Investigation on Performance of Various Power Control Strategies with Bifilar Coil for Induction Surface Melting Application

Abstract

In recent years, induction heating applications assisted by electronic power control have been very appealing. For melting applications, induction heating is widely used as it seems to be appropriate and provides higher efficiency, zero pollutants, non-contamination of material, etc. in comparison with conventional heating. The conventional variable frequency control scheme is not sufficient for melting applications because of its high switching loss, low efficiency, and lower heat rate. A superlative control technique is required to control the output power smoothly, for a high heating rate with minimum power loss, and to lower the number of components. In this paper, a capacitorless self-resonating bifilar coil is proposed for induction surface melting applications. The performance of the system in terms of modular losses, heat rate, and efficiency is analyzed for various power methods such as pulse duty cycle control, phase shift control, pulse density modulation control, and asymmetric duty cycle control. An experimental validation is performed for the 1 kW prototype, and the heating rate, efficiency, and modular losses are calculated. The control technique is digitally validated using a PIC16F877A microcontroller with 30 kHz switching frequency. The temperature distribution is analyzed using a FLIR thermal imager. Among the tested methods, pulse density modulation-based control provides smooth and varied power control from 0% to 100% with minimum modular losses. The efficiency of the system is 89% at a rated output power and is greater than 85% for pulse density modulation control with a fast heating rate.