1KW induction heating using resonant technique

A project report submitted to the faculty of department of electrical engineering of the

University of Lahore in partial fulfilment of the requirement’s for the degree of

Bachelor of Science in electrical engineering

Department of electrical engineering
University of Lahore
January 2018

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 Remarks by advisor

Advisor
Professor Hafiz Tehzeeb-ul-Hassan
The University of Lahore

Remarks by Head of Department (Electrical engineering)

Professor Tehzeeb-ul-Hassan
Head of Department (EE)
The University of Lahore

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DECLARATION
I declare that the work contained in this thesis is my own, except where explicitly stated
other wise.in addition this work has not been submitted to obtain another degree or
professional qualification.

Ammar Khalid (BSEE 01133101)

January 2018

DEDICATION
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We are thankful to Almighty ALLAH, highly merciful and graceful, who bestowed us with
courage and knowledge to complete this project.

We are especially grateful to our parents and siblings for being a constant support and
encouragement for us throughout this project, and in every walk off our lives, and for
providing us with all necessary tools and information to facilitate us in every possible
way.

We would like to express this gratitude and appreciation to the advisor Prof. Tehzeeb-
ul-Hassan whose patience, guidance and encouragement throughout this project
enabled us to develop the understanding of the subject.

CERTIFICATE OF APPROVAL
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It is certified that I have read the document meticulously and circumspectly. I am
convinced that the resultant project does not contain any spelling, punctuation or
grammatical mistakes as such. All in all, this document well organized and I am in no
doubt that its objectives have been successfully met.

: Supervisor

Professor Tehzeeb-ul-Hassan
HOD (EE)
The University of Lahore, Lahore

HOD:
Professor Tehzeeb-ul-Hassan
HOD (EE)
The University of Lahore, Lahore

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ACKNOWLEDGMENT
Final year project has been a great learning opportunity and added to our practical
experience. This project had a diverse range of topics to be understood.it has a
valuable contribution to our knowledge. We are grateful to almighty Allah for giving us
the will and without whom, nothing is possible.

We would like to express our deepest gratitude to all those who helped us complete the
project by guiding us at various points.in this regard, we present our special thanks to
our project advisor Prof. Tehzeeb-ul-Hassan who supported and guided us in all
phases, provided us with unparalleled motivation and eagerness to explore more into
the details of various aspects of the project. He has always been a source of
encouragement and appreciation which added to our enthusiasm to work harder. The
scope of this project would have not been easy without his always available help.

We are grateful to all the lab staff and department for rendering support and cooperation
in every possible way.

Ammar Khalid (BSEE 01133101)

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ABSTRACT
This project aims to implement induction heating for metals, employing single phase full
H-bridge voltage fed square wave invertor to power series resonant used along with
coupling transformer. IGBT’s are used because of their high current capability with high
frequency operation. Driving signals and feedback is implemented via controller.
Electrical model is simulated on MATLAB Simulink and observed output in a pure
sinusoidal wave form across tank circuit.
The resonant frequency of tank is tracked using PLL implemented via PID controller. A
constant phase difference of 90ͦ between voltage of inverter and tank capacitor voltage
ensure the condition of resonance and process is achieved in real time. When work
piece is introduced inside work coil, the inductance of coil changes thus resonance
frequency also changes.
The PID controller taking the feedback signals allows us to reach the resonance
frequency as quickly after the insertion of work piece. Moreover, same metal piece offer
different inductance at different temperatures, this problem is also solved by PLL.

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Contents
Acknowledgments vi
Abstract vii
List of figures x
Abbreviations xii

1. Theoretical background
1.1 Introduction 1
1.1.1 Induction 2
1.1.2 Resonance 3
1.2 Resonant inverter 3
1.3 Series resonant inverter 4
1.4 Parallel resonant inverter 8
1.5 Effect of frequency 9
1.6 Simulations 10
1.6.1 PROTEUS simulations for inverter 10
2. Hardware
2.1 selection of MOSFET 12
2.2 optocoupler 14
2.3 gate driver 15
2.3.1 Independent supplies 18
2.4 dc supply for inverter 19
2.5 tank circuit 20
2.5.1 design of work coil 21
2.5.2 work coil for the project 22
2.6 capacitor bank 23
2.7 coupling transformer 24
2.8 heat sinks 25
2.9 sequence of the hardware 26
3. Implementation
3.1 Working 27
3.1.1 Timers 28
3.1.2 inverter output results 29
3.1.3 tank circuit output 29
3.1.4 inclusion of phase difference 30
3.1.4.1 How to cater for phase shift? 31
3.2 open loop induction heater 32
3.3 PID controller 35

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 3.3.1 Proportional 36
3.3.2 Integral 37
3.3.3 Derivative 39
3.4 tuning of the system 40
3.5 obtaining the phase difference 41
3.6 problem with PD 43
4. Future extensions
4.1 power control using frequency 44
4.2 design 44
4.3 temperature sensing 44
5. Conclusion 45

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List of Figures

1.1 block diagram 2

1.2 series circuit 4
1.3 capacitive dominant behavior 5
1.4 inductive dominant behavior 6
1.5 resistive behavior at resonance 7
1.6 resistive behavior at resonance for parallel resonant inverter 8
1.7 effect of frequency on heating 9
1.8 PROTEUS simulation for inverter 10
1.9 Signals for inverter 10
1.10 Output for tank circuit 11
2.1 MOSFET IRF 740 13
2.2 MOSFET connected on CIRCUIT 13
2.3 EL817 optocoupler 14
2.4 Configuration of EL817 15
2.5 H- bridge circuit 16
2.6 Dead time 16
2.7 IR2110 gate driver providing isolated grounds 17
2.8 Independent DC supply for gate drivers 18
2.9 Implementation of independent DC supply for gate drivers 18
2.10 DC supply for inverters 19
2.11 Tank circuit 20
2.11.1 Helical shaped coil 21
2.12 Pancake shaped coil 22
2.13 Work coil for the project 22
2.14 Capacitor bank 23
2.15 Coupling transformer 24
2.16 Sequence of hardware 26
3.1 Arduino Nano 3.0 27
3.2 Square wave output 29
3.3 Tank circuit output 29
3.4 MOSFET 30
3.5 Current graph for series resonant circuit 32
3.6 Waveforms for operation at F<Fr 33
3.7 Waveforms for operation at open loop Fr 34
3.8 PID controller on a plant 35
3.9 Proportional controller 36
3.10 Proportional controller effect on system 36
3.11 Integral controller 38
3.12 Integral controller response with Ti 38
3.13 Derivative controller response 39

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3.14 PD controller 41
3.15 XOR gate symbol and truth table 41
3.16 XOR gate on square signal 42

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Abbreviations

ZVS zero voltage switching

ZCS zero current switching
MOSFET metal oxide semiconductor field effect transistor
IGBT insulated gate bipolar transistor
PLL phase lock loop
PID proportional integral derivative

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