POWER INVERTER CONTROL FOR INDUCTION HEATING PULSE DENSITY BY MODULATION IMPROVED POWER FACTOR WITH

Jamila Essadaoui, Pierre Sicard, Eloi Ngandui, Ahmed Cherid Hydro-QuPbec Research C h a i r on Power a n d Electrical Energy Department o Electrical a n d C o m p u t e r Engineering, School o Engineering f f Universiti du QuPbec a Trois-RiviBres C.P. 500, Trois-Rividres, QuPbec, C a n a d a G9A 5H7 E-mail :{Jamila-Essadaoui, Pierre-Sicard, kloi-Ngandui, A h m e d - C h i r i t v @uqtr, ca ?Tel: (819) 376-5011 ext. 3922 Fax: (819) 3 7 6 - 5 2 1 9 Abstract
This paper describes the design and analysis of a new Pulse Density Modulation (PDM) control strategy adapted f o r resonant inverters f o r induction heating applications. PDM is introduced to overcome the drawbacks of the classical control modes such as PWM, FM and Phase Shiff. One characteristic of PDM is that it operates at resonant frequency with zerovoltage and zero-current switching f o r a wide range ofoutputpower variations. The PDM strategy allows to vary the power and to reduce switching losses and electromagnetic noises. Fired length switching patteins are used and are chosen to maximize power factor whilst keeping controller implementation simple. Simulation results obtained using the Power System Blockset in the Matlab/Simulink environment and experimental results are presented to illustrate the effecfiveness of the new pulse density modulation control strategy.
KeyworcLF: Induction heating; inverter; control; power factor; PDM. these problems, different control and regulation strategies of resonant inverters have heen proposed, such as [3]: Frequency control; Pulse with modulation; and Phase+hift control. However, with these control modes, switching losses and electromagnetic noises appear because switching devices are not always tumed on and off at zero current or voltage crossings [3]. This paper describes the design and analysis of a new Pulse Density Modulation (PDM) control strategy that overcomes the drawbacks of the conventional control modes and offers the following advantages [3] [4] : Inverter operation at resonance is maintained thus resulting in a great reduction of switching losses (zero crossings) and electomagnetic noises; PDM inverter requires no high capacitor for filtering what is beneficial forthe power factor. The proposed control scheme is fully digital and contains two terms: a feedforward term based on the inverse model of the induction heater; and a feedback term to correct the error between the measured and the reference power. The test rig and principles of PDM are described in section 2. The control pattern and the static characteristics of the induction heating system are presented in section 3.The two term control scheme is described in section 4 and simulation and experimental results are presented in section 5. Conclusions are drawn in section 6.

1. INTRODUCTION
Induction heating consists of placing a conducting material in a variable magnetic field, which develops Eddy currents within the material, provoking heating by Joule effect [I]. Power ranges from a few Watts to hundreds of kW and the operation frequency can reach hundreds of kHz. High kquency applications require using specially designed converters. With remarkable progress in switching speed and capacity of semiconductor devices (MOSFET, insulated gate bipolar transistor) voltage or current nverters have been researched and developed for induction heating applications [2]. They are capable of operation at high frequency and are able to transfer a high power level. Load power regulation is important for high quality heating. Different modes can be used and control by adjusting a dc input voltage is very common. A thyristor bridge rectifier has been conventionally used as a variable power supply. This causes some important problems: high ripple in the output signal that requires using a filter and power factor is low at low power. In order to overcome

2. PULSE DENSITY MODULATION

2.1 Principle of PDM
Pulse density modulation PDM is a control stategy that used fixed f ~ n patterns. Typically, the voltage is applied g to the load during a few cycles followed by an off time (zero voltage) [5]. Power regulation is ensured by adjusting the pulse number during the on-time during the period T = N T, =N/ w, [3]. Switches operation frequency w, is equal to the resonance fhquency w r of the load. The power stage consists of an ac voltage source

(ZOOV,60Hz),a single phase diode rectifier whose output

frequency is equal to the double of network frequency

CCECE 2003 - CCGEI 2003. Montrkal. Mav/mai 2003 0-7803-7781-8/03/$17.00 0 2003 IEEE - 515

200v 60Hz

--r
DI
D3

TI

T3
Lb

s
T2

Fig.1. Power stage

(12OHz). High frequency capacitor of 1 F is inserted at the output of the rectifier to filter the high frequency components from the signal, this is beneficial for the power factor [6] (Fig. I). A series resonant inverter using four transistors TI to T4, interconnected to the free wheeling diodes DI to D4, is used to create a high frequency current wave amplitude modulated by the PDM control strategy. A step-up transformer, with tum ratio of 8:1, at the ac terminals of the inverter is used to interface the series resonant LC circuit with loss resistance R (Fig.1). Specificationsare: R=0.15 ; L = 5 HC=2.198810~2F; C o = l F;Lo=70 HF,=480kHz. Fig2 shows three switching modes of the voltagesource series resonant PDM inverter. During the on time, the transistors are turned on and off in opposite pairs, TI with T4 and T2wt T3, ih such as modes I and II, to produce a square wave voltage [3] [SI. During the off time, the PDM inverter introduces mode III to produce a zero 6 voltage state at its output terminals: when ' is tumed on the loop is closed through Dz, and when T2 is turned on the loop is closed through D4 [3J.

Fig.3. F'rinciple of PDM control and mode I1 every half resonant cycle, and during a period TONof three resonant cycles. The fourth resonant cycle presents an off period TOE (mode I Q , and therefore produces the zero voltage state to the resonant circuit (VAB = 0).

2.2 Analytical study

The study of the series resonant inverter is reduced to the study of the oscillating circuit response, assumed without loss and excited by a square wave voltage

vAa(t) U . The differential equation describing the = behaviour of the circuit is written as follows (Fig.2.a)
L -+ - , d di, 1 i t dt C Let us note that: 2L r = - = - 2Q

+ R ,i

= v m (1)

(2)

U-$
~~. m
(r)

TI

<L$.

.Qm
1.3

,.+.

........... ...........

Fig.2. Switching modes in PDM invener: (a) simplified circuit; @) Mode I; (c) Mode U; (d) Mode IU Fig.3 illustrates the principles of the PDM-based power control. It presents a case of pulse density:

wim T=NT,=T,+T,,;T,,=N,T,;T,,=N,T, Square wave voltages are produced and they vary between +U and -U when the resonant inverter is in mode I

(3) R w, Where 7 : Time constant of the envelope; Q : Quality factor of the series resonant circuit; wr : Resonant frequency. When the PDM control is applied to the series resonant circuit with a quality factor higher than 1 (Q>>I), the response of the load current consists of a sinusoidal waveform, at the resonant frequency w. and limited by an envelope that exhibits a fmt order response, as shown in Fig.4 [3] [4]. Current ich is given by: ich(t)=iE(f) w,t sin (4)

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to adapt the current to the desired power. In our study, we are interested to choose a large pulse number N to offer a better resolution in the power levels and to have a wide range of output power variation. Power control in pulse density modulation can he used in different ways. Henceforth, we set as an additional criterion to improve the power factor. A Non-regular PDM was proposed to achieve the best result [5], this case is a function of the number of partial sequences in the PDM cycles and is synmetrical.

3. CHARACTERIZATION OF THE PDM CONTROLLED CIRCUIT

We consider a circuit presented in Fig.Z(a) with a dcsupply to characterize the behaviour of the system in steady Fig.4. Current waveform in PDM state. Simulation results are obtained using the Power System Blockset in the Matlah/Simuli& environment. The where the envelope of the current expression iE is given by PDM control pattern generation for the power switches is (Fig.4) [3]: implemented using a table (N lines, 2*N columns) to select the PDM sequences. We l i t the maximum PDM length to i E ( t ) = i ( l e ;)+l,(o)e o T,, (5.1) N = 16. LrgE Fig.5 shows the 16 PDM sequences used in h e i (1) = I , (Tow)e , To,, f T (5.2) simulation, where the pulse density D is varied from 1/16 where f is the maximum current of iE for a unity pulse to 16/16. These particular patterns were used to minimize density (ToN/T = I). I steady state, we define Imin=IdO) the total harmonic distortion on the mains. =IdT)and Z n W = I E ~ owhich are related to f by: ~),
Time Is1 x

The average output power is obtained by:

If we use the assumption that equation (7) can be expressed as:

T, the development of

.,I.

U' ,
*/I'

r r

1/1.,
,I.

s , .

Where U is the inverter supply voltage and is the angle between the load current and fundamental of the square wave voltage. If the operation period of the PDM (T = N T,) is much smaller than the time constant 7 ,then the amplitude of the .resonant current is proportional to the pulse density. Thus, the relationship between the output power and pulse density in given by: lim P = Pmax D ' (10) According to the analysis used previously, we can say that power control in PDM is affected by one parameter noted pulse density D. To use PDM control strategy, we must define the sequences with an integer number of pulses with total duration T and modulate this pulse density so as

. . I

F i g 6 atput current waveformforD = 16/16

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We now consider the ac/ac converter presented in Fip.1 with an input filter (CO = 1 F; Lo = 70 H) to improve the power factor [6]. Results of table 1 illustrate the characteristics of the PDM control strategy: total harmonic distortion (60 Hz base) is negligible at high power and it is larger than 20 % at low pulse density; displacement factor is unity, which is beneficial for the power factor given by: Power factor is given by:
1

PF =

DFp

"' 2635

2-

2645

265
Tim- Is1

2555

266

2665 .I01

Pulse density Toral hannonic Displacement Power factor distortionTHD PF facfmDF,

16/16 13116 5116 2116 0.9997 0.9998 0.9995 0.9995 0.9998 0.9946 0.9346

Fig.7. Output current and voltage waveform for D = 1/16 Fig3 represents the power to pulse density curve for simulation results and theoretical results (i.e. equation based). Comparable power levels are obtained for the other length-I6 pulse sequences, but the corresponding total harmonic distoaion is higher. We ohserve the large quantization step in power, which can be reduced by increasing the length of the sequences. Fig.9 shows the time response for the 16-pulse pattems, when starting with zero initial conditions. We observe that the power reaches its steady state in about 0.4 ms.

10.2 30.32

0.9998 0.9766

4. CONTROL CIRCUIT
The power to pulse density characteristic (Fig. 8) is used to develop a simple digital closed loop controller for induction heating. Fig.10 presen6 the smcture of the control circuit developed for the PDM inverter to regulate the output power. The proposed fully digital controller contains two terms: a feedforward term based on the inverse model of the induction heater, with desired power as an input and control sequence as an output; and a feedback term to correct the error between the measured power and the reference power. To obtain the feedforward term, all admissible control sequences were obtained and, for given power levels, the sequence that yields the highest power factor was chosen (Fig. 5 and 8)'to build the feedforward table. The power factor was obtained on the mains. The desired power defines a position htin the feedforward table. For fme positioning in the table, the difference between the desired power Pc and the measured power is applied to the input of a deadband plus hysteresis function, which operates in three states -1,O and 1 (Fig. 11 with ="* '%). The relationship between the input and ih output of this control function wt integral action is givm by:

2500

E"

Ism
rmo

m
0

01

DZ

03

D l 0.5 06 P"lS*d*nr,ly

07

OB

09

Fig.8. Relationship between pulse density and power in 16 PDM

l5n
um
IM

n,(k)=%ys(k

I)+ n,,(k)

(12)

m
(yo

tm

0.2

04

06
T,mc(q

0.1

?.I

14

.d

Fig.9.Power variation in h c t i o n ofthe pulse density in 16 PDM

Fig.10. Control circuit power block diagram

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Fig. 11. Deadband plus hysteresis conml function

where k represents the sampling instant. On Fig. 10, Seq represents the final sequence number used for control and addresses the table of control sequences ordered by increasing power (see Fig. 5 , wt sequences 1 to 16). The ih simulation and experimental results presented herein correspond to the case the sampling period for the which was chosen to minimize THD controller is 1/60Hz, with the proposed PDM sequences. Simulation results of power regulation are presented in Fig.12, 13 and 14. The output power varies between two power levels close to the desired power as the control circuit switches between 2 sequences ounce per cycle (1/60Hz). We also note the average Power is modulated by the input voltage of the inverter, which is a rectified sinusoid due to the small input filter. This oscillation is acceptable in applications such as calendering. However, a longer time horizon should be used in measurement to obtain the desired average power. Indeed, the controller just assures an oscillatory steady state around the set point value.
150

+;
w,

(4

1 -

,200

1 m

100
400

200

.,
Fig.14. PowervariatianforPc= 1200W

5. EXPERIMENTAL RESULTS
Fig.15, 16 and 17 show the experimental waveforms obtained with the prototype system 60V/60Hz; , m ~ ~ ~ = 1 6 nephase-shift bemeen the output voltage and current is almost negligible. This means that the PDM inverter achieves zem-current switching (ZCS) in all the operating sequences. The experimental and simulation results are listed in table 2. The experimental results validate the simulation with the open loop control scheme.

100

E zoo

I50

100

Fig.lS.OutputvoItage(l)andcurrent(2)forD=16/16
IO
00 0.0,
002
001

OD

016

001

00 .,

7,m.w

Fig.12. PowervariationforPc =25OW

100

500

100

001

om

101
Tim.,.,

OM

0 s

008

007

Fig. 13. Power variation for Pc = 5WW

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This work can be applied to induction heating of applications such as calendering. Application to dircct heating of metallic parts is possible and can be achieved with tight tolerance is power quality requirements are relaxed.

Acknowledgements
This project was supported by funds received fiom Hydro-Qukhec Research Chair on Power a d Electrical Energy (CPEE). Simulations were performed on a system obtained with the support of Canadian Innovation Fund, Govemment of Qukbec, OpaLRT Technologies inc. and the Japanese Research Institute.

Ref er ences
[ I ] K. Izaki, H. Yamashita, H. Omori A novel highfrequency ZVS-PWM inverter for multi-bumers induction-heating appliance IEEE Power electronics and variable speed drives, 21-23 septembre 1998, conference publication No.456. [2] H. Fujita, S. Ogasawara, Senior and H. Akagi, An approach to a broad range of power control in voltaj:esource series- resonant inverters for corona discharge treatment Pulse density modulation Proceedings of PESC97 Conference, pp.1000-1006. [3) H. Fujita and H. Akagi Pulsedensity-modulated power control of a 4kW, 4501dIz voltagesource inverter for induction melting applications. lEEE Trans. Ind. Applicat, vol. 32, No.2, MarcWApril 1996, pp. 279-286. [4] H. Calleja and R. Ordonez, Improved induction heating inverter with power factor correction, in Proceedings of IEEE-PESC Conference 1999, pp.l1:121137. [SI H. Calleja and J. Pacheco Power &stribution in pulse density modulated waveforms, in Proceedings of IEEE-PESC Conference 2000, pp.1457-1462. [6] A. Sandali, P. Sicard, and A. Cheriti, Power factor improvement of aclac converter by association of PDM control and passive filtering, in Proceedings of the 2002 PESC, pp.250-255, June 23-27, Cairns, Australia.

6. CONCLUSION
This paper has proposed a voltage source series resonant PDM inverter for induction heating applications. Tbe PDM inverter is capable of adjusting the output power; in addition, it can achieve ZCS (zero current switching) and Z V S (zero voltage switching) in all operating sequences, thus resulting in decrease of switching losses and electromagnetic noises. The PDM sequences are formed in such a way that the power factor is improved. An advantage of the proposed approach is its simplicity and fully digital implementation. To reduce the amplitude of the power swing in steady state, the length of the sequences can be increased or the sampling period of the controller can be reduced down to the length of the sequence. In the second case, fine power control can be achieved but the control of the power factor and in particular the reduction of the harmonics content on the main are lost

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