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A New Generation IGBT Based High-Frequency Mirror Inverter for Induction

Heating

Article · September 2010

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A NEW GENERATION IGBT BASED HIGH-FREQUENCY MIRROR
INVERTER FOR INDUCTION HEATING

Pradip Kumar Sadhu

Professor: Department of Electrical Engg.
Indian School of Mines, Dhanbad 826004, Jharkhand, India
Email: [email protected]
Dola Sinha
Junior Research Fellow: Department of Electrical Engg.
Indian School of Mines, Dhanbad 826004, Jharkhand, India
Email: [email protected]
Nitai Pal
Assistant Professor: Department of Electrical Engg.
Indian School of Mines, Dhanbad 826004, Jharkhand, India
Email: [email protected]
Atanu Bandyopadhyay
Assistant Professor: Department of Electrical Engg.
Asansol Engineering College, Asansol, West Bengal, India
Email: [email protected]

ABSTRACT
The present paper deals with the developments of high-frequency mirror inverter for
electromagnetic induction heated domestic appliances or industrial appliances. The
inverter fed fluid heating appliance is more acceptable than gas combustion, steam
heating and electrical resistive heating methods for better heat transfer and delivery
processing under precise temperature management. The high-frequency series resonant
point image current source inverter (mirror inverter) circuit using IGBT is more efficient
due to less switching losses, compact size and faster response as compared to
conventional series resonant inverter (series bilateral inverter) and modified half bridge
series resonant inverter. No additional snubber circuit is required for IGBT in the mirror
inverter. The turn off problem is reduced because switching loss is less in proposed
circuit. It offers slow response to load changes. Link inductance provides self-protection
against any fault currents in the load. Series resonant inverters were widely used for
induction heating over wide range of frequency (from 4 kHz to 500 kHz). The high-
frequency mirror inverter system is introduced as a new conception of alternating current
source for induction-heated cooking system, pipeline fluid or vessel fluid heating for
medicinal plant, sterilization plant and dryer for surgical instruments.

KEYWORDS
Half bridge series resonant inverter, Point image, Mirror inverter, Switching loss, PSpice simulation

INTRODUCTION temperature distribution in the rails can be

Induction heating is carried out in controlled by slowly varying magnetic fields
different frequency ranges- (i) The below a frequency as low as 300 Hz [1, 2].
application of low frequency induction (ii) For medium frequency application, an
heating can be described as the heating of auxiliary voltage-fed inverter is operated in
rigid track while laying railway track. The parallel with the main current-fed inverter
since the current-fed parallel inverters gate isolation, low turn-ON ohmic

alone, when used for induction heating, fail resistance, low power requirement for gate

to start [1-5]. (iii) Series resonant inverters drive. In present context, authors

for high frequency induction heating and developed an IGBT based High Frequency

melting applications are self-started [6-10]. Mirror Inverter for maximum power transfer

For self-commutation, a resonant circuit is and more sinusoidal voltage and current

essential. It is assumed that the circuit is wave shapes.

under-damped, a mandatory condition for

the circuit. The capacitor required for

under-damping can be connected in series

DEVELOPMENT OF HIGH
or in parallel with the load. For efficient
FREQUENCY INVERTER
forced commutation [1, 2, 11, 12], reverse
The operational analysis of high frequency
voltage must appear across the SCR (in
series resonant inverter (series bilateral
earlier days), which can be obtained from
inverter) is already explained earlier by
a charging circuit consisting of an inductor
different authors [2, 6, 9, 11, 15]. However
and a capacitor, called the commutating
the above said operation faces a drawback
components. They are connected to the
in high frequency operation. The capacitor
load, so that the overall circuit becomes
charges from the source through the
under-damped and zero current is
induction coil (L) in the positive half cycle
obtained [13, 14]. In the modern times,
and then also discharges through the
IGBTs, MOSFETs, SITHs, B-SITHs are
same induction coil in the negative half
preferred to SCRs mainly because they
cycle. This charging and discharging
offer self turn OFF characteristics.
current amplitude differ practically thereby
Besides all the semiconductor switches,
making it unsuitable for high frequency
the IGBTs are more attractive for in-built
current generation for induction heating. next slot of the gate pulse, Q1 and Q2

To overcome the above problem the remain OFF and the capacitors charge to a

modified half-bridge series resonant voltage Vi / 2 each again. Gate pulse then

inverter was designed. appears at the gate of Q2, thereby turning

ON Q2. The capacitor C2 discharges

through the path NMDCN and the charging

path for capacitor C1 is AQNMDCBA. The

discharging current of C2 and the charging

current of C1 simultaneously flow from N

to M. It is thus seen that alternating current

Fig. 1: Modified half-bridge series resonant flows through the inductor thereby sorting

inverter out the problem of unequal charging and

The working principle of the circuit of Fig. 1 discharging current through induction coil

[2, 4, 6] can be explained as follows. (L) as in half bridge series bilateral inverter

Semiconductor switches are triggered (as circuit. As the modified half bridge inverter

per Fig. 2.) when there is no signal at Q1 operates at radio frequency, some

and Q2, capacitors C1 and C2 are charged auxiliary circuits and equipments are

to a voltage of Vi / 2 each. Gate pulse then required to minimize switching losses

appears at the gate of Q1 to turn ON occurring at high frequencies. Another

IGBT-I. Capacitor C1 discharges through problem is that of radio frequency current

the path QLMNQ. At the same time penetration through the inductor ‘L’ in case

capacitor C2 charges through the path of high frequency modified half bridge

AQLMNCBA. The discharging current of inverter.

C1 and the charging current of C2

simultaneously flow from M to N. In the

 in Fig. 4 with stretched single point (NM).

Point (NM) thus acts as a short circuit bar.

To show the N-M bar works as high-

frequency current source, similar

.
explanations can be given as described in

Fig.2: Control pulses for triggering the circuit of Fig. 2 for generation of

semiconductor switches alternating current in between N and M

points.
ANALYSIS OF DEVELOPED
HIGH FREQUENCY MIRROR
INVERTER
The authors propose the concept of point

image high frequency current source

inverter (high-frequency mirror inverter) for

better applications of the inverter circuits in

the high-frequency range. The point image Fig. 3: Radio-frequency mirror inverter

current source (shown in the fig 3) is

developed by replacing the inductor L

between points N and M to the new

position between points A and Q thereby,

coinciding N and M to be a single point.

The concept of high-frequency mirror

inverter can be explained with reference to

Fig. 4: Equivalent (stretched) circuit of Fig. 3
Figs. 3 to 8. The point image alternating
Figs. 5 and 6 show the equivalent circuit of
current source inverter of Fig. 3 is redrawn
Fig. 4 when gate pulse is applied to IGBT1
and Fig. 7 and 8 show the equivalent circuit with high frequency current source

circuit of Fig. 4 when gate pulse is applied in a series closed loop path. It is proved

to IGBT-2. Referring to Fig. 5, it is that high frequency alternating current will

concluded that high frequency alternating flow through the inductor L after replacing

current flows through the path its position as shown in Fig. 4. Now the

AQLMNCBA. This can be proved as generated high-frequency current source

follows. At high frequencies the capacitive reflects the high frequency current into the

reactance offered by C ( Xc = 1/ 2 πfC ) is induction coil. Fig. 4 now works as radio

negligible (as f = 24.63 kHz. to 33.33 kHz.) frequency point image current source

and hence the capacitor acts as a short inverter (high-frequency mirror inverter).

circuit, thereby allowing the high frequency

current to flow through the path

AQLMNCBA. Capacitor C also acts as

higher order harmonic filter at the same

cost. Referring to Fig. 6, C1 discharges

from V/2 to zero voltage through QLMNQ

Fig. 5: High frequency discharging current path
loop and discharging current flows from M
of C1 when IGBT-1 is ON
to N. Again, in a similar manner it can be

shown in Fig. 8 that alternating current

circulates through the path AQNMDCBA,

when IGBT-2 is ON. Referring to Fig. 7, C2

discharges from V/2 to zero voltage

through NMDCN loop and discharging

Fig.6: High frequency discharging current path
current flows from N to M. Thus Fig. 5 and
of C2 when IGBT-2 is ON
8 can be considered as a series R-L-C
 non-smoothing filter also works as a

harmonics filter. When the inverter

operates, harmonics are generated. To

avoid the harmonic injection in the system

bus at the time of induction heating

Fig. 7: High frequency charging current path of operation, this non-smoothing filter works

C2 when IGBT-1 is ON as high pass filter through capacitor C in

Fig. 3. The portion to the left of point (A)

and point (B) of Fig. 3 is not shown

separately in the circuit of Fig. 4 as it is a

common part.

B. Implementation of the Firing Circuit

Fig. 8: High frequency charging current path of
The hardware implementation was limited
C1 when IGBT-2 is ON
by the circuit constraint problem.

A. Power Supply of Present Moreover, the hardware implementation

experimental Setup carried by the series resonant inverter with

the IGBT has the disadvantage that it

The voltage available in the laboratory or in
draws very high peak circuit current from
the house is A.C., 1-φ, 220 V, 50 Hz., 2-
the source. A necessary phase difference
wire. It is taken from system bus first, then
between the two IGBTs firing is required
it has to be rectified to generate DC
which is difficult to implement using a
voltage by full bridge rectifier before
hardware approach. This approach as
feeding to inverter circuit. The DC output
generating rectangular pulses with
is filtered through a non-smoothing LC filter
required phase difference is an easy task
circuit to get rid of ripple DC supply. This
with the help of 8085 microprocessor. Real time Experimental result of mirror

inverter:
C. Salient Features of the High-
One prototype model is developed and the
Frequency Mirror Inverter Circuit
waveform has been taken into DSO
• No additional snubber circuit is required
(digital storage oscilloscope) from real
• The turn off problem is reduced
time model by 10:1 reducing probe at
because switching loss is less in
temperature set 2.
proposed circuit,

• It has the highest switching frequency,

• It offers slow response to load changes,

• Link inductance provides self protection

against any fault currents in the load.

EXPERIMENTAL RESULTS

The IGBT ON/OFF time period with

respective inverter operating frequency for

Fig. 9: Views the voltage across induction coil
different temperature set is shown in
‘L’ (between A and Q points of Fig. 3) with
Table1
temperature setting at medium (T-3) position,
Table1: Operating frequency for different
voltage setting at 100 V / div, time setting at 5
temperature setting
µ Sec / div in AC mode
Temp. Period Inverter
response ON OFF operating
setting (µ Sec) (µ Sec) frequency
(kHz)
set 1 5 25 33.33

set 2 8 22 33.33

set 3 12.6 22 28.9

set 4 16 21 27.027

set 5 19.6 21 24.63

 Fig. 12: Voltage across heating coil from

PSpice simulation result

System efficiency calculations for

Fig. 10: Views the voltage across induction
high-frequency mirror inverter operated
coil ‘L’ (between A and Q points of Fig. 3) with
induction heated home appliance for
temperature setting at medium (T-3) position,
temperature set-2 :-
voltage setting at 100 V / div, time setting at 5

m Sec / div in AC mode Input no load current = IO = 0.05 amp

Input load current = IL = 1.54 amp

PSPICE simulation of mirror inverter :
Input voltage = VI =200 volt
The developed PSPICE schematic circuit
Initial temperature of fluid (Ambient)T1 =
diagram is shown in Fig. 11. Four diodes of
20.75 OC
1N6392 type are used for bridge rectifier.
Final temperature of fluid T2 = 93 OC
And for high frequency inverter two IGBTs
Initial fluid mass (water) mi = 123.92 gm
of HGTP6N 50E1D type are used.
Stainless steel package (bowl) weight ms

L6
L7
R6
=73.14 gm
100uH 119uH 0.12
1N6392
2

D16 D17 Z3
1

Final mass of fluid after experiment mf =

C6 C7 R7
5uF 0.4uF
470k
VOFF = 0 V11 HGTP6N50E1D
VAMPL = 220V
FREQ = 50Hz

V1 = -5V V12
V2 = 5V Z4

95.86 gm
TD = 0.00001ms R8
C8
2

TR = 0.002ms
470k
2

D18 TF = 0.002ms 0.4uF

D19 PW = 0.008ms
1N6392
1

PER = 0.03ms
1N6392
1

HGTP6N50E1D

V1 = -5V V13

Mass of evaporated fluid mev = mi – mf

V2 = 5V
TD = 0.02601ms
TR = 0.002ms
0 TF = 0.002ms
PW = 0.008ms
0 PER = 0.03ms

= 123.92 – 95.86 = 28.06 gm

Fig. 11: The circuit diagram for PSPICE Simulation
Total time taking for reaching final CONCLUSION
temperature = 360 Sec The circuit of a half bridge series resonant
Taking L = 2256.9 KJ / Kg (some fluid will IGBT-based mirror inverter used in high
be evaporated which is nearer layer of frequency induction heating purpose is
steel vessel). Heat power transfer to fluid analyzed in this present paper. One

Po =
( mC (T
i p 2 - T1 ) + mev L )
=
100815.74 J prototype real time model is developed
time in Sec 360 s
= 280.0437 W and experimental waveforms are taken

Input power taken from source from DSO. At the same time, the circuit

PI = VI ILCosφ = 308W with same parameters is simulated on

PSPICE software. After having compared

where Cosφ = 1.
the wave-forms of PSPICE simulation and
Efficiency of the home appliance system at
real time experiment, it is quite obvious
temperature Set-2
that the waveforms are similar in nature for
280.0437
= ηh 2 = = 0.909 = 90.9 % the high frequency mirror inverter used in
308

System efficiencies for different set of induction heating for domestic as well as

temperature are shown in Table 2. industrial appliances.

Table 2: Different temperature set with

ACKNOWLEDGMENT
respective efficiencies

Temperature Efficiency of Authors are thankful to the

response settings home appliance
Set-1 69.5% UNIVERSITY GRANTS COMMISSION

(UGC), New Delhi, India for granting

Set-2 90.9%
financial support under Major Research
Set-3 78.9%
Project entitled “Simulation of high-
Set-4 84.7%
frequency mirror inverter for energy
Set-5 82.8%
efficient induction heated cooking oven
using PSPICE” and also grateful to the [5] N. Pal, P. K. Sadhu, R. N.

Under Secretary and Joint Secretary of Chakrabarti, “A Comparative Study of

UGC, India for their active co-operation. HF Mirror Inverter for Induction

Cooker through Real-time and

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