Design Calculation and Performance Testing of Heating Coil in Induction Surface Hardening Machine

World Academy of Science, Engineering and Technology
International Journal of Electrical, Computer, Energetic, Electronic and Communication Engineering Vol:2, No:6, 2008
Design Calculation and Performance Testing of

Heating Coil in Induction Surface Hardening
Machine
Soe Sandar Aung, Han Phyo Wai, and Nyein Nyein Soe
= specific permeability
AbstractThe induction hardening machines are utilized in f = frequency, Hz
the industries which modify machine parts and tools needed to
achieve high ware resistance. This paper describes the model of
This formula shows that as the frequency is higher, will
induction heating process design of inverter circuit and the results
of induction surface hardening of heating coil. In the design of be smaller and the heating will be concentrated as the
heating coil, the shape and the turn numbers of the coil are very surface in case the materials are same. However in actual
important design factors because they decide the overall operating heating, the heated tends to become bigger because of heat
performance of induction heater including resonant frequency, Q
International Science Index, Energy and Power Engineering Vol:2, No:6, 2008 waset.org/Publication/13504
conduction in the heated material.

factor, efficiency and power factor. The performance will be tested
by experiments in some cases high frequency induction hardening Induced
Alternating current
machine. current
KeywordsInduction Heating, Resonant Circuit, Inverter

Circuit, Coil Design, Induction Hardening Machine. Alternating
magnetic field
I. INTRODUCTION Work coil
T HE principle of induction heating is shown in Fig. 1,

there an electric conductor such as iron or steel placed
in the inductor is heated rapidly by induced eddy current
Work piece
caused by electromagnetic induction, and hysteretic heat

loss, which is generated by vibration and friction of each Fig. 1 Basic Induction Type Heating System
molecule in magnetic material under AC magnetic flux.
In induction heating, as the frequency of the heating II. SYSTEM CONFIGURATION
current tends to concentrate close to the metal surface (work
Fig. 2 shows the general block diagram of the induction
piece).This is referred to as the skin effect. The skin effect is
heating system. The AC power source is single phase and it
the phenomenon, which electric current flows only in the
applies line frequency and line voltage. The non controlled
limited area near surface of conductive material, and
rectifier converts the AC voltage to the DC values and
proximity effect is the phenomenon, which the primary applies the desired DC current to the inerter circuit. The
current in the inductor and the secondary current in the inverter changes the DC signals to the AC signals with
conductive material pull each other because the direction of desired frequency to apply the work coil. When the work
current is opposite each other, and flows in the limited area piece has been heated for a time, the quenching system is
near surface where distance is nearest each other. The depth applied to the work piece.[2]
depends upon the frequency and as the frequency is higher,
the depth becomes smaller. [1] Single phase
power
Non
controlled Inverter
Work coil
The penetration depth is calculated as follows;
rectifier circuit
supply
circuit
1
= (m) (1) Triggering
f cirrcuit
Where, = penetration depth, m Fig. 2 General Block Diagram
Soe Sandar Aung is with the Electrical Power Engineering Department, III. SYSTEM ANALYSIS
Mandalay Technological University, Mandalay, Myanmar
(corresponding author to provide phone: 095-067-22123; e-mail:
soesandarag@gmail.com). A. Equivalent Circuit
Han Phyo Wai is with the electrical Power Engineering Department, The work coil and work piece have the special property of
Mandalay Technological University, Mandalay, Myanmar (e-mail:
resistance and reactance values due to their resistivity and
hanphyowai@2007.com).
Nyein Nyein Soe is with the Electrical Power Engineering Department, inserted flux. Using Wheelers formula, the inductance of the
Mandalay Technological University, Mandalay, Myanmar (e-mail: work coil can be calculated as follows.
nyeinnsoe@gmail.com).
International Scholarly and Scientific Research & Innovation 2(6) 2008 1134 scholar.waset.org/1999.5/13504
2 C. Series Parallel Resonant Inverter
rout N
Lc = (2) This configuration has the desirable characteristics of
(
0.0254 9rout + 10l wc ) series and parallel resonant inverters. The load short circuit
Where Lc = inductance of work coil, H and the no load regulation are possible. High part-load
rout = outer radius of work coil, m efficiency is possible with the proper choice of resonating
lwc = length of work coil, m components.
A resonant inverter can be operated either below or
above resonance frequency. This inverter contains
impedance matching system. The tank circuit incorporating
the work coil (Lw) and its capacitor (Cw) can be though of as
a parallel resonant circuit
This has a resistance (R) due to the loss work piece
coupled into the work coil due to the magnetic coupling
between the two conductors. In practice, the resistance of the
Fig. 3 Impedance Circuit of Work Coil and Work Piece
work coil, the resistance of the tank capacitor and the
resistance of the work piece all introduce a loss into the tank
The work coil and work piece can be represented by an
circuit and damp resonance. Therefore, it is useful to
equipment series inductance and resistance model as shown
combine all of these cases into a single loss resistance. In the
in Fig. 4.
case of parallel resonant circuit this loss resistance appears
L eq = L c + M (3) directly across the tank circuit. This resistance represents the
only component that can consume power and therefore it can

R eq = R c + R w (4)
be though of resistance as the load that it is being tried to
Where M = magnetizing inductance, H drive power into as efficiently as possible.
Leq =equivalent inductance of work coil and work
piece
Req= equivalent resistance of work coil and work
CW LW R
piece
Fig. 6 Circuit Diagram of Tank Circuit

CS LS Lw
A
Rw
Fig. 4 Equivalent Circuit of Work Coil and Work Piece
Cp Cw
B. Resonant Circuit RL
As shown in Fig. 4, the equipment inductance and B

resistance of work coil and work piece are in series
connection. To resonate the circuit a capacitor is connected Fig. 7 Diagram of Matching Network
in parallel resonant circuit and it is shown in Fig. 5.
IV. REQUIRED SPECIFICATIONS FOR INDUCTION SURFACE

Ic Leq HARDENING MACHINE
IT C The specifications for operating are the ambient

temperature is assumed 300.15 K, the desired hardened
temperature is 1116.48 K, the duration of hardened time is
Req
10 sec, the output power is 5 kW and the use of apply
frequency is 35 kHz. Table I is for the specifications of
conductor used as work coil.
Fig. 5 Resonant Circuit for the Load
TABLE I
If the capacitor is charged to a supply voltage, the energy SPECIFICATIONS OF CONDUCTOR
stored in CVT2 2 . And this energy transfer to the inductance
Unit Specification value
Leq and returns again to the capacitor so the frequency of the
- material copper
oscillation depends on the values of inductance and m resistivity 1.710-8(at 293.15 K)
capacitance. In the circuit, the dissipated energy in resistance Hm permeability 1
Req, and after each cycle of oscillation the store of energy in kg/m2 density 7861.13
the capacitor is reduced.
TABLE II B. Calculation of Impedance Matching System
SPECIFICATIONS OF WORK PIECE
L
Unit Specification value s
C
- Material 1040 carbon steel s
m Resistivity 1.710-8(at 293.15 K) Q = (10)
115.610-8(at 1253.15 K)
R
L
Hm Permeability 1
J/kg.K Specific heat 434 (at 300 K )
1169 (at 1000 K )
s
K Melting temperature 1794.26 F= (11)
K Hardened temperature 1116.48 _ 1172.03
o
kg/m2 Density 7861.13
From Equation (10) and (11),
LS = 0.033185 mH
CS = 0.753953 F
CP = 0.753953 F
V. CALCULATIONS OF INDUCTION SURFACE HARDENING The capacitor in the matching net work (CP) and tank
MACHINE capacitor (Cw) are both in parallel. In practice, both of these
functions are usually accomplished by a single capacitor.
A. Calculation of Work Coil
Cpw = Cp + Cw
The number of turns of work coil is mainly based on the = 1.796509 F
length of work piece and the pitch of coil windings. Thus,
Cs
lw LS
Is Lw Rw
N= (5) A
d c +C p
+ It
Ic
Where,
N = number of turns of work coil VAB Cpw VC RL
Lw = length of work piece to be hardened, m
_
And the inner diameter of work coil is B
D in =d w + 2C p (6)
Fig. 8 Circuit Diagram of Matching System
The outer diameter of work coil is
1
D out =D in + 2d c (7) Z cpw =R - jX cpw = - j = - j2.531178
C pw
Where,
dw = diameter of work coil, m Vc
dc = diameter of conductor, m Ic=
Z cpw
The total length of conductor for work coil is
2 2 119
l c = 2l lead +N ( 2 m ) +(1.5d c ) (8) =
-j2.531178
Where,
lc = length of conductor, m = j47Amp
llead = length of work coil lead, m It - Is = Ic
rm = inner radius of work coil, m = 16.042916 + j22.655880
The minimum thickness of conductor must be at least two = 27.760837( =54.70)
times of depth of current penetration in conductor itself. VAB =I s Z s - Vc
Therefore, the minimum thickness of conductor is Z s =jX ls - jX cs
t c = 2 c
1
Where, = j s L s -
tc = minimum thickness of conductor, m js Cs
c = depth of current penetration in conductor, m = j7.297822 j6.0312583
The depth of current penetration in conductor is = j1.266564
1 VAB = -147.696106 +j20.317976
c = (9) =149.087088( =172.17)
f c o c
Required voltage for matching system is
Where, VAB = 149.087088Volt
c = permeability of conductor, H/m Required current for matching system is
o = permeability of free space, H/m Is = 27.760837Amp ( =54.70)
c = electric conductivity of conductor, mho/m The selected series capacitor CS is 0.8 F, 600 Volt.
f = applied frequency, Hz The selected series inductor LS is 0.03 mH, 600 Volt, 2
Amp.
The selected parallel capacitor Cpw is 1.796507 F, 600 TABLE III
RESULT FOR WORK PIECE
Volt.
Unit Specification Design Value
C. Calculation of Voltage and Current Ratings for
Inverter - Material 1040 carbon steel
- shape cylindrical
Device voltage and current rating must to be satisfied - Nature of surface uniform
supply bus voltage and the load impedance so that power m Depth of hardness 0.0009587
can be delivered to the load. m Diameter 0.067008
m Length 0.033504
The required voltage for the load is m2 Cross sectional area 0.000199
VAB =149.087088 Volt. m2 Surface area 0.007053
The supply dc voltage is 149.087088 volt. m3 Volume 6.665071
Peak of supply voltage = 2 149.087088

= 210.840982 Volt TABLE IV
The inverter is driven high frequency switching. This is RESULTS FOR WORK COIL
supplied by inductance load.

D. Calculation of Single Phase Rectifier Circuit - shape round
Inverter input voltage Ed = 149.087088 Volt - number of turns 4
m inner diameter 0.070184
Inverter input current Id = 27.760837 Amp m outer diameter 0.082884
So, required dc voltage Ed = 149.087088 149 Volt m Length 0.0381
Required dc current Id = 27.760837 28 Amp m coil pitch 0.003175

m coupling distance 0.001588
Average load voltage V0(avg) = 0.636 Vm
Vm is peak load voltage.
V= 2VRMS TABLE V
VRMS is supplied voltage RMS value. RESULTS FOR CONDUCTOR
Ed = V0 (avg) Unit Specification Design Value

Vm = V0(avg)/ 0.636
- material copper
= 149.087088 / 0.636 - shape round
= 234.276730 Volt m thickness 0.000702
m diameter 0.00635
Supply voltage for system = 234.276730 / 2 m length 1.282781
= 165.658664 166 Volt
Required supply voltage is 166 Volt to 220 Volt
RMS value of load current = average load current TABLE VI
= 27.760837 Amp RESULT FOR ELECTRICAL PROPERTIES OF THE SYSTEM
Average current in each diode ID(avg) = I0(avg) / 2
= 13.880419 14 Amp
Resistance of work
I o(avg)
coil
0.003114
Peak load current, I m = = 43.649115Amp Resistance of work
0.636 0.121220
piece
Supply current for system, H
Inductance of work
1.434858
coil
43.649115
I rms = = 30.864585 31Amp H
Magnetizing
inductance
0.551223
2
F Resonated capacitance 1.0411355
Required power =VI =5.11597 kW - Power factor 0.273791
- Quality factor 3.512809
Total impedance 1.658596
A Supply current 71
V Supply voltage 119
A.C 220V,
+
D.C VII. PERFORMANCE TESTING

-
A. Testing of Control Circuit
Fig. 9 Circuit Diagram of Rectifier Circuit Wave shape, frequency and voltage values at the input
and output of control circuit are measured with oscilloscope.
VI. DESIGN RESULTS Resulting waves are square wave and the wave shapes are
The results for work piece, conductor, work coil and shown in Fig. 10.
electrical properties of the system are calculated. The results
are shown in table respectively.
Fig. 13 Wave Shape of Inverter Output with Tank Circuit
Fig. 10 IGBT gate driver circuit (for start heating) ACKNOWLEDGMENT

Firstly, the author would like to express her deepest great
thank to her parents. The author deeply wants to express her
special appreciation to Dr. Ni Ni Win, Department of
Electrical Power Engineering Department, Mandalay
Technological University, for her invaluable support and
advice.
REFERENCES
[1] Curits,F.W.1944. High Frequency Induction Heating. 1sted. New
York: McGraw-Hill Book Company, Inc.
[2] Zinn S., and Semiatin, S.L. 1988. Coil Design and Fabrication: Basic
Design and Modifications. July 2005. Available:
http://www.ameritherm.com
[3] Bhattachrya, S.K and Chute, R.D. 1971. Industrial Electronic and
Control. New Delihi; Tata MC Graw-Hill Publishing Company Ltd.
Fig. 11 IGBT gate driver circuit (after heating)
B. Performance Testing of Inverter Soe Sandar Aung studied in Electrical Power Engineering Major and held
First, the inverter output is measured without tank circuit B.E degree in 2004 from Mandalay Technological University, Mandalay,
Myanmar. Then I was awarded M.E degree of Electrical Power
as shown in Fig. 12 and resulting wave shape is square wave Engineering in 2006 from Yangon Technological University, Yangon,
with spite. Myanmar. I am now studying and making induction heating research in my
Then, the inverter is concerned with tank capacitor and University..
measured. The resulting wave shape is pure sine wave. The
wave shapes are shown in Fig. 13.
Fig. 12 Wave Shape of Inverter Output without Tank Circuit

Design Calculation and Performance Testing of Heating Coil in Induction Surface Hardening Machine

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Design Calculation and Performance Testing of Heating Coil in Induction Surface Hardening Machine

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World Academy of Science, Engineering and Technology

Design Calculation and Performance Testing of

conduction in the heated material.

KeywordsInduction Heating, Resonant Circuit, Inverter

I. INTRODUCTION Work coil

T HE principle of induction heating is shown in Fig. 1,

caused by electromagnetic induction, and hysteretic heat

Where, = penetration depth, m Fig. 2 General Block Diagram

only component that can consume power and therefore it can

Fig. 6 Circuit Diagram of Tank Circuit

As shown in Fig. 4, the equipment inductance and B

IV. REQUIRED SPECIFICATIONS FOR INDUCTION SURFACE

IT C The specifications for operating are the ambient

Peak of supply voltage = 2 149.087088

supplied by inductance load.

Required dc current Id = 27.760837 28 Amp m coil pitch 0.003175

Ed = V0 (avg) Unit Specification Design Value

D.C VII. PERFORMANCE TESTING

Fig. 13 Wave Shape of Inverter Output with Tank Circuit

Fig. 10 IGBT gate driver circuit (for start heating) ACKNOWLEDGMENT

Fig. 12 Wave Shape of Inverter Output without Tank Circuit

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