Three-Phase High Frequency AC Conversion Circuit with Dual Mode PWM/PDM Control Strategy for High Power IH Applications

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1 Interntionl Journl of Electricl nd Electronics Engineering 3: 009 hree-phse High Frequency AC Conversion Circuit with Dul Mode /PDM Control Strtegy for High Power IH Applictions Nbil A. Ahmed Abstrct his pper presents novel three-phse utility frequency to high frequency soft switching power conversion circuit with dul mode pulse width modultion nd pulse density modultion for high power induction heting pplictions s melting of steel nd non ferrous metls, nneling of metls, surfce hrdening of steel nd cst iron work pieces nd hot wter producers, stemers nd super heted stemers. his high frequency power conversion circuit cn operte from three-phse systems to produce high current for high power induction heting pplictions under the principles of ZVS nd it cn regulte its c output power from the rted vlue to low power level. A dul mode modultion control scheme bsed on high frequency in synchroniztion with the utility frequency positive nd negtive hlf cycles for the proposed high frequency conversion circuit nd utility frequency pulse density modultion is produced to extend its soft switching operting rnge for wide c output power regultion. A dul pcks het exchnger ssembly is designed to be used in consumer nd industril fluid pipeline systems nd it is proved to be suitble for the hot wter, stem nd super heted stem producers. Experiment nd simultion results re given in this pper to verify the opertion principles of the proposed c conversion circuit nd to evlute its power regultion nd conversion efficiency. Also, the pper presents mutul coupling model of the induction heting lod insted of equivlent trnsformer circuit model. Keywords Induction heting, three-phse, conversion circuit, pulse width modultion, pulse density modultion, high frequency, soft switching. I I. INRODUCION NDUCION heting (IH) is one of wide rnge of electricl het used in industry nd household tody. he min pplictions of the process re in the food processing nd cooking pplinces, hot wter, stem nd super heted stem producers, steel nd metl working industries. Clen nd fst het being supplied to the heted work piece meets the considerbly incresed requirements with regrd to environmentl protection. he surroundings re not exposed to ny therml nd tmospheric pollution. he prticulr dvntge of this process is to produce the het inside the work piece without the need for ny externl het source []- [5]. According to the physicl lw of induction n lternting Nbil A. Ahmed is with the Electricl Engineering Deprtment, College of echnologicl Studies, Public uthority of Applied Eduction nd rining, Kuwit on leve from the Electricl Engineering Deprtment, Assiut University, Assiut 756, Egypt (phone: ; fx: ; e- mil: n.hmed@pet.edu.kw). mgnetic field is generted round ech electricl conductor through which n lternting current is flowing. By considerbly incresing these mgnetic fields, metls brought into close proximity will be heted by eddy currents produced within the metl. Heting by induction mkes use of the cpbility of the mgnetic field to trnsmit energy without direct contct. his mens heting is not done by contct trnsmission such s known in resistnce heting in light bulbs, heting pltes or electricl furnces where the direct current flow cuses resistnce wires to glow. A bsic problem of induction heting is to crete sufficiently intense electro-mgnetic field nd to position the component to be heted within the center of the field in such wy s to obtin optimum trnsmission of energy from the electricl conductor to the work piece. Normlly this is chieved by forming the electricl conductor lso referred to s inductor or coil with one or more turns. he work piece is positioned in the centre of the coil, thus concentrting the mgnetic field onto the component. he field will then force the electricl current to flow within the work piece. According to the lw of trnsformtion, the strength of the current flow in the component is equl to tht in the coil. o crete sufficiently strong mgnetic field, the current flow in the coil must be very high (000 0A). Another method of creting strong lternting mgnetic field is to increse the frequency of the current. Depending upon the ppliction, induction heting equipment cn be roughly clssified into low frequency nd high frequency (0kHz or more). hese high frequencies, which re not vilble from the norml mins electricl supply, re obtined by mens of high frequency conversion circuits [6]-[7]. It my be sked why such lrge frequency rnge is necessry nd why not ll induction heting processes cnnot be crried out t the sme frequency. his is due to physicl reson s well, i.e. the so clled skin effect. he electricl current flows into the outer skin of the work piece only, this mens the center of the work piece remins theoreticlly cold. he thickness of the lyer in which the current flows in turn is dependent on the frequency. At low frequencies, the lyer is thick, i.e. the work piece is penetrted by the current lmost to the centre, nd consequently heted through. At very high frequencies, the current flows t the surfce only nd the penetrtion depth is in the rnge of 0 to mm. his effect is mde using the frequency pproprite for the ppliction [8]. 73

2 Interntionl Journl of Electricl nd Electronics Engineering 3: 009 Fig. shows the reltion between the penetrtion depth nd the working temperture s function of the working frequency in steel. Pentrtion depth in mm kHz 0kHz 30kHz 00kHz 00kHz emprture in o C Fig. Penetrtion depths for different frequencies in steel he most common pplictions utilizing induction heting technology re: Melting of steel nd non ferrous metls t tempertures up to 500 C. Heting for forging to tempertures up to 50 C. Anneling nd normlizing of metls fter cold forming using tempertures in the rnge of C. Surfce hrdening of steel nd cst iron work pieces t tempertures from C (tempering C) nd soft nd hrd soldering t tempertures up to 00 C, moreover, specil pplictions such s heting for sticking, sintering. Hot wter, stem nd super heted stem producers. Food processing nd cooking pplinces. While for melting, forging nd nneling mostly medium frequency is used s energy source, for hrdening nd soldering pplictions it depends on the requirements whether high or medium frequency cn or is to be used. here is wide rnge of IH conversion circuits vilble in the mrket for IH pplictions, with power levels rnging from hundreds of wtts to severl kilowtts. For typicl pplictions, the typicl power level is kw. However, the mrket for IH pplictions is growing quickly, s is the power level required for such pplictions. A typicl block digrm of conventionl IH power conversion circuit supplied by n c power source, which cn be either single- or three-phse bus, consists of three stges of power conversion. he power is first processed by rectifier circuit to obtin dc voltge represented by single- or three-phse diode rectifier. Ech IH power conversion consists of smoothing stge nd high frequency inversion stge to provide high frequency power to the IH pplictions. Besides supplying power to the IH lod, the power conversion, for instnce, is lso used to regulte its output power. However, the hrmonic distortion inherently produced in the commercil c input utility side due to the rectified dc smoothing voltge link with electrolytic smoothing cpcitor. In ddition, the significnt problems on power conversion efficiency, volumetric physicl size s relibility nd life of the electrolytic cpcitor dc link power stge hve ctully ppered by using the electrolytic cpcitor bnk or ssembly for the dc voltge smoothing [6]- [8]. For the next genertion of high-power IH pplictions, not only the overll performnce but lso the cost of the entire system will be importnt issues to be considered during the design process. he power conversion circuit for IH pplictions must chieve high efficiency, low hrmonic distortion, high efficiency, high power density, high relibility nd low electromgnetic interference (EMI) noise. o reduce the cost of the IH pplinces, the power conversion circuit must be inexpensive, while still complying with stndrds for hrmonic distortion. One of the conventionl prctices, commonly used, is the use of one-stge pproch bsed upon utility frequency to high frequency conversion circuit by eliminting the rectifiction nd smoothing stges, wheres meeting hrmonic current stndrds such s the IEC In this wy, the intermedite smoothing bus cpcitor cn be eliminted, s discussed in previous ppers [9]-[]. his pper presents possible pproch for reducing the cost of the IH conversion circuit by connecting the three outputs of the single-phse modules of previously developed utility frequency to high frequency conversion circuits, which is suitble for high power IH pplictions operting from three-phse systems s het tretments of metls or super heted stem producers. It is one-stge high-frequency conversion circuit, composed of three single-phse modules of previously developed utility frequency to high frequency power converter []. Soft switching opertion, high current nd high power conversion efficiency re the min fetures of the proposed high frequency conversion circuit. In ddition, prlleling decreses the power dissiption nd current per module becuse ech module is required to hndle less power in the system, which helps simplify therml design []. II. MODELING OF IH LOAD A. rnsformer Circuit Model he equivlent trnsformer circuit model of the IH lod cn be represented s shown in Fig., where L is the selfinductnce of the IH work coil nd defined by the high frequency mgnetic flux cused by the inverter current, L nd M re the secondry side nd the mutul inductnces of the trnsformer, respectively. R is the resistnce of the IH lod which its vlue depends on the operting frequency. With neglecting the internl resistnce of the IH work coil, the following circuit equtions cn be derived s follow: 74

3 Interntionl Journl of Electricl nd Electronics Engineering 3: 009 v L jωl I jωmi L L + jωmi L = V L + ( jωl + R ) I L il il L M L = 0 v L R Fig. rnsformer model of induction heting lod Observing the bove eqution nd rerrnging, the following eqution cn be obtined, VL ω M R LR + ω L ( L L M ) = + jω () I R + ω L R + ω L L he rel nd imginry prts of the bove eqution cn be represented by R nd jω L, s follows: ω M R R = R + ω L (3) ω LM L = L R + ω L As result, the equivlent electricl model of the IH lod s shown in Fig. cn be represented by R nd L which cn be mesured experimentlly. B. Mutul Coupling Model he trnsformer electromgnetic mutul coupling coefficient k nd time constnt of the IH lod τ cn be defined s; M k = L L (4) L τ = R For time constnt τ of the IH lod, the circuit behvior of the IH lod is the sme for ny vlue of L nd R. herefore, it is better to represent the IH lod by using the prmeters L, k nd τ defined in (4) insted of using the circuit prmeters of the equivlent trnsformer circuit model of the IH lod s depicted in Fig., where L cn be esily mesured insted of L, M nd R which cnnot be esily mesured. If k nd τ defined by (4) re represented by the mesurble prmeters R, L nd L, the opertion of the inverter circuit with the IH lod nlysis will become much more simple. he following eqution cn be defined from (3) s, () M R ( R + ω L ) ω R = (5) From (3) nd (5), the following eqution cn be written, R ( L L ) = R L (6) where τ = L / R, so the time constnt τ of the IH lod cn be redefined s; L L τ = (7) R herefore, the time constnt τ cn be estimted by using the mesurble prmeters R, L nd L. he resistnce R cn be obtined by using (6) s follow: RL R = (8) L L By substituting R in (8) to (3) nd multiplying the resultnt eqution by / L, the following eqution is derived; M L L R + ω ( L L ) = ω L ( L L ) he trnsformer electromgnetic mutul coupling coefficient τ is represented by the mesurble circuit prmeters R, L nd L s, k = R + ω ( L L ) ω L ( L L ) (9) (0) he k nd τ re clculted by the experimentlly mesurble prmeters R, L nd L s described in (7) nd (0) nd function of the operting frequencyω = πf. In the experimentl work, the following prmeters hve been mesured by using the high frequency liner power mplifier (NF Circuit Design Block Co. Ltd, type 450) t the frequency 0kHz s L = 90μH ; L H = 78μ ; R =. 3Ω. he circuit prmeters of IH lod is considered constnt s the output frequency of the conversion circuit is kept constnt in spite of output power regultion. III. ASSEMBLY OF HEA EXCHANGER he ppernce of newly proposed dul pcks fluid het (DPH) exchnger driven by the proposed high frequency power conversion circuit is depicted in Fig. 3. his new spirl structure DPF het exchnger works s het exchnger, with n end ring from low resistnce mteril, formed spirlly by thin plte of nonmgnetic stinless steel SUS36, which is inserted into the non metl vessel. he non-mgnetic mteril SUS304 is selected s mteril for the IH-DPH device due to the dvntges it hs such s uniform temperture distribution, excellent corrosion protection for low pressure moving in pipeline (wter, vpor, gs, nd powder). he work coil uses enmel copper wire twisting together 75

4 Interntionl Journl of Electricl nd Electronics Engineering 3: 009 nd isolted from ech other. his work coil is clled litz wire for power. In this IH heting device (see Fig. 3), thermlly stble temperture of this wire is bout 70 degrees centigrde. Actully, the wter tube prt is not over 0 degrees centigrde, becuse the het insulting mteril is pcked in IH-DPFH hot-wter producer between work coil nd IH heting element. his IH exchnger is bsed on the mechnism, which hets the low pressure continuous movement fluid in the pipeline tube by the het exchnging ction between IH heting element nd fluid using the developed high frequency conversion circuit. herefore, thermlly stble temperture is lso necessry for the pipeline tube. he fluid heting vessel tube uses the polycrbonte, nd thermlly stble temperture is below 0 degrees centigrde. Br ring Work coil Outut fluid Spirl type DP heter v Heting vessel High frequency conversion circuit vb vc hree Input fluid utility - frequency phse Fig. 3 Internl structure of DPFH exchnger ech single-phse module. he gting pulses re synchronized with the positive nd negtive hlf cycles of the corresponding phse voltge nd they hve to be exchnged every hlf cycle in synchronism with the polrity of the utility phse voltge to supply the desired power to the IH lod. In ddition, ded time d is necessry between the gting signls of ech phse power switching devices to void shout through. he gting signl timing sequences during the positive nd negtive hlf cycles of phse re shown in Fig. 5. he output power is controlled by controlling the duty cycle d s given in (), which is determined by the durtion of the on time on of the min power switch to the high frequency switching period. By introducing this control strtegy, the proposed threephse high frequency conversion circuit enbles to supply the desired output high frequency power with ZVS opertion to the IH lod. L D D b C C S C o S D D Hz V v IH Lod Fig. 4 High power IH conversion circuit using three single-phse modules connected to the sme output R L IV. HREE-PHASE HIGH FREQUENCY CONVERSION CIRCUI A. Circuit Description he novel circuit configurtion of three-phse utility frequency to high frequency soft switching power conversion circuit proposed for high current IH pplictions is shown in Fig. 3. hree modules of singe-phse utility frequency to high frequency power converter is connected individully to ech phse of the three-phse supply from one side nd connected in prllel from the other side to the sme terminls of IH lod. Ech single-phse module is composed of two power switching devices Q (S /D ) nd Q (S / D ), two diodes D nd D b, filter inductor L in utility AC input-side, two cpcitors C nd C s ctive clmp resonnce in ccordnce with IH lod, low pss filter nd lossless qusi-resonnt snubber cpcitor C o. he work described herefter concentrtes on the three-phse topology of the conversion circuit. he opertion modes re not discussed in this pper, s they hve lredy been pproched by the previous work [4] Vg Vg d on d on Positive hlf cycle Vg Vg d d on on Negtive hlf cycle Fig. 5 Gting signls of control scheme d = on () V. DUAL MODE CONROL he proposed three-phse utility frequency to high frequency soft switching power conversion circuit uses dul mode control of combining conventionl nd PDM control for gting the power switching devices S nd S of Fig. 6 Pulse density modultion control ( d =0.7) PDM 76

5 Interntionl Journl of Electricl nd Electronics Engineering 3: 009 Besides to the control, the proposed three-phse high frequency conversion circuit uses pulse density modultion (PDM) or utility voltge integrl-cycle control t low output power levels to extend the soft switching opertion rng. In the PDM control the IH lod current is gted to flow from the utility supply for n integrl number of cycles (ON period) nd then quenched for few further number of complete cycles (OFF period) s depicted in Fig. 6 for control period of 0 cycles utility power. he ZVS-bsed utility frequency AC-PDM time rtio s control vrible d PDM is defined s given in (). hus, the effective IH lod voltge is vried by controlling the rtio of the ON to the OFF cycles nd the PDM duty cycle cn be given s = () on off d on PDM + In ddition, the proposed three-phse high frequency conversion circuit cn lso regultes its high-frequency output power on the bsis of dul-mode control of nd PDM control under condition of complete ZVS conditions. experimentl voltge nd current opertion wveforms s it illustrted in Fig. 8. d=0.4 d=0.3 d=0. d=0. Fig. 7 Input (phse ) voltge nd current wveforms for different duty cycles VI. SIMULAION AND EXPERIMENAL RESULS he design specifictions nd circuit prmeters of the experimentl setup of the proposed three-phse utility frequency to high frequency conversion circuit using IGB modules re indicted in ble I. he simultion nd experimentl results re described in the following. ABLE I DESIGN SPECIFICAION AND CIRCUI PARAMEERS Item Symbol Vlue vq iq vq vq iq vq hree-phse utility voltge Filter nd resonnt cpcitors Lossless snubbing qusi-resonnt cpcitor C v c 380V, 60 Hz C, C o Inductor of utility side filter L Effective resistnce of IH lod R Effective Inductnce of H lod L Switching frequency f s Ded ime t d 5 μf 0.μF.0mH.65Ω 34.5μH 0 khz μs Fig. 7 shows input voltge nd current (phse ) wveforms of the proposed high frequency conversion circuit for different vlues of duty cycles d of 0.4, 0.3, 0. nd 0. respectively. he relevnt simulted nd mesured soft switching operting voltge nd current wveforms ner the pek vlue of utility voltge wveform for control of the high frequency conversion circuit set up in cse of duty fctor d = 0.5 re shown in Fig. 8. A very good qulity nd quntity greement is obtined between the simultion nd iq Simultion iq Experimentl v Q, v Q : 00[V/div], v RL : 50[V/div], i Q, i Q, i RL : 00[A/div], ime: 0[μs/div] Fig. 8 Soft switching voltge nd current wveforms in control, d = 0.5. From Fig. 7, it is cler to note tht the input current wveform is much distorted t low duty cycles d = 0.. herefore, the control is more effective nd suitble for high output power rnges of the proposed high frequency conversion circuit. However, the ZVS commuttion opertion cn be relized over ll the output power regultion re on 77

6 Interntionl Journl of Electricl nd Electronics Engineering 3: 009 the bsis of dul mode control implementtion in cse of low power setting re using the utility frequency AC-PDM-ZVS control nd the symmetricl control in cse of high power setting re. he chnging point of symmetricl nd utility frequency AC PDM in this high frequency cycloinverter is set to be t duty rtio of d = 0.3. In ll the high frequency AC power regultion rnges, this high frequency cycloinverter opertes in soft switching commuttion by chnging the control scheme chnging from symmetricl control to PDM control t low duty rtios. he simulted nd mesured operting wveforms in cse of dul-mode control in cse of d = 0.3 nd d PDM = 0.5 re comprtively illustrted in Fig. 9. re. he soft switching opertion rnge cn be expnded s shown in Fig.. he high frequency cycloinverter controlled by dul-mode control of the symmetricl control nd the utility frequency AC-PDM control opertes completely in soft switching opertion mode even in low power setting re. herefore, the output power of this proposed high frequency power conversion circuit cn be regulted up to bout 50 W with ZVS soft switching opertion using dul mode nd utility frequency PDM control. 0 ZVS Are 8 vq iq vq iq Input power [kw] 6 4 vq iq vq iq Duty cycle Fig. 0 Input power vs. duty cycle chrcteristic with control ZVS Are Simultion Experimentl v Q, v Q : 00[V/div], v RL : 50[V/div], i RL : 00[A/div], i Q 50[A/div], i Q : 60[A/div], ime: 40[μs/div] Fig. 9 Soft switching voltge nd current wveforms in cse of dulmode control, d =0.3, d =0.5. PDM he input power vs. the duty fctor chrcteristics of this high frequency converter circuit under symmetricl control is depicted in Fig. 0. While, Fig. shows the input power vs. the pulse density modultion chrcteristics of this high frequency converter circuit under the principle of dulmode of symmetricl nd pulse density control in cse of d = 0.3. he soft switching opertion re of the high frequency converter circuit is lso illustrted in Figs. 0 nd. In Fig. 0, the high frequency cycloinverter controlled by the symmetricl ZVS- technique opertes in hrd switching commuttion opertion mode in low power setting Input power [kw] Pulse density duty cycle Fig. Input power vs. ZVS-PDM chrcteristics in cse of dul-mode control, d =0.3. Fig. illustrtes the power conversion efficiency chrcteristics of the proposed three-phse high frequency conversion circuit under control nd dul-mode control. It is cler to note tht the ctul efficiency might be reduced in the low power setting re, due to the hrd switching opertion in low power setting rnge. he high conversion efficiency over 93% cn be lmost mintined when the dulmode control of nd utility frequency PDM is used for low power setting re nd the proposed conversion circuit cn operte under condition of complete ZVS conditions in 78

7 Interntionl Journl of Electricl nd Electronics Engineering 3: 009 ll high frequency power regultion re. herefore, the dul mode /PDM is more effective to put it into prcticl use for the high-efficient power control implementtion. Efficiency % control /PDM control Input power [kw] Fig. Actul power conversion efficiency vs. output power chrcteristics with nd PDM control [5] S. Hinchliffe nd L. Hobson, Review of solid stte devices nd circuits for HF Electric Process Heting Applictions: Prt_ circuit, Int'l Journl of Electronics, vol. 6, no. 3, pp. 6-79, 986. [6] L. Mlesni, P. enti, High Efficiency Qusi-Resonnt DC Link hree- Phse Power Inverter for Full- Rnge, IEEE rns. on Industril Applictions., vol. 3, no., pp.4-47, 995 [7] E. Hirki, S. Ngi, Present Sttus nd Future Development of High- Frequency Pulse Modulted Soft Switching Inverter, Proc. of Ntionl Conventionl Meeting IEE-Jpn, vl.4, no. 8, pp. 9-3, Mrch 004. [8] W. C. Morelnd, "he Induction Rnge: Its Performnce nd its Development Problems", IEEE rns. on Industry Applictions, vol. IA- 9, pp.8~85, 973. [9] Y. D. Son, Design of Single-Stge Electronic Bllst using Hlf- Bridge Resonnt Inverter, KIEE Interntionl rnsctions on Electricl Mchinery nd Energy Conversion Systems, vol., B-3, pp. 04-, 00. [0] Nbil A. Ahmed nd Mutsuo Nkok, Boost-Hlf Bridge Edge Resonnt Soft Switching High Frequency Inverter for Consumer Induction Heting Applinces, IEE Proceedings Electric Power Appliction, vol. 53, no. 6, pp , November/December, 006. [] H. Sugimur, Nbil A. Ahmed,. Ahmed, H. W. Lee, M. Nkok, Utility AC Frequency to High Frequency AC Power Conversion Circuit with Soft Switching Strtegy, KIEE Interntionl rns. on Electricl Mchinery nd Energy Conversion Systems, vol. 5-B, no., pp. 8-88, 005. [] W. A. bisz, M. Jovnovic nd F. C. Lee, Present nd Future of Distributed Power Systems, Proc. of IEEE Applied Power Electronics Conference, APEC 99, pp. -8. VII. CONCLUSION In this pper, novel circuit topology of three-phse utility frequency to high frequency soft switching power conversion circuit with dul mode pulse width modultion nd utility frequency pulse density modultion for high power induction heting pplictions hs been newly proposed. his high frequency power conversion circuit is tested with dul pcks fluid heter het exchnger designed for the hot wter, stem nd super heted stem producers, nd it proves the fetures of compctness, low cost, high relibility, high efficiency nd long life. High power conversion efficiency over 93% hs been obtined with dul-mode control. Experiment nd simultion results re given to verify the opertion principles nd to evlute its power regultion nd conversion efficiency. he induction heted lod is represented using mutul coupling model insted of equivlent trnsformer circuit model. REFERENCES [] B. K. Lee, J. W. Jung, B. S. Suh, nd D. S. Hyun, A New Hlf-Bridge Inverter opology with Active Auxiliry Resonnt Circuit Using Insulted Gte Bipolr rnsistors for Induction Heting Applinces, Proc. of IEEE Power Electronics Specilists Conference, PESC'99, vol., pp. 3-37, June, 999. [] H. eri, H. Sdkt, H. Omori, H. Ymshit, nd M. Nkok, High Frequency Soft Switching Inverter for Fluid-Heting Applince Using Induction Eddy Current-bsed Involuted ype Het, Proc. of IEEE Power Electronics Specilists Conference, PESC'0, vol. 4, pp , Cirns, Austrli, June, 00. [3] Nbil A. Ahmed,. Iwi, H. Omori, H. W. Lee nd M. Nkok "A Novel Auxiliry Edge-Resonnt Snubber-Assisted Soft Switching High Frequency Inverter with Series Cpcitor Compensted Resonnt Lod for Consumer Induction Heting", KIPE J. Power Electronics, vol. 6, no., pp , April 006. [4] S. Hinchliffe nd L. Hobson, "Review of Solid Stte Devices nd Circuits for HF Electric Process Heting Applictions", Prt_ devices, Int'l Journl of Electronics, vol. 6, no., pp.43-67,

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