Induction and direct resistance heating theory and numerical modeling pdf

Design and fabrication of inductors for induction heat. What, then, is the effect of resistance on power consumption. Another field of frequent use of numerical simulations is induction heating for surface hardening where local surface heating only to a certain depth is required. Magnetic fields and induced power in the induction heating of aluminium billets. Using numerical methods to design and control heating induction systems 105 it is necessary to point out that all the turns of the heating coil has to be defined as a circuit in femm to accomplish correctly the simulation see circuits in femm manual. Theory of heating by induction 7 tromagnetic, or flux around it. Theory and calculation of induction heating devices. Numerical techniques for optimization of 3d induction heating systems s. Fem modeling of a continuous induction heating process of. By comparing the results of the experiment and the numerical. Numerical simulation of induction heating enables optimisation of the process variables. Due to the inherent resistance of the charge, there is heat produced in the charge itself. In fact, resistance and current are inversely proportional in this case.

Unit 16 electric motors washington state university. Numerical simulation of electromagnetic induction heating in. Analytical and fem modeling of aluminum billet induction heating with. This book offers broad, detailed coverage of theoretical developments in induction and direct resistance heating and presents new material on the solution of problems in the. Stanford libraries official online search tool for books, media, journals, databases, government documents and more. The basic principles of induction heating have been understood and applied to manufacturing since the 1920s. The physical basis of induction and conduction heating processes is explained and. Induction and direct resistance heating theory and numerical. Induction motors are the commonest type of motor and account for a very large proportion of heavy duty motors. This chapter deals with direct resistance heating drh installations used for heating electrical conductive materials, metallic or nonmetallic, by means of an electrical current flowing directly in the workpiece to be heated. Record all nameplate information for the induction motor.

Aspects regarding numerical modeling of inductive heating process for low voltage 241. Theory and numerical modeling or any other file from books category. Theory and numerical modeling sergio lupi, michele forzan, aleksandr aliferov auth. In the direct resistance heating, the current flows directly through the substance to be heated. Electric resistance heating is 100% energy efficient in the sense that all the incoming electric energy is converted to heat. The first is conduction, which is defined as transfer of heat occurring through intervening matter without bulk motion of the matter. What is common to all the members of this family is that the basic. Considerable differences between simulations were obtained and therefore temperaturedependent material properties are recommended to use when modeling induction heating. Parameter optimization and prediction model of induction. Induction heating ih is a multiphysical phenomenon comprising a complex interac. Local heat treatmend by induction on repair welded aerospace components is one example of induction heating in manufacturing. The induction heating calculation, especially the direct calculation of the.

Hulko1 1institute of automation, measurement and applied informatics, faculty of mechanical engineering, stu bratislava, slovak republic abstract this paper deals with numerical modeling of modular industrial induction heating of steel. Highfrequency heating in the highfrequency heating methods, the electromagnetic energy converted into the heat energy in side the material. Induction cooking is performed using direct induction heating of cooking vessels, rather than relying on indirect radiation, convection, or thermal conduction. Numerical investigation of an inhomogeneous conduction heating. A coil, suitably dimensioned, placed close to the metal parts to be heated, conducting high or medium frequency alternated current, induces on the work piece currents eddy currents whose intensity can be controlled and modulated. The paper firstly introduces the principle and mode of electromagnetic induction heating. Induction heating is the process of heating an electrically conducting object usually a metal by electromagnetic induction, where eddy currents also called foucault currents are generated within the metal and resistance leads to joule heating of the metal.

Tips and tricks for modeling induction furnaces comsol blog. The accuracy of the new correlation by direct measurement of work piece heating rates, and by the application of 2d axial symmetric finite element modelling, to. Temperature estimation of liquid steel in induction furnace. Theory and numerical modeling sergio lupi, michele forzan, aleksandr aliferov. This document pdf may be used for research, teaching and private study. Induction heating has become an important process in many applications, from cooking meals to manufacturing.

Induction heating is a process which is used to bond, harden or soften metals or other conductive materials. Numerical computer modeling allows predicting how different factors may influence. Heat transfer is the relaxation process that tends to do away with temperature gradients in isolated systems recall that within them t 0, but systems are often kept out of equilibrium by imposed. Design and simulation of induction heating equipment using matlab. Induction heating uses the heat produced by currents induced within a conducting body exposed to the alternating magnetic field produced by ac current flowing in an inductor coil. Ambedkar institute of technology, bangalore, india abstract. Index terms induction furnace, heat balance, heat loss, latent heat, heat model. Induction and direct resistance heating springerlink. In this paper, x 80 pipeline steel induction heating is taken as the. Then give an example of the electromagnetic induction heating. Wang state key laboratory of digital manufacturing equipment and technology, huazhong university of science. Induction heating vs resistance heating asme mechanical. Oct 12, 2019 after the heating is finished, the surface is naturally cooled and the temperature maximum moves to the core.

The total domain for the induction heating of steel tubes is shown in fig. The heating process is represented by the energy conservation equation where the heat generation during heating is added as a volumetric source term. How an induction motor works by equations and physics. Induction and direct heating, theory and numerical modeling springer. Additionally, this method of heating is very efficient, as the heat is generated inside the workpiece, as opposed to somewhere else and then applied to the workpiece. Numerical 3d modelling and verification of inductive. Magnetic fields and induced power in the induction heating of aluminium billets mark willia m kennedy licentiate thesis in materials science and engineering stockholm, sweden 20.

Theory and numerical modeling this book offers broad, detailed coverage of theoretical. In the direct induction heating, the current gets induced in the charge itself due to changing current nearby. Induction heating principle theory,what is induction. Power in the induction heating of aluminium billets mark willia m kennedy licentiate thesis in materials science and engineering stockholm, sweden 20. Numerical results were compared to measurements obtained by thermography, which proved to be an efficient and simple measurement method for relatively accurate assessment of. Modeling of induction heating of steel billets for control. Aleksandr aliferov this book offers broad, detailed coverage of theoretical developments in induction and direct resistance heating and presents new material on the solution of problems in the application of such. Numerical and experimental investigation of induction. The full text of this article hosted at is unavailable due to technical difficulties. Temperature development in case of progressive twostage heating. Finite element method was employed in this electromagneticheat transfer coupled problem. Induction and direct resistance heating are presented in an unified theory that, starting from the solution of maxwells equations, gives the basic quantities that characterizes thermal. Numerical analysis and thermographic investigation of.

Induction heating spiral inductor comparison between. Edge effect of load in transverse flux induction heating systems. Basics of induction inductive heating is based on the supply of energy by means of electromagnetic induction. In the present work, the heat transfer behavior during induction heating of a cylindrical aluminum billet is performed numerically. One thing for sure is that obtaining of temperature uniformity is never easy, because a strong edge effect of the load plays determining role in quality of heating. Schulbe abstract transverse flux heating tfh is one of the most effective induction heating technologies in the field of flat metal products. Modelling of induction heating of carbon steel tubes. Highlights numerical simulations of the heating by induction in steel tubes were performed. Heat sealing fundamentals, testing, and numerical modeling a major qualifying project submitted to the faculty. Faculty of electrical engineering, technical university of clujnapoca, romania.

You should also make a dc measurement of stator winding linetoline resistance. Induction furnaces were introduced as early as 1887. Numerical modelling of induction heating for complex geometrical. Magnetic fields and induced power in the induction heating. The heat transfer by the conventional method is very low of the order of 0.

Since these approaches are based on discretization, the resulting differential equation system is very large, in the order of millions. The outside temperature evolution of the steel tubes was determined experimentally and numerically. A simplified calculation method of heat source model for induction. Heat transfer tends to change the local thermal state according to the energy. Design and simulation of induction heating equipment using matlab simulink environment r.

How an induction motor works by equations and physics introduction. The alternating current in the loop creates an alternating magnetic flux within the metal to be heated. Numerical modeling of induction assisted subsurface heating technology by lei zhang a thesis submit to the faculty of worcester polytechnic institute in partial fulfillment of the requirements for the degree of master of science in manufacturing engineering by. Induction heating principle theory,what is induction heating. Theory and numerical modeling kindle edition by sergio lupi, michele forzan, aleksandr aliferov. Mar 04, 2015 today, we are pleased to introduce a new guest author, vincent bruyere of simtec, who shares insight into the modeling of induction furnaces. It is valued for its precision and efficiency along with being a noncontact form of heating. Dear all, in which case the induction heating of piping components are mandatory over resistance heating is there any code reference or bindings th.

Abstract the induction heating phenomenon is well known and has been used for a long period in practice. Temperatures in the inner and outer tube surface and the heat affected zone were determined. Magnetic fields and induced power in the induction heating of. This book presents a thorough treatment of ac machine design, starting from basic electromagnetic principles and. Taking into account the symmetry of revolution and the symmetry plane at the joint, since it is placed at midlength of coil, the model domain can be simplified as the one shown in fig. The parameters of induction heating of largediameter pipes have a direct effect on the final processing quality of the elbow, and the complexity of multifield coupling of magnetothermal force in induction heating can make it impossible to quantitatively optimize the design parameters of the induction heating device. In this paper, x 80 pipeline steel induction heating is taken as the research. A numerical model for induction heating processes coupling. Variable in the current injected into a conductor has a different distribution.

Heat sealing fundamentals, testing, and numerical modeling. Modeling of induction heating of steel billets for control design purposes j. The substance which to be heated in an electric heating system is called charge. Induction and direct resistance heating are presented in an unified theory that, starting from the solution of maxwells equations, gives the basic quantities that characterizes thermal processes based on internal heating sources. Comparison between practical construction and numerical modeling. Other members of the family are the direct current dc motor or generator, the induction motor or generator, and a number of derivatives of all these three. The key here is that resistive heating depends on the square of the current, meaning that the power is more sensitive to changes in current than resistance. The electromagnetictemperaturestress multifield coupling model of heavy cylinder induction heating was established. When the induction coil is placed next to or around a workpiece, the lines of force concentrate in the air gap between the coil and the workpiece. As here the charge itself provides the path for passing current and heat gets produced in the charge itself, the efficiency of the system is quite high. Resistance heating arc heating infrared radiation heating electron beam heating low frequency. Theory and numerical modeling lupi, sergio, forzan, michele, aliferov, aleksandr on. Using numerical methods to design and control heating.

Numerical modeling of induction assisted subsurface heating. Thomson also contributed to the theory of induction heating. Introduction this research relates to the measure of the liquid steel temperature in the indirect electric induction furnace and the design of heat balance equation with the objective to increase the efficiency for energy saving and quality of liquid steel by. Pdf a numerical model for induction heating processes. Edge effect of load in transverse flux induction heating. Handbook of induction heating theoretical background routledge. Heat transfer processes are classified into three types. In general, the induction motor is cheaper and easier to maintain compared to other alternatives. Working principles of induction heating induction heating involves applying an ac electric signal to a heating loop or coil placed near a specific location on or around the metallic object to be heated. In other words, with induction heating, we can avoid heat losses from the surfaces that would provide the electrical connection, thus improving the overall heating efficiency.

The main advantages of this process are transmission of electromagnetic energy from the inductor to the workpiece without direct contact. The induction coil actually functions as a transformer primary, with the workpiece to be heated becoming the transformer secondary. May 23, 2014 a quick excerpt from chapter 1 of fluxtrols basic of induction heating. The two dimensional axisymmetric comsol model of the furnace is used to study the induction heating in the mockup furnace. Prior to that the induction heating interface algorithm under the heat transfer module of comsol multiphysics was validated with the experimental data reported in the literature. Induction cooking allows high power and very rapid increases in temperature to be achieved, and changes in heat settings are instantaneous. The starting step in the mathematical modeling of ac machines is to describe them as coupled stator and rotor polyphase circuits in terms of socalled phase variables, namely stator currents ias, ibs, ics. Sizes vary from fractional horsepower to several thousand horsepower used for such appli. This book offers broad, detailed coverage of theoretical developments in induction and direct resistance heating and presents new material on the solution of problems in the application of such heating. Induction motor theory jerry bednarczyk, pe course content introduction the ac induction motor is well suited to applications requiring constant speed operation. Numerical simulation of induction heating roboterm. Numerical modelling of induction heating for complex. The only book on the market that emphasizes machine design beyond the basic principles of ac and dc machine behavior ac electrical machine design is a key skill set for developing competitive electric motors and generators for applications in industry, aerospace, and defense.

Induction motor the induction motor is the motor most commonly used in agriculture. Induction and direct resistance heating theory and. This paper describes the design of power electronic converter circuit and simulating the power electronic converter circuit. Design and fabrication of inductors for induction heat treating rob goldstein, fluxtrol william stuehr, induction tooling micah black, tucker induction systems for induction melting and mass heating, the early induction heating coils were manufactured from copper tubing wrapped in multiple turns around a mandrel. A numerical model for induction heating processes coupling electromagnetism and thermomechanics. Numerical modelling of the induction heating procedure requires the development. Numerical techniques for optimization of 3d induction heating. Induction heating ih is a method of heating electrically conductive materials used in many domestic and industrial applications because it has many advantages to other heating systems e. Induction furnace and eddy current heater are two wellknown examples of direct induction electric heating.

This paper describes the thermal and electromagnetic modeling of induction furnace and discusses the numerical results obtained. The final two chapters consider analytical solutions and numerical modeling of problems in the application of induction and direct resistance heating, providing industrial engineers with the knowledge needed in order to use numerical tools in the modern design of installations. The popular examples of direct resistance heating are resistance welding. Numerical approaches such as the finite element fe and finite difference fd are quite popular for the analysis and modeling of coupled problems like induction heating. Design and simulation of induction heating equipment using. Accordingly the basic equations of electromagnetic field and temperature field in the heating material are derived from maxwells equations and heat conduction differential equations. Simulation model the simulation model has a three phase, 415 volts, 50 hertz. However, most electricity is produced from coal, gas, or oil generators that convert only about 30% of the fuels energy into electricity. One singlephase wattmeter plus miscellaneous apparatus as needed. Induction heating in transverse flux can be economically effective for thin workpieces from aluminum, copper, gold, silver and other metals with low resistivity. Numerical modeling of induction assisted subsurface. According to the numerical simulation results, the resistance furnace heating process is.