Parts of certain objects need hardening. Hardening is a heat treatment process which can be achieved by induction heating. Certain objects like gears require alternating source with two different frequencies. Simultaneous application of dual frequencies is desirable for proper hardening of a gear. This study proposes a three-leg inverter topology with a load resonant circuit which can provide independent and simultaneous control of low-frequency (LF) and high-frequency (HF) currents through the load coil. The load circuit is a combination of two series resonant circuits which operates at the desired LF and HF. Power control is achieved with phase modulation and asymmetric duty cycle control techniques. A 240 W prototype of the proposed dual-frequency inverter is implemented and tested. Experimental results obtained are in good agreement with the simulation results.

References

1. 1)
  - 13. Schwenk, W.R.: ‘Simultaneous dual-frequency induction hardening’. Heat Treating Progress, April 2003, vol. 3, pp. 35–38.
2. 2)
  - K. Ogura , L. Gamage , T. Ahmed . Performance evaluation of edge-resonant ZVS-PWM high-frequency inverter using trench-gate IGBTs for consumer induction cooking heater. IEE Proc. Electr. Power Appl. , 5 , 563 - 568
3. 3)
  - 18. Okudaira, S., Matsuse, K.: ‘Power control of an adjustable frequency quasi-resonant inverter for dual frequency induction heating’. Proc. of IPEMC-2000, S-34-2, 2000, pp. 968–973.
4. 4)
  - 18. Lucia, O., Burdio, J.M., Barragan, L.A., Carretero, C., Acero, J.: ‘Series resonant multi-inverter with discontinuous-mode control for improved light-load operation’, IEEE Trans. Ind. Electron., 2011, 58, (11), pp. 5163–5171 (doi: 10.1109/TIE.2011.2126541).
5. 5)
  - N.A. Ahmed , M. Nakaoka . Boost-half-bridge edge resonant soft switching PWM high-frequency inverter for consumer induction heating appliances. IEE Proc. Electr. Power Appl. , 6 , 932 - 938
6. 6)
  - H. Fujita , N. Uchida , K. Ozaki . A new zone-control induction heating system using multiple inverter units applicable under mutual magnetic coupling conditions. IEEE Trans. Power Electron. , 99 , 1 - 23
7. 7)
  - 22. Carretero, C., Lucia, O., Acero, J., Alonso, R., Burdio, J.M.: ‘Frequency-dependent modelling of domestic induction heating systems using numerical methods for accurate time-domain simulation’, IET Trans. Power Electron., 2012, 5, (8), pp. 1291–1297 (doi: 10.1049/iet-pel.2012.0113).
8. 8)
  - 7. Pham, H., Fujita, H., Ozaki, K., Uchida, N.: ‘Dynamic analysis and control of a zone-control induction heating system’. IEEE Energy Conversion Congress and Exposition (ECCE), 2011, pp. 4093–4100.
9. 9)
  - 26. Diong, B., Basireddy, S., Corzine, K., Familiant, Y.: ‘Multilevel inverters with equal or unequal sources for dual-frequency induction heating’. Proc. 19th Annual IEEE (APEC'04), 2004, vol. 2, pp. 825–831.
10. 10)
  - 11. Burdio, J.M., Barragan, L.A., Monterde, F., Navarro, D., Acero, J.: ‘Asymmetrical voltage-cancellation control for full-bridge series resonant inverters’, IEEE Trans. Power Electron., 2004, 19, (2), pp. 461–469 (doi: 10.1109/TPEL.2003.823250).
11. 11)
  - 22. Sarnago, H., Lucia, O., Mediano, A., Burdio, J.M.: ‘High-efficiency parallel quasi-resonant current source inverter featuring Sic metal-oxide semiconductor field-effect transistors for induction heating systems with coupled inductors’, IET Power Electron., 2013, 6, (1), pp. 183–191 (doi: 10.1049/iet-pel.2012.0537).
12. 12)
  - 23. Esteve, V., Pardo, J., Jordan, J., Dede, E.J., Sanchis-Kilders, E., Maset, E.: ‘High power resonant inverter with simultaneous dual-frequency output’. Proc. 36th Annual IEEE (PESC'05), 2005, pp. 1278–1281.
13. 13)
  - 22. Okudaira, S., Matsuse, K.: ‘Dual frequency output quasi-resonant inverter for induction heating’, Trans. Inst. Electric. Eng. Jpn. D, 2001, 121-D, (5), pp. 563–568.
14. 14)
  - 17. Egalon, J., Caux, S., Maussion, P., Souley, M., Pateau, O.: ‘Multiphase system for metal disc induction heating: modeling and RMS current control’, IEEE Trans. Ind. Appl., 2012, 48, (5), pp. 1692–1699 (doi: 10.1109/TIA.2012.2210176).
15. 15)
  - 21. Wojda, R.P., Kazimierczuk, M.K.: ‘Winding resistance of litz-wire and multi-strand inductors’, IET Power Electron., 2012, 5, (2), pp. 257–268 (doi: 10.1049/iet-pel.2010.0359).
16. 16)
  - 14. Biasutti, F., Krause, C., Lupi, S.: ‘Induction hardening of complex geometry and geared parts’. Heat Processing, 2012, vol. 3, pp. 60–70.
17. 17)
  - 2. Kifune, H., Hatanaka, Y., Nakaoka, M.: ‘Quasi-series-resonant-type soft-switching phase shift modulated inverter’, Proc. Inst. Elect. Eng., Electr. Power Appl., 2003, 150, (6), pp. 725–732 (doi: 10.1049/ip-epa:20030558).
18. 18)
  - 17. Rudnev, V.: ‘Recent inventions and innovations in induction hardening of gear and gear-like components’ (American Gear Manufacturers Association, 2012).
19. 19)
  - 25. Diong, B., Corzine, K., Basireddy, S., Lu, S.: ‘Multilevel inverters based dual-frequency power supply’, IEEE Power Electron. Lett., 2003, 1, (4), pp. 115–119 (doi: 10.1109/LPEL.2004.825543).
20. 20)
  - 27. Porpandiselvi, S., Vishwanathan, N.: ‘Inverter configuration for simultaneous dual frequency induction hardening with independent control’, Eur. Power Electron. Drives J., 2013, 23, (1), pp. 13–20.
21. 21)
  - 20. Ishimaru, Y., Oka, K., Sasou, K., Matsuse, K., Tsukahara, M.: ‘Dual high frequency quasi-resonant inverter circuit by using power MOSFET for induction heating’. IPEMC-2009, 2009, pp. 2545–2550.
22. 22)
  - 1. Lucia, O., Maussion, P., Dede, E., Burdio, J.: ‘Induction heating technology and its applications: past developments, current technology, and future challenges’, IEEE Trans. Ind. Electron., 2013, 61, (5), pp. 2509–2520 (doi: 10.1109/TIE.2013.2281162).
23. 23)
  - 9. Lucía, O., Burdío, J.M., Barragán, L.A., Acero, J., Millán, I.: ‘Series-resonant multiinverter for multiple induction heaters’, IEEE Trans. Power Electron., 2010, 24, (11), pp. 2860–2868 (doi: 10.1109/TPEL.2010.2051041).
24. 24)
  - 24. Esteve, V., Jordan, J., Dede, E.J., Sanchis-Kilders, E., Maset, E.: ‘Induction heating inverter with simultaneous dual frequency output’. Proc. of Applied Power Electronics Conf. and Exposition, March 2006, pp. 1505–1509.
25. 25)
  - 21. Okudaira, S., Matsuse, K.: ‘A new quasi-resonant inverter with two-way short-circuit switch across a resonant capacitor’. PCC-Osaka 2002, 2002, pp. 1496–1501.
26. 26)
  - 15. Hammond, M.: ‘Simultaneous dual-frequency gear hardening’. Induction Heat Treating, June 7, 2001.
27. 27)
  - 19. Okudaira, S., Matsuse, K.: ‘Adjustable frequency quasi-resonant inverter circuits having short-circuit switch across resonant capacitor’, IEEE Trans. Power Electron., 2008, 23, (4), pp. 1830–1838 (doi: 10.1109/TPEL.2008.924838).
28. 28)
  - 16. Schwenk: ‘Surface hardening using the simultaneous dual frequency method’. Metallurgia, 2003, pp. 8–9.

Three-leg inverter configuration for simultaneous dual-frequency induction hardening with independent control

References

Related content