Introduction

Induction heating is a non-contact heating process. It uses high frequency electricity to heat materials that are electrically
conductive. Since it is non-contact, the heating process does not contaminate the material being heated. It is also very
efficient since the heat is actually generated inside the workpiece. This can be contrasted with other heating methods
where heat is generated in a flame or heating element, which is then applied to the workpiece. For these reasons Induction
Heating lends itself to some unique applications in industry.
How does Induction Heating work ?
A source of high frequency electricity is used to drive a large alternating current through
a coil. This coil is known as the work coil. See the picture opposite.
The passage of current through this coil generates a very intense and rapidly changing
magnetic field in the space within the work coil. The workpiece to be heated is placed
within this intense alternating magnetic field.
Depending on the nature of the workpiece material, a number of things happen...
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The alternating magnetic field induces a current flow in the conductive workpiece. The
arrangement of the work coil and the workpiece can be thought of as an electrical
transformer. The work coil is like the primary where electrical energy is fed in, and the
workpiece is like a single turn secondary that is short-circuited. This causes tremendous
currents to flow through the workpiece. These are known as eddy currents.
In addition to this, the high frequency used in induction heating applications gives rise to
a phenomenon called skin effect. This skin effect forces the alternating current to flow in
a thin layer towards the surface of the workpiece. The skin effect increases the effective
resistance of the metal to the passage of the large current. Therefore it greatly increases
the heating effect caused by the current induced in the workpiece.
(Although the heating due to eddy currents is desirable in this application, it is interesting to note that transformer
manufacturers go to great lengths to avoid this phenomenon in their transformers. Laminated transformer cores,
powdered iron cores and ferrites are all used to prevent eddy currents from flowing inside transformer cores. Inside a
transformer the passage of eddy currents is highly undesirable because it causes heating of the magnetic core and
represents power that is wasted.)
And for Ferrous metals ?
For ferrous metals like iron and some types of steel, there is an additional heating mechanism that takes place at the same
time as the eddy currents mentioned above. The intense alternating magnetic field inside the work coil repeatedly
magnetises and de-magnetises the iron crystals. This rapid flipping of the magnetic domains causes considerable friction
and heating inside the material. Heating due to this mechanism is known as Hysteresis loss, and is greatest for materials
that have a large area inside their B-H curve. This can be a large contributing factor to the heat generated during induction
heating, but only takes place inside ferrous materials. For this reason ferrous materials lend themselves more easily to
heating by induction than non-ferrous materials.
It is interesting to note that steel looses its magnetic properties when heated above approximately 700C. This temperature
is known as the Curie temperature. This means that above 700C there can be no heating of the material due to hysteresis
losses. Any further heating of the material must be due to induced eddy currents alone. This makes heating steel above
700C more of a challenge for the induction heating systems. The fact that copper and Aluminium are both non-magnetic
and very good electrical conductors, can also make these materials a challenge to heat efficiently. (We will see that the
best course of action for these materials is to up the frequency to exaggerate losses due to the skin effect.)
What is Induction Heating used for ?
Induction heating can be used for any application where we want to heat an electrically conductive material in a clean,
efficient and controlled manner.
One of the most common applications is for sealing the anti-tamper seals that are stuck to the top of medicine and drinks
bottles. A foil seal coated with "hot-melt glue" is inserted into the plastic cap and screwed onto the top of each bottle
during manufacture. These foil seals are then rapidly heated as the bottles pass under an induction heater on the production
line. The heat generated melts the glue and seals the foil onto the top of the bottle. When the cap is removed, the foil
remains providing an airtight seal and preventing any tampering or contamination of the bottle's contents until the
customer pierces the foil.
Another common application is "getter firing" to remove contamination from evacuated tubes such as TV picture tubes,
vacuum tubes, and various gas discharge lamps. A ring of conductive material called a "getter" is placed inside the
evacuated glass vessel. Since induction heating is a non-contact process it can be used to heat the getter that is already
sealed inside a vessel. An induction work coil is located close to the getter on the outside of the vacuum tube and the AC
source is turned on. Within seconds of starting the induction heater, the getter is heated white hot, and chemicals in its
coating react with any gasses in the vacuum. The result is that the getter absorbs any last remaining traces of gas inside the
vacuum tube and increases the purity of the vacuum.
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Yet another common application for induction heating is a process called Zone purification used in the semiconductor
manufacturing industry. This is a process in which silicon is purified by means of a moving zone of molten material. An
Internet Search is sure to turn up more details on this process that I know little about.
Other applications include melting, welding and brazing or metals. Induction cooking hobs and rice cookers. Metal
hardening of ammunition, gear teeth, saw blades and drive shafts, etc are also common applications because the induction
process heats the surface of the metal very rapidly. Therefore it can be used for surface hardening, and hardening of
localised areas of metallic parts by "outrunning" the thermal conduction of heat deeper into the part or to surrounding
areas. The non contact nature of induction heating also means that it can be used to heat materials in analytical applications
without risk of contaminating the specimen. Similiarly, metal medical instruments may be sterilised by heating them to
high temperatures whilst they are still sealed inside a known sterile environment, in order to kill germs.
What is required for Induction Heating ?
In theory only 3 things are essential to implement induction heating:
1. A source of High Frequency electrical power,
2. A work coil to generate the alternating magnetic field,
3. An electrically conductive workpiece to be heated,
Having said this, practical induction heating systems are usually a little more complex. For example, an impedance
matching network is often required between the High Frequency source and the work coil in order to ensure good power
transfer. Water cooling systems are also common in high power induction heaters to remove waste heat from the work
coil, its matching network and the power electronics. Finally some control electronics is usually employed to control the
intensity of the heating action, and time the heating cycle to ensure consistent results. The control electronics also protects
the system from being damaged by a number of adverse operating conditions. However, the basic principle of operation of
any induction heater remains the same as described earlier.
Practical implementation
In practice the work coil is usually incorporated into a resonant tank circuit. This has a number of advantages. Firstly, it
makes either the current or the voltage waveform become sinusoidal. This minimises losses in the inverter by allowing it
to benefit from either zero-voltage-switching or zero-current-switching depending on the exact arrangement chosen. The
sinusoidal waveform at the work coil also represents a more pure signal and causes less Radio Frequency Interference to
nearby equipment. This later point becoming very important in high-powered systems. We will see that there are a number
of resonant schemes that the designer of an induction heater can choose for the work coil:
Series resonant tank circuit
The work coil is made to resonate at the intended operating frequency by means of a capacitor placed in series with it. This
causes the current through the work coil to be sinusoidal. The series resonance also magnifies the voltage across the work
coil, far higher than the output voltage of the inverter alone. The inverter sees a sinusoidal load current but it must carry
the full current that flows in the work coil. For this reason the work coil often consists of many turns of wire with only a
few amps or tens of amps flowing. Significant heating power is achieved by allowing resonant voltage rise across the work
coil in the series-resonant arrangement whilst keeping the current through the coil (and the inverter) to a sensible level.
This arrangement is commonly used in things like rice cookers where the power level is low, and the inverter is located
next to the object to be heated. The main drawbacks of the series resonant arrangement are that the inverter must carry the
same current that flows in the work coil. In addition to this the voltage rise due to series resonance can become very
pronounced if there is not a significantly sized workpiece present in the work coil to damp the circuit. This is not a
problem in applications like rice cookers where the workpiece is always the same cooking vessel, and its properties are
well known at the time of designing the system.
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The tank capacitor is typically rated for a high voltage because of the resonant voltage rise experienced in the series tuned
resonant circuit. It must also carry the full current carried by the work coil, although this is typically not a problem in low
power applications.
Parallel resonant tank circuit
The work coil is made to resonate at the intended operating frequency by means of a capacitor placed in parallel with it.
This causes the current through the work coil to be sinusoidal. The parallel resonance also magnifies the current through
the work coil, far higher than the output current capability of the inverter alone. The inverter sees a sinusoidal load current.
However, in this case it only has to carry the part of the load current that actually does real work. The inverter does not
have to carry the full circulating current in the work coil. This is very significant since power factors in induction heating
applications are typically low. This property of the parallel resonant circuit can make a tenfold reduction in the current that
must be supported by the inverter and the wires connecting it to the work coil. Conduction losses are typically proportional
to current squared, so a tenfold reduction in load current represents a significant saving in conduction losses in the inverter
and associated wiring. This means that the work coil can be placed at a location remote from the inverter without incurring
massive losses in the feed wires.
Work coils using this technique often consist of only a few turns of a thick copper conductor but with large currents of
many hundreds or thousands of amps flowing. (This is necessary to get the required Ampere turns to do the induction
heating.) Water cooling is common for all but the smallest of systems. This is needed to remove excess heat generated by
the passage of the large high frequency current through the work coil and its associated tank capacitor.
In the parallel resonant tank circuit the work coil can be thought of as an inductive load with a "power factor correction"
capacitor connected across it. The PFC capacitor provides reactive current flow equal and opposite to the large inductive
current drawn by the work coil. The key thing to remember is that this huge current is localised to the work coil and its
capacitor, and merely represents reactive power sloshing back-and-forth between the two. Therefore the only real current
flow from the inverter is the relatively small amount required to overcome losses in the "PFC" capacitor and the work coil.
There is always some loss in this tank circuit due to dielectric loss in the capacitor and skin effect causing resistive losses
in the capacitor and work coil. Therefore a small current is always drawn from the inverter even with no workpiece
present. When a lossy workpiece is inserted into the work coil, this damps the parallel resonant circuit by introducing a
further loss into the system. Therefore the current drawn by the parallel resonant tank circuit increases when a workpiece
is entered into the coil.
Impedance matching
Or simply "Matching". This refers to the electronics that sits between the source of high frequency power and the work
coil we are using for heating. In order to heat a solid piece of metal via induction heating we need to cause a
TREMENDOUS current to flow in the surface of the metal. However this can be contrasted with the inverter that
generates the high frequency power. The inverter generally works better (and the design is somewhat easier) if it operates
at fairly high voltage but a low current. (Typically problems are encountered in power electronics when we try to switch
large currents on and off in very short times.) Increasing the voltage and decreasing the current allows common switch
mode MOSFETs (or fast IGBTs) to be used. The comparatively low currents make the inverter less sensitive to layout
issues and stray inductance. It is the job of the matching network and the work coil itself to transform the high-
voltage/low-current from the inverter to the low-voltage/high-current required to heat the workpiece efficiently.
We can think of the tank circuit incorporating the work coil (Lw) and its
capacitor (Cw) as a parallel resonant circuit.
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This has a resistance (R) due to the lossy workpiece coupled into the
work coil due to the magnetic coupling between the two conductors.
See the schematic opposite.
In practice the resistance of the work coil, the resistance of the tank
capacitor, and the reflected resistance of the workpiece all introduce a
loss into the tank circuit and damp the resonance. Therefore it is useful to
combine all of these losses into a single "loss resistance." In the case of a
parallel resonant circuit this loss resistance appears directly across the
tank circuit in our model. This resistance represents the only component
that can consume real power, and therefore we can think of this loss
resistance as the load that we are trying to drive power into in an efficient
manner.
When driven at resonance the current drawn by the tank capacitor and the work coil are equal in magnitude and opposite in
phase and therefore cancel each other out as far as the source of power is concerned. This means that the only load seen
by the power source at the resonant frequency is the loss resistance across the tank circuit. (Note that, when driven
either side of the resonant frequency, there is an additional "out-of-phase" component to the current caused by incomplete
cancellation of the work coil current and the tank capacitor current. This reactive current increases the total magnitude of
the current being drawn from the source but does not contribute to any useful heating in the workpiece.)
The job of the matching network is simply to transform this relatively large loss resistance across the tank circuit down to
a lower value that better suits the inverter attempting to drive it. There are many different ways to achieve this impedance
transformation including tapping the work coil, using a ferrite transformer, a capacitive divider in place of the tank
capacitor, or a matching circuit such as an L-match network.
In the case of an L-match network it can transform the relatively high
load resistance of the tank circuit down to something around 10 ohms
which better suits the inverter. This figure is typical to allow the inverter
to run from several hundred volts whilst keeping currents down to a
medium level so that standard switch-mode MOSFETs can be used to
perform the switching operation.
The L-match network consists of components Lm and Cm shown
opposite.
The L-match network has several highly desirable properties in this application. The inductor at the input to the L-match
network presents a progressively rising inductive reactance to all frequencies higher than the resonant frequency of the
tank circuit. This is very important when the work coil is to be fed from a voltage-source inverter that generates a
squarewave voltage output. Here is an explanation of why this is so
The squarewave voltage generated by most half-bridge and full-bridge circuits is rich in high frequency harmonics as well
as the wanted fundamental frequency. Direct connection of such a voltage source to a parallel resonant circuit would cause
excessive currents to flow at all harmonics of the drive frequency! This is because the tank capacitor in the parallel
resonant circuit would present a progressively lower capacitive reactance to increasing frequencies. This is potentially very
damaging to a voltage-source inverter. It results in large current spikes at the switching transitions as the inverter tries to
rapidly charge and discharge the tank capacitor on rising and falling edges of the squarewave. The inclusion of the
L-match network between the inverter and the tank circuit negates this problem. Now the output of the inverter sees the
inductive reactance of Lm in the matching network first, and all harmonics of the drive waveform see a gradually rising
inductive impedance. This means that maximum current flows at the intended frequency only and little harmonic current
flows, making the inverter load current into a smooth waveform.
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Finally, with correct tuning the L-match network is able to provide a slight inductive load to the inverter. This slightly
lagging inverter load current can facilitate Zero-Voltage-Switching (ZVS) of the MOSFETs in the inverter bridge. This
significantly reduces turn-on switching losses due to device output capacitance in MOSFETs operated at high voltages.
The overall result is less heating in the semiconductors and increased lifetime.
In summary, the inclusion of an L-match network between the inverter and the parallel resonant tank circuit achieves two
things.
1. Impedance matching so that the required amount of power can be supplied from the inverter to the workpiece,
2. Presentation of a rising inductive reactance to high frequency harmonics to keep the inverter safe and happy.
Looking at the previous schematic above we can see that the capacitor in
the matching network (Cm) and the tank capacitor (Cw) are both in
parallel. In practice both of these functions are usually accomplished by a
single purpose built power capacitor. Most of its capacitance can be
thought of as being in parallel resonance with the work coil, with a small
amount providing the impedance matching action with the matching
inductor (Lm.) Combing these two capacitances into one leads us to
arrive at the LCLR model for the work coil arrangement, which is
commonly used in industry for induction heating.
The LCLR work coil
This arrangement incorporates the work coil into a parallel resonant circuit and uses the L-match network between the tank
circuit and the inverter. The matching network is used to make the tank circuit appear as a more suitable load to the
inverter, and its derivation is discussed in the section above.
The LCLR work coil has a number of desirable properties:
1. A huge current flows in the work coil, but the inverter only has to supply a low current. The large circulating current
is confined to the work coil and its parallel capacitor, which are usually located very close to each other.
2. Only comparatively low current flows along the transmission line from the inverter to the tank circuit, so this can
use lighter duty cable.
3. Any stray inductance of the transmission line simply becomes part of the matching network inductance (Lm.)
Therefore the heat station can be located away from the inverter.
4. The inverter sees a sinusoidal load current so it can benefit from ZCS or ZVS to reduce its switching losses and
therefore run cooler.
5. The series matching inductor can be altered to cater for different loads placed inside the work coil.
6. The tank circuit can be fed via several matching inductors from many inverters to reach power levels above those
achievable with a single inverter. The matching inductors provide inherent sharing of the load current between the
inverters and also make the system tolerant to some mismatching in the switching instants of the paralleled inverters.
For more information about the behaviour of the LCLR resonant network see the new section below labelled
"LCLR network frequency response."
Another advantage of the LCLR work coil arrangement is that it does not require a high-frequency transformer to provide
the impedance matching function. Ferrite transformers capable of handling several kilowatts are large, heavy and quite
expensive. In addition to this, the transformer must be cooled to remove excess heat generated by the high currents flowing
in its conductors. The incorporation of the L-match network into the LCLR work coil arrangement removes the necessity
of a transformer to match the inverter to the work coil, saving cost and simplifying the design. However, the designer
should appreciate that a 1:1 isolating transformer may still be required between the inverter and the input to the LCLR
work coil arrangement if electrical isolation is necessary from the mains supply. This depends whether isolation is
important, and whether the main PSU in the induction heater already provides sufficient electrical isolation to meet these
safety requirements.
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Conceptual schematic
The system schematic belows shows the simplest inverter driving its LCLR work coil arrangement.
Note that this schematic DOES NOT SHOW the MOSFET gate-drive circuitry and control electronics!
The inverter in this demonstration prototype was a simple half-bridge consisting of two MTW14N50 MOSFETs made my
On-semiconductor (formerly Motorola.) It is fed from a smoothed DC supply with decoupling capacitor across the rails to
support the AC current demands of the inverter. However, it should be realised that the quality and regulation of the power
supply for induction heating applications is not critical. Full-wave rectified (but un-smoothed) mains can work as well as
smoothed and regulated DC when it comes to heating metal, but peak currents are higher for the same average heating
power. There are many arguments for keeping the size of the DC bus capacitor down to a minimum. In particular it
improves the power factor of current drawn from the mains supply via a rectifier, and it also minimises stored energy in
case of fault conditions within the inverter.
The DC-blocking capacitor is used merely to stop the DC output from the half-bridge inverter from causing current flow
through the work coil. It is sized sufficiently large that it does not take part in the impedance matching, and does not
adversely effect the operation of the LCLR work coil arrangement.
In high power designs it is common to use a full-bridge (H-bridge) of 4 or more switching devices. In such designs the
matching inductance is usually split equally between the two bridge legs so that the drive voltage waveforms are balanced
with respect to ground. The DC-blocking capacitor can also be eliminated if current mode control is used to ensure that no
net DC flows between the bridge legs. (If both legs of the H-bridge can be controlled independently then there is scope for
controlling power throughput using phase-shift control. See point 6 in the section below about "Power control methods"
for further details.)
At still higher powers it is possible to use several seperate inverters effectively connected in parallel to meet the high load-
current demands. However, the seperate inverters are not directly tied in parallel at the output terminals of their H-bridges.
Each of the distributed inverters is connected to the remote work coil via its own pair of matching inductors which ensure
that the total load is spread evenly among all of the inverters.
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These matching inductors also provide a number of additional benefits when inverters are paralleled in this way. Firstly,
the impedance BETWEEN any two inverter outputs is equal to twice the value of the matching inductance. This inductive
impedance limits the "shoot between" current that flows between paralleled inverters if their switching instants are not
perfectly synchronised. Secondly, this same inductive reactance between inverters limits the rate at which fault current
rises if one of the inverters exhibits a device failure, potentially eliminating failure of further devices. Finally, since all
distributed inverters are already connected via inductors, any additional inductance between the inverters merely adds to
this impedance and only has the effect of slightly degrading current sharing. Therefore the distributed inverters for
induction heating need not necessarily be located physically close to each other. If isolation transformers are included in
the designs then they need not even run from the same supply!
Fault tolerance
The LCLR work coil arrangement is very well behaved under a variety of possible fault conditions.
1. Open circuit work coil.
2. Short circuit work coil, (or tank capacitor.)
3. Shorted turn in work coil.
4. Open circuit tank capacitor.
All of these failures result in an increase in the impedance being presented to the inverter and therefore a corresponding
drop in the current drawn from the inverter. The author has personally used a screwdriver to short-circuit between turns of
a work coil carrying several hundred amps. Despite sparks flying at the location of the applied short-circuit, the load on the
inverter is reduced and the system survives this treatment with ease.
The worst thing that can happen is that the tank circuit becomes detuned such that its natural resonant frequency is just
above the operating frequency of the inverter. Since the drive frequency is still close to resonance there is still significant
current flow out of the inverter. But the power factor is reduced due to the detuning, and the inverter load-current begins to
lead the voltage. This situation is undesirable because the load current seen by the inverter changes direction before the
applied voltage changes. The outcome of this is that current is force-commutated between free-wheel diodes and the
opposing MOSFET every time the MOSFET is turned on. This causes a forced reverse recovery of the free-wheel diodes
whilst they are already carrying significant forward current. This results in a large current surge through both the diode and
the opposing MOSFET that is turning on.
Whilst not a problem for special fast recovery rectifiers, this forced recovery can cause problems if the MOSFETs intrinsic
body diodes are used to provide the free-wheel diode function. These large current spikes still represent a significant
power loss and threat to reliability. However, it should be realised that proper control of the inverter operating frequency
should ensure that it tracks the resonant frequency of the tank circuit. Therefore the leading power factor condition should
ideally not arise, and should certainly not persist for any length of time. The resonant frequency should be tracked up to its
limit, then the system shut-down if it has wandered outside of an acceptable frequency range.
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Power control methods
It is often desirable to control the amount of power processed by an induction heater. This determines the rate at which
heat energy is transferred to the workpiece. The power setting of this type of induction heater can be controlled in a
number of different ways:
1. Varying the DC link voltage.
The power processed by the inverter can be decreased by reducing the supply voltage to the inverter. This can be done by
running the inverter from a variable voltage DC supply such as a controlled rectifier using thyristors to vary the DC supply
voltage derived from the mains supply. The impedance presented to the inverter is largely constant with varying power
level, so the power throughput of the inverter is roughly proportional to the square of the supply voltage. Varying the DC
link voltage allows full control of the power from 0% to 100%.
It should be noted however, that the exact power throughput in kilowatts depends not only on the DC supply voltage to the
inverter, but also on the load impedence that the work coil presents to the inverter through the matching network.
Therefore if precise power control is required the actual induction heating power must be measured, compared to the
requested "power setting" from the operator and an error signal fed back to continually adjust the DC link voltage in a
closed-loop fashion to minimise the error. This is necessary to maintain constant power because the resistance of the
workpiece changes considerably as it heats up. (This argument for closed-loop power control also applies to all of the
methods that follow below.)
2. Varying the duty ratio of the devices in the inverter.
The power processed by the inverter can be decreased by reducing the on-time of the switches in the inverter. Power is
only sourced to the work coil in the time that the devices are switched on. The load current is then left to freewheel
through the devices body diodes during the deadtime when both devices are turned off. Varying the duty ratio of the
switches allows full control of the power from 0% to 100%. However, a significant drawback of this method is the
commutation of heavy currents between active devices and their free-wheel diodes. Forced reverse recovery of the free-
wheel diodes that can occur when the duty ratio is considerably reduced. For this reason duty ratio control is not usually
used in high power induction heating inverters.
3. Varying the operating frequency of the inverter.
The power supplied by the inverter to the work coil can be reduced by detuning the inverter from the natural resonant
frequency of the tank circuit incorporating the work coil. As the operating frequency of the inverter is moved away from
the resonant frquency of the tank circuit, there is less resonant rise in the tank circuit, and the current in the work coil
diminishes. Therefore less circulating current is induced into the workpiece and the heating effect is reduced.
In order to reduce the power throughput the inverter is normally detuned on the high side of the tank circuits natural
resonant frequency. This causes the inductive reactance at the input of the matching circuit to become increasingly
dominant as the frequency increases. Therefore the current drawn from the inverter by the matching network starts to lag
in phase and diminish in amplitude. Both of these factors contribute to a reduction in the real power throughput. In
addition to this the lagging power factor ensures that the devices in the inverter still turn on with zero voltage across them,
and there are no free-wheel diode recovery problems. (This can be contrasted with the situation that would occur if the
inverter were detuned on the low side of the work coil's resonant frequency. ZVS is lost, and the free-wheel diodes see
forced reverse-recovery whilst carrying significant load current.)
This method of controlling power level by detuning is very simple since most induction heaters already have control over
the operating frequency of the inverter in order to cater for different workpieces and work coils. The downside is that it
only provides a limited range of control, as there is a limit to how fast power semiconductors can be made to switch. This
is particularly true in high power applications where the devices may already be running close to maximum switching
speeds. High power systems using this power control method require a detailed thermal analysis of the results of switching
losses at different power levels to ensure device temperatures always stay within tolerable limits.
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For more detailed information about power control by detuning see the new section below labelled "LCLR network
frequency response."
4. Varying the value of the inductor in the matching network.
The power supplied by the inverter to the work coil can be varied by altering the value of the matching network
components. The L-match network between the inverter and the tank circuit technically consists of an inductive and a
capacitive part. But the capacitive part is in parallel with the work coil's own tank capacitor, and in practice these are
usually one and the same part. Therefore the only part of the matching network that is available to adjust is the inductor.
The matching network is responsible for transforming the load impedance of the workcoil to a suitable load impedance to
be driven by the inverter. Altering the inductance of the matching inductor adjusts the value to which the load impedance
is translated. In general, decreasing the inductance of the matching inductor causes the work coil impedance to be
transformed down to a lower impedance. This lower load impedance being presented to the inverter causes more power to
be sourced from the inverter. Conversely, increasing the inductance of the matching inductor causes a higher load
impedance to be presented to the inverter. This lighter load results in a lower power flow from the inverter to the work
coil.
The degree of power control achieveable by altering the matching inductor is moderate. There is a also a shift in the
resonant frequency of the overall system - This is the price to pay for combining the L-match capacitance and tank
capacitance into one unit. The L-match network essentially borrows some of the capacitance from the tank capacitor to
perform the matching operation, thus leaving the tank circuit to resonate at a higher frequency. For this reason the
matching inductor is usually fixed or adjusted in coarse steps to suit the intended workpiece to be heated, rather than
provide the user with a fully adjustable power setting.
5. Impedance matching transformer.
The power supplied by the inverter to the work coil can be varied in coarse steps by using a tapped RF power transformer
to perform impedance conversion. Although most of the benefit of the LCLR arrangement is in the elimination of a bulky
and expensive ferrite power transformer, it can cater for large changes in system parameters in a way that is not frequency
dependent. The ferrite power transformer can also provide electrical isolation as well as performing impedance
transformation duty to set the power throughput.
Additionally if the ferrite power transformer is placed between the inverter's output and the input to the L-match circuit its
design constraints are relaxed in many ways. Firstly, locating the transformer in this position means that the impedances at
both windings are relatively high. i.e. voltages are high and currents are comparitively small. It is easier to design a
conventional ferrite power transformer for these conditions. The massive circulating current in the work coil is kept out of
the ferrite transformer greatly reducing cooling problems. Secondly, although the transformer sees the square-wave output
voltage from the inverter, it's windings carry currents that are sinusoidal. The lack of high frequency harmonics reduces
heating in the transformer due to skin effect and proximity effect within the conductors.
Finally the transformer design should be optimised for minimum inter-winding capacitance and good insulation at the
expense of increased leakage inductance. The reason for this is that any leakage inductance exhibited by a transformer
located in this position merely adds to the matching inductance at the input to the L-match circuit. Therefore leakage
inductance in the transformer is not as damaging to performance as inter-winding capacitance.
6. Phase-shift control of H-bridge.
When the work coil is driven by a voltage-fed full-bridge (H-bridge) inverter there is yet another method of achieving
power control. If the switching instants of both bridge legs can be controlled independently then it opens up the possibility
of controlling power throughput by adjusting the phase shift between the two bridge legs.
When both bridge legs switch exactly in phase, they both output the same voltage. This means there is no voltage across
the work coil arrangement and no current flows through the work coil. Conversely, when both bridge legs switch in anti-
phase maximum current flows through the work coil and maximum heating is achieved. Power levels between 0% and
100% can be achieved by varying the phase shift of the drive to one half of the bridge between 0 degrees and 180 degrees
when compared to the drive of the other bridge leg.
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This technique is highly effective as power control can be achieved at the lower power control side. The power factor seen
by the inverter always remains good because the inverter is not detuned from the resonant frequency of the work coil,
therefore reactive current flow through free-wheeling diodes is minimised.
Induction Heating Capacitors
The requirements for capacitors used in high power induction heating are perhaps the most demanding of any type of
capacitor. The capacitor bank used in the tank circuit of an induction heater must carry the full current that flows in the
work coil for extended periods of time. This current is typically many hundreds of amps at many tens or hundreds of
kilohertz. They are also exposed to repeated 100% voltage reversal at this same frequency and see the full voltage
developed across the work coil. The high operating frequency causes significant losses due to dielectric heating and due to
skin effect in the conductors. Finally stray inductance must be kept to an absolute minimum so that the capacitor appears
as a lumped circuit element compared to the reasonably low inductance of the work coil it is connected to.
Correct choice of dielectrics and extended foil construction techniques are used to minimise the amount of heat generated
and keep effective-series-inductance to a minimum. However, even with these techniques Induction heating capacitors still
exhibit significant power dissipation due to the enormous RF currents they must carry. Therefore an important factor in
their design is allowing the effective removal of heat from within the capacitor to extend the life of the dielectric.
The following manufacturers produce purpose built components:
High Energy Corp. (UK distributer is AMS Technologies.)
Vishay Components.
Celem Power Capacitors. based in Israel.
Range of high power induction heating capacitors from High Energy Corp.
High power conduction cooled mica capacitor from Celem Power Capacitors.Celem
(Pictures courtesy of Steve Conner)
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Note the large surface area of the connection plates on the Celem conduction-cooled components and the reactive power
rating (KVAR) printed on the rating label. Higher power units pictured above in aluminium cases have connections for
water cooling hoses to remove the heat generated internally.
LCLR network frequency response
The LCLR network is a 3rd order resonant system consisting of two inductors, one capacitor and one resistor. The bode
plot below shows the way in which some of the voltages and currents within the network change as the drive frequency is
altered. The GREEN traces represent the current passing through the matching inductor, and therefore the load current
seen by the inverter. The RED traces represent the voltage across the tank capacitor, which is the same as the voltage
across the induction heating work coil. The top graph shows the AC magnitudes of these two quantities, whilst the bottom
graph shows the relative phase of the signals relative to the AC output voltage from the inverter.
From the amplitude part of the bode plot it can be seen that maximum voltage is developed across the work coil (top red
trace) at one frequency only. At this frequency current through the work coil is also maximum and the largest heating
effect is developed at this frequency. It can be seen that this frequency corresponds to the maximum load current drawn
from the inverter (top green trace.) It is worth noting that the magnitude of the inverter load current has a null at a
frequency only slightly lower than that which gives maximum heating. This plot shows the importance of accurate tuning
in an induction heating application. For a high Q system these two frequencies are very close together. The difference
between maximum power and minimum power can be only a few kilohertz.
From the bottom graph we can see that for frequencies below the maximum power point, the work coil voltage (green) is
in-phase with the output voltage from the inverter. As the operating frequency increases the phase angle of the work coil
voltage changes abruptly through 180 degrees (phase inversion) right at the point where maximum power is being
processed. The phase angle of the work coil voltage then remains shifted by 180 degrees from the inverter output voltage
for all frequencies above the maximum power point.
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From the bottom graph we can also see that the load current from the inverter exhibits not one but two abrupt phase
changes as the operating frequency is progressively increased. Inverter load current initially lags the inverter's output
voltage by 90 degrees at low frequencies. Load current abruptly slews through 180 degrees to a phase lead of 90 degrees
as the operating frequency passes through the "null frequency" of the network. Inverter current remains leading by 90
degrees until the maximum power point is reached, where it again abruptly slews through 180 degrees and returns to the
90 degree lagging phase once again.
When we consider that only current out of the inverter that is in-phase with the output voltage contributes to real power
transfer we can see that these abrupt transitions from -90 degrees to +90 degrees clearly need a more detailed
examination...
The bode plot above shows the area of interest around the null frequency and the maximum power point in more detail. It
also shows a family of curves depicting the behaviour of the induction heating tank circuit with a variety of different
workpieces present. This allows us to get a feel for how the network behaves with a large lossy workpiece to having no
workpiece present at all, and all loads in between.
With no workpiece installed, losses are low and Q factor is high. This gives rise to the sharply peaking currents and
voltages in the top graph, and the abruptly changing phase shifts in the bottom graph. As a lossy workpiece is introduced
the overall Q factor of the LCLR network falls. This causes less resonant rise in the inverter load current and the voltage
across the work coil. The resonant peaks become less tall, and broader as the Q factor falls. Likewise the phase of the
inverter current waveform and the work coil voltage slew less rapidly for lower Q factors.
From these graphs we can deduce a few implications for any control system that must track the resonant frequency of the
LCLR arrangement and control power throughput. Firstly there is more resonant rise in the LCLR network when there
is no workpiece present. Therefore the current delivered from the inverter should be decreased to prevent the work coil
and tank capacitor currents sky-rocketing in the absence of any significant loss in the system. Secondly, the inverter load
current with no load must be tracked very accurately if the inverter is not to see either a leading or lagging load current
because it slews so quickly through zero degrees.
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Conversely we can say that with a large lossy workpiece present, there will be less resonant rise inherent in the
LCLR arrangement and the inverter will have to supply more load current in order to achieve the required level of
current in the work coil. However, the control electronics now do not need to track the resonant frequency so closely
since the diminished Q gives a load current that shifts phase in a more leisurely manner.
Finally a number of points are worthy of consideration from the plot above when considering an automatic control
stratergy to track the resonant frequency of an LCLR induction heater. For very lossy workpiece materials, (or large
volumes of metal that introduce a significant overall loss) we can see that the inverter load current phase (bottom green
plot) sometimes fails to ever cross through zero degrees to leading phase. This means that the inverter load current with
heavy workloads cannot be in-phase and is always lagging by some amount. Furthermore the inverter load current is not
monotonic as frequency is swept. Therefore direct feedback from a Current Transformer (CT) on the inverter output is not
a viable option. Whilst it may appear to work fine with no workpiece fitted or only moderate heating loads, it does not
track the resonant frequency correctly and will fail to operate satisfactorily as the workload increases and network Q falls!
(Direct feedback from inverter output current using a CT to form a free-running power oscillator results in a design which
oscillates at low load but falls out of self-oscillation when the workload is increased.)
In contrast we can see that the work-coil voltage (and tank capacitor voltage) phase (bottom red plot) is monotonic with
increasing frequency. Furthermore it consistently passes through the -90 degree phase-lag point exactly at the frequency
which gives maximum power regardless of how heavily the work coil is loaded. These two merits make the tank capacitor
voltage waveform an excellent control variable. In conclusion the inverter frequency should be controlled so as to
achieve a consistent 90 degree lag between the tank capacitor voltage and the inverter output voltage in order to
achieve maximum power throughput. We can now label some areas of interest on the bode plot diagram below.
The white vertical line indicates the frequency at which the tank capacitor voltage (and also the work coil voltage) lag the
inverter output voltage by 90 degrees. This is also the point where maximum voltage is developed across the work coil and
maximum current flows through it. The white line is where you want to be to develop the maximum possible heating effect
in the workpiece. If we look at the inverter load current phase (bottom green plot) we can see that this is always between 0
degrees and -90 degrees when it crosses the white line no matter how abruptly or slowly it slews. This means that the
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inverter always sees a load current that is either in-phase or at worst slightly lagging in power factor. Such a situation is
ideal for supporting ZVS soft-switching in the inverter and preventing free-wheel diode reverse-recovery problems.
Looking to the right of the white line we have the area shaded in blue labelled "Inductive Load region." As the operating
frequency is increased above the maximum power point, the voltage across the work coil decreases and less heating effect
is generated in the workpiece. The inverter load current also falls and begins to lag in phase relative to the output voltage
of the inverter. These properties make the blue shaded region the ideal place to operate in order to achieve control over
induction heating power. By detuning the inverter drive frequency on the high-side of the maximum power point, power
throughput can be reduced and the inverter always sees a lagging power factor.
Conversely, to the left of the white line we have a band of frequencies labelled "Capacitive Load region." As the operating
frequency is decreased below the maximum power point, the work coil voltage also falls and less heating effect takes
place. However, this is accompanied by the inverter load current possibly slewing to a leading phase angle when losses in
the workpiece are low and Q factor is high. This is undesirable for many solid-state inverters as the leading load current
causes loss of ZVS and leads to forced reverse-recovery of free-wheeling diodes incurring raised switching losses and
voltage overshoots. Therefore the capacitive load region is not recommended for achieving power throughput control.
The vertical purple line marks the other end of the capacitive load region, where the inverter load current transitions again
to lagging "Inductive" load current. This second Inductive region is of little interest since it does not achieve significant
power throughput, and cannot be reached without passing through the potentially damaging capacitive load region
anyway. When the LCLR network is driven from a squarewave inverter voltage there is also risk of significant current
flow at a harmonic of the drive frequency. It is marked on the diagram here merely for completeness.
Note: The phase of the tank capacitor voltage was suggested as a control variable and discussed extensively in the plots
above. This is because this voltage can be easily sensed using a high-frequency voltage transformer and provides all the
necessary control information. Whilst it exhibits a 90 degree phase shift relative to the inverter output voltage (which may
at first appear undesirable) it is still a better control variable than trying to sense the tank capacitor current. Although the
tank capacitor current is in-phase with the inverter output this current can be many hundreds of amps making closed-core
ferrite CTs impractical. Furthermore the 90 degree phase shift of the tank capacitor voltage waveform means that it's zero
crossings are intentionally displaced in time away from the potentially noisy switching instants of the inverter. This -90
degree phase shift of the voltage feedback signal can be allowed for in the design of the control electronics and is a small
price to pay for the eased sensing and increased noise immunity gained.
Cooling requirements
#Add comments here about water cooling#
Heating pictures
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Waveforms
This shows the inverter output current waveform when driving the LCLR work coil arrangement close to its resonant
frequency. This point corresponds to maximum power throughput and therefore maximum heating effect. Note how the
inverter load current is almost a pure sinusoid.
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This shows the inverter output current waveform when driving the LCLR work coil arrangement substantially above its
natural resonant frequency. This operating point gives reduced power throughput and diminished heating effect. At
frequencies above the natural resonant frequency of the LCLR work coil arrangement the inductive reactance of the
matching network dominates and the inverter's load current lags the applied voltage. Notice the triangular load current
caused by the inductive load integrating the inverter's squarewave voltage output over time.
This shows the voltage across the work coil under normal operation when driven close to resonance. Notice that the
voltage waveform is a pure sinusoid in shape. This is also true for the current waveform and minimises harmonic radiation
and RF interference. In this case the voltage across the work coil is also higher than the DC bus voltage supplied to the
inverter. Both of these properties are attributed to the high-Q factor of the induction heating tank circuit.
This shows the output voltage from the inverter when it is mistuned to a frequency that is below the natural resonant
frequency of the work coil. Notice the very fast rise and fall times of the squarewave accompanied by excessive voltage
overshoot and ringing. These are all attributed to forced reverse-recovery of the MOSFET body diodes whilst enduring
this undesirable operating mode. (Overshoot and ringing is due to reverse recovery current spikes shock-exciting stray
inductance in the inverter layout into parasitic oscillation.)
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This shows the output voltage from the inverter when it is tuned very slightly above the natural resonant frequency of the
work coil. Notice that the rise and fall times of the squarewave are more controlled, and there is comparatively little
overshoot or ringing. This is due to the Zero Voltage Switching (ZVS) which takes place when the inverter runs in this
favourable operating mode.
This shows the output voltage from the inverter when it is tuned precisely to the resonant frequency of the work coil.
Although this situation actually achieves maximum power throughput, it does not quite achieve Zero Voltage Switching of
the MOSFETs. Notice the little notches on the rising and falling edges of the voltage waveform. These occur because the
mid-point of the bridge leg has not been fully commutated to the opposite supply rail during the dead-time before the next
MOSFET turns on. In practice a small amount of inductive reactance presented to the inverter helps provide the required
commutating current and achieve ZVS. For this reason the situation described for the previous photograph is preferable to
being precisely in tune.
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