo= VCN
[1.6]
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AOA
V/2
-> wt
-V/2
BO*
wt
CO
wt
AB A
wt
-V
'BC
wt
-V
CA,
wl
-V
'NO
V/6
wt
AN
wt
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