Medium frequency Parallel Resonant SiC Inverter

for Surface Hardening Application in Automobile

Industries.

Synopsis of Proposed Research Work

Submitted to

Shivaji University, Kolhapur

For the Degree of

Doctor of Philosophy
In

Electrical Engineering
Under Faculty of Engineering & Technology

By

Mr. Patil Vijay Jagannath

Under the Guidance of

Dr. A.M.Mulla

Department of Technology, Kolhapur

Year: 2017-18
SHIVAJI UNIVERSITY, KOLHAPUR
 Medium Frequency, Parallel Resonant SiC Inverter For Surface Hardening Application in Automobile Industries

Name of Research Center: Department of Technology, Kolhapur.

Name of Department: Electrical Engineering

Name of Course: Ph.D. (Electrical Engineering)

Name of the Student: Mr. Vijay Jagannath Patil
Date of Registration: 12-10-2017
Name of the Guide: Dr. A.M.Mulla

Proposed Title:
Medium frequency, parallel resonant SiC inverter for surface
hardening application in automobile industries.

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 Medium Frequency, Parallel Resonant SiC Inverter For Surface Hardening Application in Automobile Industries

1. Introduction
The technique of heating by electromagnetic induction is a well established and an
invaluable tool for industries engaged in the heat treatment of metals. IH process is a non-
contact heating process. It uses high frequency electricity to heat the materials that are
electrically conductive. Since it is a non-contact heating process, it does not contaminate the
material being heated.
The most basic elements in an induction heating system are the piece to be heated,
also known as a work-piece and the inductor or work-coil. The high frequency AC supply
applied to the work-coil produces the high frequency magnetic field required to the heat the
work-piece. Induction heating system requires a power conversion circuit to convert
commercial frequency AC into high frequency AC supply. The circuit of an induction heating
system typically includes an uncontrolled rectifier and a current source resonant inverter and
the heating load (work piece).
The efficiency of the power converter (inverter) is a key design aspect in the IH
system. For the reduction in the converter losses, the resonant inverter is used to produce high
frequency AC supply. Different topologies of the resonant inverter can be used to supply the
high frequency AC supply to the induction heating load. Current source parallel resonant
inverter (CSPRI) fed is one of the topology which is used as induction heating unit in the
industry. The efficiency of the resonant inverter gets decreased during the control of inverter.
The resonant inverter enables soft switching of the switches and increases the efficiency. The
load requires the control over the input voltage and input power applied to the induction coil
for the control of the heating process. The output voltage and power of the resonant inverter
can be varied using different modulation methods.
A number of switching element has been applied to the medium-frequency induction
heating system which is capable of fulfilling most of these requirements. with the
development of advanced power semiconductor devices and inventions of new circuit
techniques and control schemes, for the medium power, high power induction heating(surface
heat treatment where operating frequency up to 10kHz) application IGBT,MOSFET,IGCT
etc. have been used. The various resonant inverters using power devices such as MOSFETs
and IGBTs offer reduced switching loss by using soft-switching technique and offer attractive
possibilities in developing higher frequencies of operation, higher efficiency, a smaller size
and lighter weight and better performance and hence these switched resonant inverter has
become the primary source of medium frequency power for induction heating applications,
replacing the motor-alternator set. It has been extensively applied for the frequency ranges
between 1KHz and 10 KHz, because of its high current handling capability.
This research presents the design, development, modelling, performance analysis and
simulation of lab prototypes of SiC MOSFET and Si IGBT current fed parallel resonant
inverters used in induction hardening application over a medium frequency range of 1 kHz to
50 kHz. SequelGUI2 software is used to carry out simulation. The experimental results and
relative performance have been highlighted.

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 Medium Frequency, Parallel Resonant SiC Inverter For Surface Hardening Application in Automobile Industries

2. Significance
Induction heating is widely used in industry for many applications including forming,
melting, joining and hardening and has achieved enormous significance because of its
benefits over conventional methods of heating. Some of the benefits associated with the
induction heating process are: short heating times, measurable reduction of scale, the precise
control of the temperature of the work piece, Readiness for automatization with lower labor
cost, a good working environment, low space requirements, rapid availability and high energy
conversion efficiency.
In today's automobile industries, for the application of surface hardening of the
crankshaft parts, it is expected to design an energy efficient, high frequency induction power
sources for hardening different work pieces of different geometries. Inverter or DC-AC
converter is one of the main components of induction heating system that changes dc power
to an ac power at a desired output voltage and frequency. Power electronic switches like
SCR, IGBT, IGCT, MOSFET forms the inverter circuit. When these switches operate they
consume some powers and thus switching loss takes place. Due to these losses, efficiency of
the heating system get reduced which imposes the extra financial burden in terms of energy
bill. Hence, to conserve the energy, it is important to find out the solution for the above
problem by designing the inverter having resonant switching technique. The increase in
system efficiency can be achieved by using resonant inverters where the concept of LC
resonance is utilized during switching instances. The most significant part of resonant
inverter is, here switching takes place when voltage and current are zero which is known as
"soft switching". Since switching takes place in zero voltage and current stage there is no
possibility of power loss in resonant inverter.
Along with the above described high efficiency feature, high frequency operation is
also significant in today's switch mode or PWM technique design inverters. But with the
increase in frequency, switching stress increases and average power loss in the device also
increases. The steep rise and snap of high current increases Electro Magnetic Interference
(EMI) due to large di/dt and do/dot. Imperfect switching is a vital contributor to power loss in
these converters. This power loss generates heat. As a result heat sink must be designed to
drive out heat for proper functioning of the unit. The increase of switch stress and EMI has
new design challenge. One way of dealing with stress on switch is to use snubber circuits.
Snubbers are included in circuit so that during turn ON/OFF the stress is bypassed through
the snubber. As a result stress on switch reduces but not the loss during switching. The use of
soft switched resonant inverters reduces not only the switching losses during turn on/off but
also minimizes stress on devices and electromagnetic interference (EMI.)
With the significant improvement in SiC technology based wide band materials w.r.t.
the operating-voltage range for uni-polar devices and of the switching speed and/or specific
on resistance, it is proposed to switch over use of conventional Si technology by SiC
technology to achieve increase in the system-level performance Due to these advantages of
SiC technology over Silicon base technology, the proposed inverter acquires an extraordinary
significance with respect to achieve performance enhancement of complete IH system

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3. Statement of the problem

The aim of this work is to design, develop, model, analyze and simulate lab
prototypes for the medium frequency induction heating system using SiC MOSFET and Si
IGBT technology based current source parallel resonant inverter for surface hardening
application in automobile industries.
4. Literature Review
Literature review of the induction heating systems in the following areas is presented:
a. Induction Heating
b. Surface hardening/Induction hardening
c. Modelling, analysis and simulation of electromagnetic and thermal process.
d. Design and simulation of induction heating coil.
e. Implementing SiC technology.
f. IGBT & MOSFET based parallel resonant current source inverter-Design and
simulation.
a) Induction Heating
O.Lucía, P.Maussion, E.Dede, J.M.Burdío reviewed induction heating technology
summarizing the main milestones in its development, and analyzing the current state-of-art of
induction heating systems in industrial, domestic and medical applications, paying special
attention to the key enabling technologies involved. Finally, an overview of future research
trends and challenges is given, highlighting the promising future of induction heating
technology.
b) Surface Hardening/Induction Hardening
N.S. Bayındır, O. K.Ukrer and M. Yakup described DSP-based PLL-controlled 50–
100 kHz, 20 kW high frequency induction heating system for surface hardening and welding
applications. A digital signal processor (DSP)-based phase locked loop (PLL)-controlled high
frequency induction heating system is described. The rectifier and insulated gate bipolar
transistor (IGBT) inverter are controlled by a TMS320F240 DSP system, which has the
hardware feature of providing a dead-band delay independent of the frequency of operation.
This feature, together with the high speed of the DSP, allows the use of zero current resonant
switching at a high power factor for frequencies up to 100 KHz. Resonant operation of the
inverter is maintained by a simple digital PLL scheme implemented on the DSP. The
frequency converter enables safe operation at all load conditions with digital over current,
overvoltage and over temperature protection features. The cost effective system described is
operated successfully at outputs up to 19.8 kW at 72 kHz and 500 V.
Edmund Zok, Dirk M.Schibisch-Induction heating is an established, highly energy-
efficient industrial process. The traditional areas of application include, among other things,
induction hardening, forge heating, tube welding and annealing as well as the heating and
quenching followed by tempering of steel bars or tubes. More and more new applications are
being added, as the shortage of fossil fuels means that heating processes are being
increasingly switched from oil or gas to electro heat. This does not always mean that
conventional furnaces should not be used; rather both combustion furnaces and induction
technology can be used intelligently side by side.

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Amit Kohli, Hari Singh studied the effect of different input parameters such as feed
rate, dwell time, current and gap between the induction coil &work-piece on the output
parameters of the material (AISI 1040 steel). The degree of membership function of an object
in a fuzzy set is defined by membership functions (MF). It has been found that after the
formulation of rules, the optimum value of hardness at any points (may be in decimal place)
in between the low and high limits of the process parameters selected, can be found out. The
predicted results are compared with a reliable set of experimental data for the validation of
fuzzy model and mathematical model (developed by response surface methodology). It was
found that proposed fuzzy model gives the better results than mathematical results and it was
well in agreement with experimental results. By Intelligent, model based design and control
of induction hardening process parameters in this study will surely help to enables
dramatically decreased product and process development cycle times, improved product
quality, decreased product cost and maintains the competitive position of steel in applications
requiring high strength –to-weight ratio at an affordable cost.
c) Modelling, analysis and simulation of electromagnetic and thermal
process
José Carlos Zerbini, Alexander Ivanov, Vladimir Bukanin, Ademir Angelo de
Vasconcelos considered simulation techniques for validation and revalidation of induction
heating forging lines with approach on the thermal process and focuses on energy
optimization through the use of the software 2DELTA-ELectroThermal Analysis.
Presentation contains information of induction heating of steel products, material
characteristics, electromagnetic and thermal process in inductors, and simulation technique
for optimal design of induction heating lines. 2DELTA is also an effective tool for learning
induction heating. 2DELTA software allows users to systematically implement simulations
for the induction heating applications for the most commonly geometries used in the forging
shops. It is used by manufacturers and users of induction heating systems for thermal and
electrical design of the induction heating forging line. General considerations about use of
simulation for validation and optimal design of heating lines are supported with an example
of validation of one multi-stage line for heating billets for forging purposes.
d) Design and simulation of induction heating coil.
M.Roy, M.Sengupta studied electromagnetic analysis and power converter efficiency
on a laboratory prototype induction heating coil. An electromagnetic field based study was
first done for the induction heating coil used in the experimental set-up using available finite
element analysis software package (FEMM 4.2). The results of the FEM based study are also
used in the choice of the operating frequency depending on the applications. Thereafter
verifications are done experimentally on a small-scale laboratory developed setup. The
approach to be adopted for choice of induction heating operating frequency and the choice of
converter type, based on the efficiency and performance, are also briefly presented here.
Oscilloscope traces uphold the accuracy of the practical tests conducted.

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The induction hardening machines are utilized in the industries which modify
machine parts and tools needed to achieve high ware resistance. Soe Sander Aung, Han
Phyo Wai, Nyein Nyein Soe described the model of induction heating process design of
inverter circuit and the results of induction surface hardening of heating coil. In the design of
heating coil, the shape and the turn numbers of the coil are very important design factors
because they decide the overall operating performance of induction heater including resonant
frequency, Q factor, efficiency and power factor. The performance will be tested by
experiments in some cases high frequency induction hardening machine.
Induction heating systems employ non-contact heating. Inducing heat
electromagnetically rather than using a heating element in contact with a part to conduct heat,
as does resistance heating. Umar Shami discussed a technique to calculate the parameters of
the coil to be used to heat an iron piece of given parameters, to 850 oC. A design of the
voltage fed full bridge series resonant inverter is also presented followed by the results. The
induction coil is usually made of copper tubing and water cooled. Diameter, shape, and
number of turns influence the efficiency and field pattern of the heating system.
Understanding the different aspects of induction heating process is a crucial factor which can
help the users to design and apply the proper heating system. One of the interesting
parameters in induction heating is calculation of current and voltage distribution in the coil
turns.
e) Implementing SiC technology
The arrival of SiC has opened new opportunities enabling the development of high
voltage devices even in uni-polar structure. Before using these devices in a commercial
application, it is crucial to understand their performance gain compared to their Si
counterparts. Therefore, in this paper, the calorimetric loss evaluation is performed in a full
bridge series resonant converter using1.2kV SiC MOSFET module and a1.2kV Si IGBT
module.
f) IGBT & MOSFET based parallel resonant Current source inverter
design and simulation
Alireza Harrasi, Ahmed F. Zobaa introduced a combinational modulation method
to be used in classic full-bridge single phase inverters. The proposed method eliminates even-
order harmonics at PWM stage in control section unlike the conventional method of even
order harmonic cancelation in power stage and offers a cost effective design by switching one
leg at high frequency. Using a low cost digital signal controller (DSC) platform, regular
sampling technique based on real time calculation was employed to verify the feasibility of
the proposed method on a 500W single phase Voltage Source Inverter. Performance
characteristics such as switching losses and harmonic distortions are presented
Alireza Namadmalan presented a bidirectional current fed parallel resonant push–
pull inverter (CFPRPI) for contactless energy conversions. In conventional CFPRPIs, each
switch is in series with a blocking diode. Direct zero voltage switching (ZVS) is proposed to
remove the series blocking diodes for higher efficiency and boosting ratio. In addition, the
modified inverter has bidirectional power flow capability when these blocking diodes are
omitted.

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Resonant tuning of the system is investigated by using a phase-locked loop and a new self-
oscillating switching technique (SST). By using the new SST, the inverter has direct ZVS in a
wide range of operating frequencies, which is necessary for inductively coupled power
transfer systems. Finally, a laboratory prototype with an input voltage of 12 V and a
maximum output power of 60 W has been implemented
Yongxing Wang, Yabin Li, Yonglong Peng, Xingkun Qi introduced a new method,
using PLL and fixed angle control, to track the converter’s frequency automatically. After
analyzing the work state of parallel inverter, a new control method using closed-loop rectifier
control of voltage and current. The commonly-happening faults in the IGBT Medium
Frequency Induction Heating Power Supply are analyzed, and the corresponding protective
measures and protection circuits are designed. 100kw / 8 kHz Parallel induction heating
power is developed, and the designed control method is verified to be scientific and effective.
Prof. Ruchit R. Soni, Prof. Hirenkumar D. Patel, Mr. N. D. Patel, Mahendra
Rathod-High frequency three phase inverter circuit that can output at different frequency by
Power Metal Oxide Semiconductor Field Effect Transistor (MOSFET) for induction heating.
The induction heating is often used for the heat-treatment of a metal work-piece. In hardening
of a gear, the bottom or tips are heated at lower frequency or higher frequency respectively.
The proposed circuit cannot realize with the IGBT to output the high frequency. The circuit
uses the Power MOSFET instead of the IGBT. Otherwise, the device has the disadvantages of
withstand voltage and current. However, this problem can be solved by the methods of
connecting switching devices to series and using step down transformer. A simplified
analysis and simulation results are experimentally verified in prototype module.
Induction heating is a non-contact heating process which became popular due to its
energy efficiency. Current source inverter (CSI) based induction heating units are commonly
used in the industry. Most of these CSIs are thyristor based, since thyristors of higher ratings
are easily available. These being load commutated apparatus a startup circuit is needed to
initiate commutation. In this paper M.Roy,M.Sengupta presented the design and fabrication
of two laboratory prototypes. The first one, a SCR-based CSI fed controlled induction heating
unit, has been tested with two different types of start-up procedures. Thereafter the
fabrication and performance of another IGBT-based CSI is compared with the thyristor-based
CSI for a 2 kW, 10 kHz application. These two types of CSIs are fully fabricated in
laboratory along with the induction heating unit. Performance analysis and simulation of two
different CSIs has been done by using SequelGUI2. The triggering pulses for the inverter
devices (for both CSI devices as well as auxiliary thyristor of start-up circuit) have been
generated and closed-loop control has been done in FPGA platform built around an Altera
make cyclone EPIC12Q240C processor which can be programmed using Quartus II software.
Close agreement between simulated and experimental results highlight the accuracy of the
experimental work.

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Modern induction heating (IH) power converters operate marginally above resonant
frequency to supply power to the targeted work-piece at near unity power factor (upf).The
resonant frequency continuously increases as the work-piece gets heated up. A possible
method of dynamically detecting the resonant frequency may be to calculate the phase-shift
between current and voltage continuously during the process. The phase shift between
voltage and current is ideally zero at resonance. So resonant frequency may be identified by
varying the frequency until the phase-shift is zero. For this some controllers use a phase-
locked loop (PLL) strategy. In this paper, M.Roy, M.Sengupta presented the dynamic
tracking of resonant frequency, using a field-programmable gate array (FPGA) based digital-
PLL. The scheme is first simulated off-line. Finally, the logic is implemented on controller
hardware and practically tested in a laboratory made experimental set-up of 2kW at around
10 KHz.
R.Hemalatha, Jyoti P.Koujalagi described the design of power electronic converter
circuit and simulating the power electronic converter circuit using Matlab/Simulink for
induction heating equipment. The circuit designed has the load as induction coil and high
frequency electricity is required to heat the work piece placed within the induction coil. The
output power of the load coil is varied by changing the frequency of the inverter.
Riyadh G. Omar, Dr.Rabee H. Thejel suggested the use of the traditional parallel
resonant dc link (PRDCL) circuit to give soft switching to the four-leg space vector pulse
width modulation (SVPWM) inverter. The proposed circuit provides a short period of zero
voltage across the inverter during the zero-vectors occurrence. The transition between the
zero and active vectors accomplished with zero- voltage condition (ZVC), this reduces the
switching losses. Moreover, the inverter output voltage total harmonic distortion (THD) not
affected by circuit operation, since the zero voltage periods occur simultaneously with zero-
vector periods. To confirm the results, balanced and unbalanced loads are used.
Matlab/Simulink model is implemented for simulation.
H.Javadi, A.Shoulaie discussed the theory and presented experimental results for a
current-source parallel-resonant inverter employed for induction heating. The analysis is
performed in the frequency domain using Fourier series techniques to predict output power,
efficiency, dc-to-ac voltage transfer function, and component voltage and current stresses.
The inverter consists of four switches, a large choke inductor, and a parallel-resonant circuit.
Each switch consists of a MOSFET in series with a fast diode. An inverter was designed and
constructed. The dc input voltage was 70 V and the output voltage was a sine wave with a
peak value of 100 V at an operating frequency of 83 kHz. The output power at full load was
400 W.
Current source inverter (CSI) fed induction heating units are commonly used in the
industry. Most of these CSIs are thyristor based. For high power and low frequency induction
heating operation (melting applications where operating frequencies are less then 1KHz),
thyristor is the best choice. Thyristors of higher rating are easily available. But for the
medium power and high frequency induction heating (surface heat treatment where operating
frequency up to 10KHz) application IGBT may be used to get better performance.

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 Medium Frequency, Parallel Resonant SiC Inverter For Surface Hardening Application in Automobile Industries

In this paper, M.Roy, M.Sengupta, presented the comparative analysis of an IGBT-based

CSI with a thyristor-based CSI for a 2kW, 10 KHz application. These two types of CSIs are
fabricated in laboratory along with the induction heating unit. Performance analysis and
simulation of two different CSIs has been done by using indigenously developed software
(i.e. SequelGUI2). Finally, two small laboratory prototypes of rating 2kW, 10 KHz have been
fabricated and tested. The experimental results and relative performance have been
highlighted.
Kirubakaran.D, Rama Reddy.S investigated the circuit configuration and topology,
control strategy, principle characteristics, performance parameters of series resonant and
parallel resonant converter AC/AC converters with resonant switching and important
conclusions are obtained.
5 Observations
The following short comings have been identified after surveying the literature.
 Researches carried out in above citations had not attended the design,
development analysis and simulation of single phase full bridge current fed
parallel resonant dc link inverter using the SiC technology used to supply heat
to the work pieces of simple geometry and made up of cast iron and steel
material for surface hardening application at10 KHz output frequency.
 The theory presented in above citations has not focused the attention towards
the mathematical modeling of electromagnetic and thermal process present in
electromagnetic induction heating process. Also electromagnetic analysis and
thermal analysis theory is unattended.
 None of the above researchers had tried design and simulation of load adaptive
phase locked loop,FPGA based controllers, fuzzy logic based frequency
tracking control, WAVELET based frequency estimation and switching power
analysis,FEM model of surface hardening application. Also measurement of
the hardness and case depth parameter inside the cast iron and steel work
pieces after surface hardening has not been concentrated in above literatures.
6. Objectives
Understanding the gaps in the literature, aims and objective of thesis are framed as
follows:
The primary objective of this work is to design, develop and simulate, reliable, cost
effective, Energy efficient, Medium frequency, soft switched, current fed parallel resonant
inverter for surface hardening application. Key to a successful induction heater design is to
select a well-suited inverter with suitable selection of semiconductor switches. A comparative
study can be made among the various semiconductor switches in terms of efficiency of the
same power rating inverter through PSPICE-based computer simulation and real time
experiments. Other set objectives for the present work are as follows:

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1) To develop, the mathematical model of Electro-magnetic field and the Thermal

process and to carry out electromagnetic and thermal analysis to study effects
of different parameters of IH converter system on its performance.
2) To design and simulate phase locked loop & load adaptive phase locked loop
for IH.
3) develop fuzzy logic controlled full bridge current fed parallel resonant inverter
fed IH system for output voltage regulation during the step change in the load.
4) To model and develop the PID and fuzzy control loops for PDM based closed
loop power control of SiC MOSFET full bridge resonant inverter fed IH
system.
5) To develop the fuzzy logic based frequency tracking control of IH system for
tracking the switching frequency of the SiC MOSFET based soft switched
resonant to achieve dynamic soft switching during the change in load
condition.
6) To develop FPGA based controllers in CFPR SiC MOSFET based power
converter system
7) To develop WAVELET based frequency estimation and switching power loss
analysis.
8) To develop model of Induction Hardening and model to predict the hardness.
To simulate FEM model for hardening application.
9) To measure hardness and case depth inside work pieces after surface hardening
operation.
10) To carry out power quality analysis at input source and inverter output side.

7. Research Methodology
7.1.Conceptual Framework
Figure 1, 2, 3 indicates the block diagram, schematic diagram and for the proposed
research work. The research will be concentrated towards building a high efficient, SiC
MOSFET inverter base medium frequency induction heating system for hardening
application in Automobile industries. Also, the proposed work will take care of comparative
performance analysis in between proposed SiC MOSFET technology with Si based IGBT
technology under same operating conditions.

Figure 1: Block Diagram for Proposed Work

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 Medium Frequency, Parallel Resonant SiC Inverter For Surface Hardening Application in Automobile Industries

Figure 2: Schematic Diagram of Induction heating system.

Figure 3: Schematic Diagram of proposed soft switching CFPRI using SiC MOSFET.

7.2.Research Design
The Process of Research Design of lab prototype model is to be carried out in the
following sequence to achieve the Research objectives set in section 6 of this synopsis.
Power Circuit Design:
 Diodes of proper ratings are to be selected to design three phase uncontrolled rectifier
to carry out input 3 phase 50 Hz AC to constant pure DC from pulsating output of
rectifier.
 The design of L & C components of intermediate DC link/ LC filter is to be carried
out.

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 Designing an energy efficient induction heating system for hardening application,

selections of proper topology of high frequency resonant inverter and semiconductor
switch are important. In the thesis, a comparative study has been made among the
various semiconductor switches in terms of switching and conduction losses through
PSPICE based computer simulations and real time experiments. Comparing the wave-
forms of both PSPICE simulations and real time experiments, the selection of proper
power semiconductor switch in medium frequency resonant inverter can be made.
 Design of output choke at the output side of DC-AC inverter stage has to be done.
 Next to this, the components of resonant tank circuit i.e. inductance of heating coil
and compensating parallel capacitor bank is to be designed along with the matching
transformer.
Control circuit Design:
Two printed circuit cards, one for analogue and other for digital electronics has to be
designed. Analogue signals are to be measured, controlled, regulated and indicated on
analogue measurement meters through analogue card. Digital electronic card is
planned to supply all necessary voltages in the circuit required to monitor and control
the process of converter. Also design of digital card is to be done in such a way to
receive all fault conditions and operational signals which interfere correspondingly in
the process of converter behavior.
 Soft-computing based calculation of Heating coil parameters is to be done in order to
supply the maximum amount of heat to the work-piece of particular material.
 Operational analysis and computation of parallel resonant converter parameters and
MATLAB simulation has been proposed. Also calculation for resonant frequency,
Quality factor, power in the workpiece, commutation analysis has to be done to
investigate AC-AC converter system.
 Design of software phase locked loop for current fed parallel resonant
inverter(CFPRI) to identify correct resonant frequency by controlling the phase shift
between two electrical variables (voltage and current) along with MATLAB
simulation has been proposed in this research. Also design and simulation of load
adaptive phase locked loop has been planned in this thesis.
 To simulate the process of induction heating, finite element analysis software tool
COMSOL(modules of AC/DC, structural mechanics and heat transfer) is to be used
which is to calculate the parameters subjecting to a comprehensive study of
electromagnetic analysis and thermal analysis.
 Next to this, PID and fuzzy controller based PDM power control for full bridge
inverter systems is to be designed. The steady state and dynamic behavior of the
inverter with the controllers are to be studied during the change in the set power. The
simulation is to be carried out for the different values of set power.

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 The modeling and simulation of the PI and fuzzy logic based frequency control loop
(to improve the dynamic response of the full bridge resonant inverter fed IH system)
to maintain the operation of the inverter closer to the resonant frequency irrespective
of the variation in the load parameters have been proposed and to be worked out in
this research. The simulink models of the PID and fuzzy based frequency control
loops are to be prepared and simulated for output voltage and output current of the
inverter for different IH loads.
 The designed CFPRI is to be tested for doing the hardening of different sets of work
pieces under assumed operating conditions and results are to be compared and
analyzed in both case of Si IGBT & SiC MOSFET based technology.
7.3.Methods of Data Collection
The research will be carried out on data from e-Learning resources, industrial tests
and lab prototype simulations. The datasets of form multivariate can be used to perform the
research work and used for experimentation purposes.
References
1) O.Lucia, P.Maussion, E. Dede, J.M. Burdio-Induction heating technology and its
applications: Past developments, current technology, and future challenges- Oatao,
DOI: 10.1109/TIE.2013.2281162.
2) N.S. Bayındır, O. K.Ukrer and M. Yakup- DSP-based PLL-controlled 50–100 kHz,
20 kW high frequency induction heating system for surface hardening and welding
applications, IEEE Proceedings online no. 20030096, 29th April 2002.
3) Edmund Zok, Dirk M.Schibisch-Energy efficient power supply for induction
hardening and heating processes, Induction Technology-Reports.
4) Amit Kohli, Hari Singh-A Fuzzy logic approach for optimization of Hardness in
induction hardening process.
5) Eng. José Carlos Zerbini, Dr. Alexander Ivanov, Dr. Vladimir Bukanin, Eng. Ademir
Angelo de Vasconcelos- Use of the ELTA software for study of electromagnetic and
thermal processes in induction heating steel forging lines,35th SENAFOR, 19th
International Forging Conference.
6) M.Roy,M.Sengupta-Electromagnetic investigations and power converter efficiency
studies on a laboratory made induction heating prototype, Journal of The Institutions
of Engineers (India): Series B, Electrical, Electronics and Telecommunication and
Computer Engineering, ISSN 2250-2106, Vol. 94, No.3.
7) Soe Sander Aung,Han Phyo Wai, Nyein Nyein Soe- Design calculation and
performance testing of heating coil in induction surface hardening machine-
International Journal of Electrical,Computer,Electronics and Communication
Engineering - Vol.2,No.6,2008.
8) Umar Shami-Design and development of an efficient coil for a resonant high
frequency inverter for induction heating.
9) Subhadra Tiwari,John Kare Langelid,Ole-Morten Midtgard,Tore Marvin Undeland-
SiC MOSFETs for future resonant converter applications-NEF 2017,April 27,2017.

Shivaji University, Kolhapur 13 / 14

 Medium Frequency, Parallel Resonant SiC Inverter For Surface Hardening Application in Automobile Industries

10) Alireza Harrasi,Ahmed F. Zobaa-A cost effective harmonic cancellation method for
high frequency silicon carbide MOSFET based single phase inverter.
11) Alireza Namadmalan -Bidirectional current fed resonant inverter for contactless
energy transfer systems, IEEE Transaction on Industrial Electronics, Vol.62, No.1,
January 2016.
12) Yongxing Wang, Yabin Li, Yonglong Peng, Xingkun Qi-Research and design on
IGBT induction heating power supply, 2012 International Conference on Future
Energy, Envioronment and Materials, Energy Procedia 16(2012)1957-1963.
13) Prof.Ruchit R.Soni, Prof. Hirenkumar D. Patel, Mr.N.D.Patel, Mahendra Rathod-
Hardware implementation of MOSFET based high frequency inverter for induction
heating, Journal of Information, Knowledge and Research in Electrical Engineering.
14) M.Roy, M.Sengupta-Design, fabrication and testing of two different laboratory
prototypes of CSI based induction heating units-Journal of The Institutions of
Engineers (India): Series B, Electrical, Electronics and Telecommunication and
Computer Engineering, ISSN 2250-2106.
15) M.Roy,M.Sengupta-Application of FPGA based PLL in a CSI fed induction heating
prototype,2014 International Conference on Power Electronics, Drives and Energy
Systems
16) R.Hemalatha,Jyoti P.Koujalagi-Design and simulation of induction heating equipment
using MATLAB/SIMULINK Environment, International Journal of Science and
Research, India Online ISSN: 2319-7064.
17) Riyadh G. Omar, Dr.Rabee H. Thejel- MATLAB/SIMULINK modeling of parallel
resonant DC link soft-switching four-leg SVPWM inverter, Electrical and Electronic
Engineering, Vol.11 No.1 , 201 5
18) H.Javadi, A.Shoulaie- Analysis of H- bridge current source parallel resonant inverter
for induction heating- Proceedings of 17th Iranian Conference on Electrical
engineering, 12-14 May, 2009, Vol.3, Power-Electric Machines and Power
Electronics.
19) M.Roy,M.Sengupta-Comparision in performance between an IGBT based and
thyristor based current source inverter feeding 2 KW,10 KHz induction heating unit
20) Kirubakaran.D.,Rama Reddy.S.-Comparision of parallel resonant inverter and series
resonant inverter for induction heating,Journal of Electrical engineering

Date: May 4, 2018

Place: Sangli

Mr. Vijay J. Patil Dr. A.M.Mulla

(Research Student) (Research Guide)

Head of Research Centre

Department of Technology, Kolhapur

Shivaji University, Kolhapur 14 / 14