Computer Simulation for Fundamental Study and Practical Solutions to Induction Heating Problems

Computer Simulation for Fundamental

Study and Practical Solutions to

Induction Heating Problems

Dr. Valentin S. Nemkov

Eng. Robert C. Goldstein

Centre for Induction Technology, Inc.

1388 Atlantic Blvd

Auburn Hills, MI USA

www.induction.org

Overview

• What’s New in Computer Simulation of

Induction Heating Processes

• 3-D EM Fields in a Slab

– Age Old Question

– Prior Scientific Studies - End and Edge Effects

– 3-D EM Computer Simulation

• Conclusions

What’s New Since IHS’98 in

Computer Simulation?

• Computer Hardware

• Computer Software Improvement

• Market Demand

• Material Properties?

Computer Hardware Available for Less

than $15,000 USD

• 2-1.7 GHz Processors

with 400 MHz Buss

• 4 GB RAM with 800

MHz speed

• 4-73 GB, 10000 RPM

Hard Drives

• 4.7 GB DVD Drives

• 1-400 MHz Processor

with 100 MHz Buss

• 256 MB RAM with

100 MHz speed

• 2-10 GB, 5600 RPM

Hard Drives

• 100 MB Zip Drives

1998 2001

Computer Software

Improvements

• New Applications (1D and 2D Scanning)

• Coupled 3D for Some Types of Systems

• More User Friendly (Flux 2D Windows based)

• Post Processors and Graphics (Videos of 2D

coupled process simulation with Flux 2D)

• Faster and More Precise Solvers

• 16 X’s Memory Capacity in 3D Simulation

• Cubic and Prismatic Elements for 3D

1D Scanning Application

1D Scanning Application

3D EM Fields in Slab

Age Old Question

• Initial Studies Done by Prof. V. Vologdin and

Dr. G. Razorionov in early 1940’s in Russia

Power density distribution in a long square prism with

a side equal to the reference depth

Heating of Infinitely Long Slab

• Study made by Dr. V. Peysakhovich around 1960

in St. Petersburg, Russia

Power Transfer Factor

2D End and Edge Effects

• Study made by Prof. V. Nemkov’s Group (Dr. V.

Rudnev, et. al) in 1970’s and 1980’s in St.

Petersburg, Russia

End and Edge Effects in Slab

3D EM Computer Simulation

• Study Made by Prof. V. Nemkov and Eng. R. Goldstein in

2000 at CIT in Auburn Hills, MI USA

Top View of Slab Geometry (0,0,1) plane

Side View of Slab Geometry (0,1,0) plane

Power Density Color Map

Demonstrating Edge Effects in Slab Frequency 9.5 kHz

Power Density Color Map

Demonstrating End Effects in Slab Frequency 9.5 kHz

Slab Power Density Color Shade Frequency 9.5 kHz

A

E

F

C

B

D

A

Surface Current Density Demonstrating

End and Edge Effects

0.00E+00

5.00E+06

1.00E+07

1.50E+07

2.00E+07

0.00 10.00 20.00 30.00 40.00 50.00

Last 50 mm from End or Edge of Slab (mm)

Mo

du

lus o

f C

urr

en

t D

en

sit

y

Edge Effects (A-B)

End Effects (A-C)

Edge End Effects (D-E)

End Edge Effects (C-F)

Volumetric Power Distribution in Slab

5.8

25.8

45.8103.2

148.2

193.2

0

0.2

0.4

0.6

0.8

1

Total Column Power for 9.5 kHz Geometrically

Adjusted

Experimental Temperature Measurements

with Related Power Density Color Map

A

E

C

D

A

Point A C D E

Temperature 155 C 185 C 170 C 190 C

Frequency 9.5 kHz

Color Map of Power Density in Slab Frequency 2 kHz

Color Map of Power Density in Slab Frequency 15 kHz

Conclusions

• Modern computers make everyday 1D and 2D

simulation possible even for small companies

• 3D simulation is used mainly by universities and

research centres for both practical and

fundamental studies

• 3D EM fields in slab have been studied for the

first time through computer simulation

• Coupled 3D simulation should be the final step in

solving this old mystery