SURFACE HARDENING PROCESS

Job to be Heating coil Coolent Hose Machine Control

hardened DOhivaji University
1
POWER CONTROL METHODS

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The power required for a given application depends on the volume and
kind of metal to be heated, the rate of heating, and the efficiency of the
heating process. Power control is required in order achieve a desired
heating pattern, or to maintain a desired billet (work-piece)
temperature. This is achieved by varying the DC voltage supplied to the
inverter. Various types of power control systems include:
1. Controlled rectifiers
2. DC-DC converters (provides an output voltage variable from zero to
maximum available input voltage by varying duty cycle of switch).
3. Uncontrolled rectifiers (achieves power control by varying
duty cycle of inverter switches from 0 to less than 50 %.)

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 FIG: Uncontrolled rectifier used to feed Swept Frequency inverters or
PWM inverters. These inverter topologies perform both frequency
and power control in the inverter stage of the induction heating
power source.
Uncontrolled rectifiers feed stages in which the inverter performs
both frequency and power control. This type of inverter is classified
into two categories namely, PWM inverters, and swept frequency
inverters. The PWM inverter achieves power control by varying the
duty cycle of the inverter switches from 0 to less than 50%.
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 FREQUENCY CONTROL

Due to the dynamic nature of induction heating loads, a

considerable change in natural resonant frequency of the load circuit
can occur during the heating cycle. Solid-state switches cannot tolerate
mismatched load circuits very well at high frequencies (because of
excessive power dissipation in the semiconductors), making these
supplies unstable and inefficient under these conditions.
In order for the inverter to maintain efficient operation at
resonance, the inverter must now have the ability to search, find and
continuously track the load resonant frequency during operation. This
added feature has led to a new field of study in induction-heating
control strategies. The most common form of frequency control
available is based on phase locked loop techniques. The next section
presents a brief overview of frequency control using this technology.

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 PHASE LOCKED LOOP
A phase-locked loop is a circuit which synchronizes the signal from an
oscillator with a second input signal, called the reference, so that they
operate at the same frequency with a fixed phase relationship between
the two .Phase-locked loops are often used because they provide filtering
for the phase or frequency of a signal that is similar to that which is
provided to voltage or current waveforms by ordinary electronic filters.
Phase locked loops find wide application in the areas such as
communications, wireless systems, digital circuits, etc.

FIG: Block diagram of basic PLL configuration showing all its basic components showing the phase detector provides
information regarding the phase-difference between the two input signals. The loop filter produces a DC voltage proportional to
the phase difference, and drives the VCO, which produces a frequency output within its operating range. Often the VCO operates
at a frequency higher than the input signal frequency. The VCO output frequency can then be divided down in the feedback loop
before it reaches the phase-detector. 9/18/2018 DOT,SHIVAJI UNIVERSITY 6
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INDUCTION HEATING POWER SUPPLY

1. Alternator (M-G SET).

2. Solid state(static/Transistorized) inverters.

FIG: LAYOUT OF HIGH FREQUENCY POWER SOURCE SHOWING

CONVERTER,INVERTER AND HEATING
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 Induction heating power supplies are frequency changers
that convert the available utility line frequency power to the
desired single-phase power at the frequency required by the
induction heating process. They are often referred to as
converters, inverters, or oscillators, but they are generally a
combination of these.
The converter portion of the power supply converts the line
frequency alternating current input into direct current, and the
inverter or oscillator portion changes the direct current into a single-
phase alternating current of the required heating frequency.
Inverter circuits use solid-state switching devices such as
thyristors (SCR's) and transistors. For high power and lower
frequencies, large thyristors are commonly used. For low power or
frequencies above 25kHz, transistors are used because of their ability
to be turned on and off very fast with low switching losses.
Many different power supply types and models are available
to meet the heating requirements of a nearly endless variety of
induction heating applications.
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 FIG: Schematic Diagram of Induction Heating Process

The input is generally three phase 50 or 60 Hz at a voltage that is

between 220 and 575 V. The first block represents the AC to DC converter
or rectifier. This section may provide a fixed DC voltage, a variable DC
voltage, or a variable direct current. The second block represents the
inverter or oscillator section, which switches the direct current to
produce a single-phase AC output. The third block represents the load-
matching components which adapt the output of the inverter to the level
required by the induction coil. The control section compares the output of
the system to the command signal and adjusts the DC output of the
converter, the phase or frequency of the inverter, or both to provide the
desired heating. 9/18/2018 DOT,SHIVAJI UNIVERSITY 10
 Alternator for High Frequency
Generation
Mettalic
outer
jacket

Cooling
Terminal
Lines
box

Input and output power

cables
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FIG: CURRENT FED PARALLEL
RESONANT FULL BRIDGE
INVERTER TOPOLOGY

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DOT,Shivaji University 13
 INDUCTION HEATING COIL

Coil design is essential to the effectiveness and efficiency of an

induction heating process. The coil is to be designed by first
understanding where the heat needs to be generated in the part to
perform the process, and then designs the coil to achieve the heating
effect. Induction coils are water-cooled copper conductors made of
copper tubing that is readily formed into the shape of the coil for the
induction heating process. Induction heating coils are cold and do not
themselves get hot when water is flowing through them. Matching the
coil to the induction power supply is also essential to the efficiency of
the process. Induction systems are easily matched to a wide range of
coils by using the multi-tap output transformer in the power supply.

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Single turn coil Multi-turn Helical coil Multi-position
Helical coil

Pancake coil
Internal coil Split Helical coil
HEATING COILS AND THE WORK-PIECE TO BE
HARDENED

J1

J2

J3
Heating coils
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 COUPLING EFFICIENCY
Coupling efficiency is a measure of the amount of power transferred
between the coil and work-piece. The efficiency of coupling in this case is
dependent on the resistance of the coil and that of the work-piece and is
given by following equation.

Above Equation gives a broad-brush idea of what controls the coupling

efficiency. If for example one considers a load material with high
resistivity and permeability such as steel, an efficiency approaching
100% can be achieved, but copper with a low resistivity, has an
efficiency of about 50%. The efficiency increases during the heating
cycle due to fact that the resistivity of the work-piece increases with
temperature.

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 WATER COOLED MATCHING TRANSFORMER

Outlet tap

Tappings on
primary
Inlet taps

Electrical
Supply
connection
Terminals DOT,Shivaji University 19
 LOAD MATCHING

A very important fact of induction heat treatment that is often

overlooked in the initial design stages, is the ability to successfully deliver to the
work piece the maximum available power from a given power supply at the
minimum cost. Circumstances do not always allow for the optimal design of a
complete induction heat treatment system in which the power supply design is
based on the application, including the specific induction coil parameters. Quite
often, the induction coil is designed to achieve the desired induction heat
treatment pattern without regard for the power supply that will be used. When
this is the case, a flexible interface is required to match the output characteristics
of the power supply to the input characteristics of the induction coil and work
piece combination. If this match is not provided, the power supply will not be
able to develop its rated power, so the coil requires more voltage or current than
the supply can deliver.
Variable ratio transformers, capacitors, and sometimes inductors are
connected between the output of the power supply and the induction coil. The
adjustment of these components is commonly referred to as “load matching” or
“load tuning”.

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WATER COOLED CAPACITOR BANKS FOR
POWER FACTOR IMPROVEMENT
Supply to
panel

Power panel
contactors

Water cooled
capacitor banks

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 POWER LOSS IN INVERTER

1.SWITCHING LOSSES

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2.CONDUCTION LOSSES

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