Generator Power [kw]

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Dylan Warren
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2 PW3-25-SA/80 PW3-50-SA/80 PW3-100-SA/ Generator Power [kw]

3 100-SA/80 Generator Overall Dimensions 25-SA/80 and 50-SA/80 Generator

PWH-22 PWH-20 PWH-24 Capacity Output Power Dimensions (mm) Weight

34 PWH-20 14 2500 206 x 328x 256 24 PWH-24 8-16 1250 120 x 285 x 200

4 PWH-22 PWH-20 PWH-24 Capacity Output Power Dimensions (mm) Weight Model (uf) (KVAR) (W x L x H) (Kg) PWH x 328 x PWH x 328x PWH x 285 x PW3-100-SA/80 PW3-50-SA/80 PW3-25-SA/80 Magnetic Metals i.e. Carbon Steel C40, C45, AISI 420, Nickel PWH-20 PWH-24 PWH-24 Non Magnetic Metals i.e. Stainless Steel, Aluminum, Brass Copper PWH-22 PWH-20 PWH-20

Main Features SA Series Generators Automatic tracking and best optimization to load Constant, repeatable power generation via microprocessor control Continuous generation Minimum cooling water flow

5 Main Features SA Series Generators Automatic tracking and best optimization to load Constant, repeatable power generation via microprocessor control Continuous generation Minimum cooling water flow required High Safety: output isolated from the mains Highly integrated with a small footprint User Friendly Operations through graphical touch-screen interface Stainless Steel casing State-of-the-art electronics Built-in Self-diagnosis Compliant with the Regulations on Electrical Safety and Electromagnetic Compatibility Data Log System and built-in Web server Overall efficiency greater than 96% and maximum operational flexibility

Maximum operational Flexibility Main Features SA Series Generators Automatic tracking and best optimization to load The Auto-Learn Function allows Generator parameters

100% (linear) Resolution: - Digital 1% - Analog 0,1% Output Power Stability : ± 0,1 % Power Cable can be disconnected from Heating Head Standard Cable Length: 3meter

6 Maximum operational Flexibility Main Features SA Series Generators Automatic tracking and best optimization to load The Auto-Learn Function allows Generator parameters automatic tuning for low medium or high impedance loads Extended Working Frequency Range: khz Very wide coil admitted inductance range Output Power Set: from 2% to 100% (linear) Resolution: - Digital 1% - Analog 0,1% Output Power Stability : ± 0,1 % Power Cable can be disconnected from Heating Head Standard Cable Length: 3meter Custom Length: Upon Request Touch-screen interface (Web server) Continuous monitoring of: - Inductor Current - Inductor Voltage - Output Power - Working frequency - Heating Temperature

7 Main Features SA Series Generators Overall Efficiency greater than 96% New Stand Alone Generator Hardware Layout New Heating Head hardware layout To minimize the power loss on the capacitor block Automatic Best optimization to load In order to maximize the power transferred to the workpiece Minimum cooling water flow required Independent Generator+Heating Head and Coil cooling circuits. Two independent circuits with specific water flow and water temperature monitoring on each one) Focus on Generator and Coil Efficiency

Coil used for the test Coil 1 Coil 2 Coil 3 Coil 4 Coil 5 Coil # Ø internal [mm] Loops

8 Coil Efficiency Calculation Test Resume: The comparison will be carried out using different coils, and different metals. Coil used for the test Coil 1 Coil 2 Coil 3 Coil 4 Coil 5 Coil # Ø internal [mm] Loops number Copper Tubing [mm] Coil /8 Coil /8 Coil /8 Coil /6 Coil x6 140 mm 118 mm 95 mm Coil Øint Comparison Scale 1:20

Coil Efficiency Calculation Each Coil have been connected

Generator Measured Value: Resonant Frequency V1 (provided

the Sine Wave Signal, provided by the Function Generator

system (Head + Coil) V coil In resonant condition the two

9 Coil Efficiency Calculation Each Coil have been connected to a Heating Head (Capacitor Block) and fed by a Function Generator Measured Value: Resonant Frequency V1 (provided by Function Generator) V coil R 500 Ω V1 The Frequency of the Sine Wave Signal, provided by the Function Generator is manually tuned up to the resonant frequency of the L-C system (Head + Coil) V coil In resonant condition the two signals: V coil V1 = V Function Generator are in phase

The capacity of the Heating Head is known (i.e. 19 μf) Equivalent Circuit of Heating Head+Coil with no load (1) The resonant frequency is determined when the system is in resonant condition (i.

10 The capacity of the Heating Head is known (i.e. 19 μf) Equivalent Circuit of Heating Head+Coil with no load (1) The resonant frequency is determined when the system is in resonant condition (i.e. 28 khz) So the coil inductive value is calculated by the equation: 1 f resonant = 2π LC L = 1 4π 2 f 2 C = 1 4 3, ( ) V coil = 1,7 uh 19 μ

11 Equivalent Circuit of Heating Head+Coil with no load (2) Using the simulator LTSpice, we insert in the model the R resistor to calculate the losses on coil. The value of R is manually adjusted until the simulator calculates the same V coil as the measured one. R 3.95 m We find R= 3,95 m ohm

The head cooling water temperature increment (ΔT 1 ) and the coil cooling water (ΔT 2 ) are measured, by running the generator with the water connection indicated below.

12 The head cooling water temperature increment (ΔT 1 ) and the coil cooling water (ΔT 2 ) are measured, by running the generator with the water connection indicated below. Equivalent Circuit of Heating Head+Coil with no load (3) R 3.95 m We calculate ΔT 1 = 2,0 C ΔT 2 = 17,8 C ΔT 1 ΔT 2 Running the same current on L1 and C1 (resonant condition) it means that the losses on the coil are nearly 9 times higher than the losses on the head, in fact ΔT 1 ΔT 2 = 8,9

13 We add the resistor R3 to take in consideration the losses on the heating head. The resistor R2 allow the calculation of the losses on the coil only. The two resistors are in series so: R = R 2 + R 3 = 3,95 m ohm Final Equivalent Circuit of Heating Head+Coil with no load (4) and R 2 R 3 = 8,9 We obtain: R 2 = 3,55 m ohm R 3 = 0,40 m ohm This is the Mathematic Model of the system, with the coil empty. R 2 R 3 = ΔT 1 ΔT 2 = 8,9

course, compared with the previous case (empty coil), now the system works with: - Different Resonant

14 Now, following exactly the same procedure as before, we insert a metallic piece into the coil (i.e. carbon steel) and we calculate the new mathematic model, the new equivalent circuit Equivalent Circuit of Heating Head + Coil with Load (1) Of course, compared with the previous case (empty coil), now the system works with: - Different Resonant Frequency (a new L value has to be calculated; This is taken in account by paralleling the inductor L2) - Lower V coil (a new R2 value has to be calculated, we add R4 ) To simplify the calculation we consider that R3 remains constant In fact could be slightly affected by the different resonant frequency

This is final the equivalent circuit of the system: Heating Head + Coil + Work

WorkPiece We underline that the Mathematic model depends on the coil shape and

It is independent from the Induction Heating Generator used The same procedure has

15 This is final the equivalent circuit of the system: Heating Head + Coil + Work Piece Equivalent Circuit of Heating Head + Coil with Load (2) Head+ Coil + WorkPiece We underline that the Mathematic model depends on the coil shape and heating head used. It is independent from the Induction Heating Generator used The same procedure has been carried out placing into the coil metallic rods, with exactly the same diameter (Ø85mm) made of: - Carbon Steel - Stainless Steel AISI Copper - Brass

16 Coil #1 Loops: 3 Ø140mm 10/8mm tubing 19uF #2 Loops: 3 Ø118mm 10/8mm tubing 19uF #3 Loops: 3 Ø95mm 10/8mm tubing 19uF #4 Loops: 3 Ø95mm 8/6mm tubing 19uF #5 Loops: 1 Ø95mm 30x6mm tubing 19uF Parameters Empty Resuming Table Carbon Steel Stainless Steel Copper Coil Efficiency Calculation Brass Coil Parameters Empty Carbon Steel Stainless Steel Frequency [Hz] Frequency [Hz] V coil [V rms] 2,42 0,35 0,84 1,64 1,46 V coil [V rms] 1,44 0,21 0,49 0,95 0,85 #1 L tot [H] 1,76 E-06 1,64 E-06 1,44 E-06 1,45 E-06 1,45 E-06 Loops: 3 L tot [H] 1,75 E-06 1,67 E-06 1,44 E-06 1,44 E-06 1,44 E-06 L2 L Workpiece [H] 2,39 E-05 8,00 E-06 8,00 E-06 8,32 E-06 Ø140mm L2 L Workpiece [H] 3,99 E-05 8,20 E-06 8,09 E-06 8,28 E-06 R2 R coil [mω] 3,55 3,55 3,55 3,55 3,55 10/8mm tubing R2 R coil [mω] 2,85 2,85 2,85 2,85 2,85 R4 R Workpiece [mω] 22,25 5,6 0,7 1,55 42uF R4 R Workpiece [mω] 17,65 4,35 0,7 1,2 Power coil [KW] 100,0 13,8 38,8 83,5 69,6 Power coil [KW] 100,0 13,9 39,6 80,3 70,4 Powe Workpiece [KW] 0,0 86,2 61,2 16,5 30,4 Powe Workpiece [KW] 0,0 86,1 60,4 19,7 29,6 Frequency [Hz] Frequency [Hz] V coil [V rms] 2,21 0,20 0,41 1,15 0,98 V coil [V rms] 1,29 0,13 0,28 0,66 0,57 #2 L tot [H] 1,40 E-06 1,27 E-06 1,01 E-06 1,01 E-06 1,01 E-06 Loops: 3 L tot [H] 1,39 E-06 1,29 E-06 1,00 E-06 9,94 E-07 1,01 E-06 L2 L Workpiece [H] 1,33 E-05 3,54 E-06 3,57 E-06 3,67 E-06 Ø118mm L2 L Workpiece [H] 1,79 E-05 3,56 E-03 3,46 E-03 3,67 E-06 R2 R coil [mω] 3,03 3,03 3,03 3,03 3,03 10/8mm tubing R2 R coil [mω] 2,47 2,47 2,47 2,47 2,47 R4 R Workpiece [mω] 33,97 10,47 1,47 2,34 42uF R4 R Workpiece [mω] 24 6,73 1,175 1,86 Power coil [KW] 100,0 8,2 22,4 67,3 56,4 Power coil [KW] 100,0 9,3 26,8 67,8 57,0 Powe Workpiece [KW] 0,0 91,8 77,6 32,7 43,6 Powe Workpiece [KW] 0,0 90,7 73,2 32,2 43,0 Frequency [Hz] Frequency [Hz] L2 V coil [V rms] 1,84 0,11 0,18 0,52 0,44 V coil [V rms] 1,07 0,10 0,11 0,31 0,26 #3 L tot [H] 1,11 E-06 9,36 E-07 5,66 E-07 5,67 E-07 5,89 E-07 L tot [H] 1,10 E-06 1,02 E-06 5,74 E-07 5,64 E-07 5,85 E-07 Loops: 3 L Workpiece [H] 5,90 E-06 1,15 E-06 1,15 E-03 1,25 E-06 L2 L Workpiece [H] 1,49 E-05 1,20 E-06 1,16 E-06 1,26 E-03 Ø95mm R2 R coil [mω] 2,9 2,9 2,9 2,9 2,9 10/8mm tubing R2 R coil [mω] 2,4 2,4 2,4 2,4 2,4 R4 R Workpiece [mω] 48,1 15,1 2,8 4,2 42uF R4 R Workpiece [mω] 24,6 11,4 2,11 3,2 Power coil [KW] 100,0 5,7 16,1 50,9 40,8 Power coil [KW] 100,0 8,9 17,4 53,2 42,9 Powe Workpiece [KW] 0,0 94,3 83,9 49,1 59,2 Powe Workpiece [KW] 0,0 91,1 82,6 46,8 57,1 Frequency [Hz] Frequency [Hz] V coil [V rms] 1,73 0,10 0,14 0,43 0,36 V coil [V rms] 1,01 0,07 0,09 0,25 0,21 #4 L tot [H] 1,16 E-06 9,92 E-07 5,50 E-07 5,50 E-07 5,75 E-07 L tot [H] 1,15 E-06 1,07 E-06 5,66 E-07 5,44 E-07 5,77 E-07 Loops: 3 L2 L Workpiece [H] 6,69 E-06 1,04 E-06 1,04 E-03 1,14 E-06 Ø95mm L2 L Workpiece [H] 1,54 E-05 1,12 E-03 1,05 E-06 1,16 E-03 R2 R coil [mω] 3,35 3,35 3,35 3,35 3,35 8/6mm tubing R2 R coil [mω] 2,6 2,6 2,6 2,6 2,6 R4 R Workpiece [mω] 56,65 18,85 3,4 5,35 42uF R4 R Workpiece [mω] 39,4 14,2 2,65 4,1 Power coil [KW] 100,0 5,6 15,1 49,6 38,5 Power coil [KW] 100,0 6,2 15,5 49,5 38,8 Powe Workpiece [KW] 0,0 94,4 84,9 50,4 61,5 Powe Workpiece [KW] 0,0 93,8 84,5 50,5 61,2 Frequency [Hz] Frequency [Hz] V coil [V rms] 0,65 0,07 0,12 0,28 0,25 V coil [V rms] 0,35 0,05 0,09 0,16 0,15 #5 L tot [H] 1,84 E-07 1,49 E-07 1,09 E-07 1,13 E-07 1,16 E-07 L tot [H] 1,85 E-07 1,55 E-07 1,14 E-07 1,16 E-07 1,18 E-07 Loops: 1 L2 L Workpiece [H] 7,66 E-07 2,68 E-07 2,90 E-07 3,09 E-07 L2 L Workpiece [H] 9,51 E-07 2,93 E-07 3,06 E-07 3,22 E-07 Ø95mm R2 R coil [mω] 1,18 1,18 1,18 1,18 1,18 R2 R coil [mω] 1,143 1,143 1,143 1,143 1,143 30x6mm tubing R4 R Workpiece [mω] 10,52 3,66 0,73 1 R4 R Workpiece [mω] 7,157 1,957 0,457 0,717 42uF Power coil [KW] 100,0 35,7 48,3 68,5 66,5 Power coil [KW] 100,0 13,8 36,9 71,4 61,5 Powe Workpiece [KW] 0,0 64,3 51,7 31,5 33,5 Powe Workpiece [KW] 0,0 86,2 63,1 28,6 38,5 Copper Brass

Power to Workpiece [%] Coil Efficiency with 19 uf Heating Head 100,0 80,0 60,0 40,0 Carbon Steel 19 uf Stainless Steel 19 uf Copper 19 uf Brass 19 uf 20,0 0,0 1 2 3 4 5 Coil

17 Power to Workpiece [%] Coil Efficiency with 19 uf Heating Head 100,0 80,0 60,0 40,0 Carbon Steel 19 uf Stainless Steel 19 uf Copper 19 uf Brass 19 uf 20,0 0, Coil # Coil Øint Comparison Scale 1:20 Coil # Ø internal [mm] Loops number Copper Tubing [mm] Coil /8 Coil /8 Coil /8 Coil /6 Coil x6

Generator Parallel Resonance Generator Head + Coil + WorkPiece Example Coil 1x95 42uF with Cu workpiece Serial Resonance Generator Ideal Generator Head + Coil + WorkPiece Simulating the system in

18 Cable Cable Serial vs. Parallel Resonance The Mathematic Models determined are now used to calculate the: - Voltage - Current on the heading head cable to be provided by ideal Generators to deliver 100kW of Power: Ideal Generator Parallel Resonance Generator Head + Coil + WorkPiece Example Coil 1x95 42uF with Cu workpiece Serial Resonance Generator Ideal Generator Head + Coil + WorkPiece Simulating the system in order to absorb 100 kw from the Generator, we measure: - Voltage on the Head Cable= 415 V rms - Current on the Head Cable= 240 A rms We add the resistor (R capacitor) to calculate the losses on the capacitors block Simulating the system in order to absorb 100 kw from the Generator, we measure: - Voltage on the Head Cable= 416 V rms - Current on the Head Cable= 7950 A rms It s absolutely necessary to use a Transformer to reduce the current on the Head s Cable and on the active component as well

next page is explained how the losses on the Transformer have been calculated With this configuration: Simulating the system in order to absorb

19 Parallel Resonance Generator Serial Resonance Generator With this configuration: Simulating the system in order to absorb 100 kw from the Generator, we measure: - Voltage on the Head Cable= 390 V rms - Current on the Head Cable= 268 A rms - Current on the Load = 7380 A rms At the next page is explained how the losses on the Transformer have been calculated With this configuration: Simulating the system in order to absorb 100 kw from the Generator, we measure: - Voltage on the Head Cable= 2500 V rms - Current on the Head Cable= 513 A rms - Current on the Load = 6320 A rms

20 Series Resonant System : Matching Transformer Mathematic Model The magnetic losses (dispersed field) haven t been taken in consideration. So we consider: Reactive Power Transfer=100% Considering Active efficiency = 97% and connecting the transformer to a load that absorbs 6000 A, it means 30kW lost on a 1000 kw load

21 LT Spice software Running Simulation Example

Frequency Limit Results Coil Parameter Parallel Series Coil #6 Loops: 1 Øint=95mm 30x6mm Tubing (42 uf Head) material: COPPER Coil #6 Loops: 1 Øint=95mm 30x6mm Tubing (42 uf Head) material: Carbon

Head Cable [A rms] 256 526 Power Workpiece [kw] 83,8 77,8 Power Coil [kw] 13,4 12,4 Power Capacitors [kw] 2,4 Power Tranfromer [kw] 9,8 Resonant Frequency [khz] 62 62 Voltage on Head Cable [V rms]

22 Frequency Limit Results Coil Parameter Parallel Series Coil #6 Loops: 1 Øint=95mm 30x6mm Tubing (42 uf Head) material: COPPER Coil #6 Loops: 1 Øint=95mm 30x6mm Tubing (42 uf Head) material: Carbon STEEL Power Workpiece [kw] 25,3 18,3 Power Coil [kw] 63,3 45,6 Power Capacitors [kw] 11,1 Power Tranfromer [kw] 35,9 Resonant Frequency [khz] Voltage on Head Cable [V rms] Current on Head Cable [A rms] Power Workpiece [kw] 83,8 77,8 Power Coil [kw] 13,4 12,4 Power Capacitors [kw] 2,4 Power Tranfromer [kw] 9,8 Resonant Frequency [khz] Voltage on Head Cable [V rms] Current on Head Cable [A rms] Coil #6 Inductor holders length= 30mm Coil #4 Loops: 3 Øint=95mm 8/6mm Tubing (19 uf Head) material: COPPER Coil #4 Loops: 3 Øint=95mm 8/6mm Tubing (19 uf Head) material: Carbon STEEL Power Workpiece [kw] 47,8 44,5 Power Coil [kw] 47,1 43,9 Power Capacitors [kw] 5,6 Power Tranfromer [kw] 11,8 Resonant Frequency [khz] Voltage on Head Cable [V rms] Current on Head Cable [A rms] Power Workpiece [kw] 93,9 93,3 Power Coil [kw] 5,7 5,7 Power Capacitors [kw] 0,7 Power Tranfromer [kw] 1,5 Resonant Frequency [khz] Voltage on Head Cable [V rms] Current on Head Cable [A rms] Voltage Limit

23 Results Coil Parameter Parallel Series Coil #6 Loops: 1 Øint=95mm 30x6mm Tubing (42 uf Head) material: COPPER Coil #6 Loops: 1 Øint=95mm 30x6mm Tubing (42 uf Head) material: Carbon STEEL Power Workpiece [kw] 25,3 18,3 Power Coil [kw] 63,3 45,6 Power Capacitors [kw] 11,1 Power Tranfromer [kw] 35,9 Resonant Frequency [khz] Voltage on Head Cable [V rms] Current on Head Cable [A rms] Power Workpiece [kw] 83,8 77,8 Power Coil [kw] 13,4 12,4 Power Capacitors [kw] 2,4 Power Tranfromer [kw] 9,8 Resonant Frequency [khz] Voltage on Head Cable [V rms] Current on Head Cable [A rms] Coil #4 Loops: 3 Øint=95mm 8/6mm Tubing (19 uf Head) material: COPPER Coil #4 Loops: 3 Øint=95mm 8/6mm Tubing (19 uf Head) material: Carbon STEEL Power Workpiece [kw] 47,8 44,5 Power Coil [kw] 47,1 43,9 Power Capacitors [kw] 5,6 Power Tranfromer [kw] 11,8 Resonant Frequency [khz] Voltage on Head Cable [V rms] Current on Head Cable [A rms] Power Workpiece [kw] 93,9 93,3 Power Coil [kw] 5,7 5,7 Power Capacitors [kw] 0,7 Power Tranfromer [kw] 1,5 Resonant Frequency [khz] Voltage on Head Cable [V rms] Current on Head Cable [A rms] % efficiency

CEIA Generator structure Head + Coil + WorkPiece Ideal Current Generator connected

Coil + WorkPiece Schematic layout Matching Network Matching Network Automatic

insulator transformer Load Matching and User Safety.

24 CEIA Generator structure Head + Coil + WorkPiece Ideal Current Generator connected to load Ideal current generator CEIA Generator Output Transformer Head Cable Head + Coil + WorkPiece Schematic layout Matching Network Matching Network Automatic Selection of the most suitable: - Generator Output impedance - Working Band Galvanic insulator transformer Load Matching and User Safety. The operator is physically isolated from the power supply line Possible Settings: - 4:2-4:3-4:4 Low/Medium /High Impedance

Output Power [kw] 105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 AUTOLEARN Function Impedance Adaption, Output Transformer Setting Generator Output Power vs.

25 Output Power [kw] AUTOLEARN Function Impedance Adaption, Output Transformer Setting Generator Output Power vs. Coil Voltage Coil Voltage [V rms] Trasf High Impedance Setting 4:4 Trasf Med Setting Impedance 4:3 Trasf Low Setting Impedance 4:2

26 P [kw] PW3-100-SA/80 Generator Output Power vs. Working Frequency and Load Impedance R [Ohm] f [khz]

27 P [kw] P [kw] PW3-50-SA/80 PW3-50-SA/80 vs. PW3-720/50 Generator Output Power vs. : - Working Frequency - Load Impedance Very wide Band Adjustment R [Ohm] f [khz] PW3-720/50 PW3-720/50 Output transformer setting 16:6 R [Ohm] f [khz]

POWER CUBE SA/80 series

POWER CUBE SA/80 series The 100, 50, 25 kw Green Generators Features / Benefits High Power output High level of performance with minimal operating costs Automatic tracking and best optimization to load