causes a decrease in the generator output
Design of Induction Heating Coils
for Cylindrical Magnetic Loads
J. T. VAUGHAN
ASSOCIATE AIEE
'Synopsis: Equations are presented whereby
the authors' previous paper1 is extended to
the design of coils for heating magnetic
loads, where the load remains in a fixed posi­
tion relative to the coil during the heat.
In heating magnetic materials, there is con­
siderable variation in impedance of the coil
circuit as the load temperature changes.
The present paper first develops certain
general principles by which a variable im­
pedance circuit may be designed to absorb a
predetermined maximum power, on the
basis of constants determining the maxi­
mum and minimum impedance. Methods
then are given by which these constants
may be calculated for carbon steel loads of
types SAE 1015 to SAE 1045, or their
equivalent. In practice, these methods ap­
ply to most through heating and some sur­
face heating applications. The accuracy of
calculations is substantiated experimentally.
W ITH the advent of considerable ap­
plication of magnetic induction in
heating steel for forging, it becomes more
essential that the designer is able to pre-
calculate the power, kilovolt-amperes, and
efficiency variations during the heat in or­
der to determine the required coil turns,
capacitor values, and heating rates. It
is the purpose of the present paper to out­
line methods by which these variations
may be calculated and coil turns and ca­
pacitor values determined.
Numerous attempts have been made to
adapt the theory of the induction heating
of nonmagnetic loads to magnetic loads
These may be compared to Pi of Figures
9 and 10.
References
1. THREE-PHASE SHORT-CIRCUIT SYNCHRONOUS
MACHINES—V, R. E. Doherty, C. A. Nickle. A I E E
TRANSACTIONS, volume 49, 1930, pages 700-14.
2. INHERENT ERRORS IN THE DETERMINATION OF
SYNCHRONOUS-MACHINE REACTANCES BY T E S T ,
C. Concordia, F. J. Maginniss. A I E E TRANSAC­
TIONS, volume 64, 1945, June section, pages 288-94.
3. AN ANALYSIS OF THE INDUCTION MACHINE
H . C. Stanley. AIEE TRANSACTIONS, volume 57,
1938, pages 751-5
4. Discussion by C. Concordia of TRANSIENT PER­
FORMANCE OF INDUCTION MOTORS. A I E E TRANS­
ACTIONS, F. J. Maginniss, N. R. Schultz, volume 63
1944, pages 1457-8.
5. P E R - U N I T IMPEDANCES OF SYNCHRONOUS M A ­
CHINES—II, A. W. Rankin. AIEE TRANSACTIONS,
volume 64, 1945, December section, pages 839-41.
1946, VOLUME 65 Vaughan, Williamson—Induction Heating Coils
voltage. In this case it is desirable to add
J. W. WILLIAMSON
ASSOCIATE AIEE
by assuming a constant permeability.
However, unless some means is given of
determining the value of permeability to
use, the results are ambiguous. Baker 2
has shown that a value
μ = 1.8ΒΜ/ΗΜ
where BM is the maximum flux density
(taken in Baker's paper as 18,000 lines
per square centimeter) and HM is the peak
magnetic intensity at the outside of the
load may be used , to calculate the
power input to thin moving steel
strip. Kinn 3 proposes an almost identical
formula for permeability for use with
loads of various shapes. His value for
BMi however, is 16,000 lines per square
centimeter. Kinn's paper is confined
mainly to practical applications and,
therefore, does not give theoretical deriva­
tion or experimental confirmation of the
formulas supplied.
The conventional induction heating
circuit used with rotating generators is
shown in Figure 1. TJie purpose of the
capacitor is to adjust the power factor
at the generator terminals. In heating
operations where the load remains in fixed
position during the heat, the capacitor
usually is adjusted to give a power factor
at generator terminals in the range of
unity to 0.9 leading while the load is in
the magnetic state. As the load tempera­
ture rises above the Curie or critical
point, there is an increase in current and
lagging kilovolt-amperes to the induction
heating coil.
If the generator voltage output is held
constant by means of a regulator, usually
the power output will decrease, but the
increase in lagging kilovolt-amperes to
the induction heating coil may cause an
increase in generator output current to a
value above its rating. In this case it is
necessary to add capacitance in order to
keep the generator output current within
its rating. In typical applications the
power output after the load temperature
passes critical may decrease to as low as 30
per cent of the peak output occurring dur­
ing the heat.
If there is no voltage regulator on the
generator, as the load temperature rises
above the critical point the resulting lag­
ging power factor load on the generator
capacitance to keep the generator output
voltage up to a value near its rating.
Usually, the number of coil turns is so
selected that with rated generator termi­
nal voltage the maximum power absorp­
tion during the heat is equal to the genera­
tor output rating. However, in cases
where the power at the end of the heat is
considerably less than the peak during the
heat for a given coil voltage, fewer coil
turns may be used, resulting in a maxi­
mum power absorption equal to generator
output rating with a voltage less than the
generator rating. In this case the genera­
tor output voltage is reduced by operat­
ing with a lagging power factor while the
load is below the critical point. Then the
generator output voltage is increased by
addition of capacitance after passing the
critical point. By this means it is some­
times possible to realize a higher average
power during the heat and hence reduce
heating time compared to that which
would be obtained with a coil designed to
absorb a maximum power output equal
to generator rating at rated voltage.
Changes as Load Heats
In the definitions which follow, A} B,
C, D, E, F, and G are defined implicitly
to save space. For example, RP = N2 A
is equivalent to A = RP/N2.
N—number of turns
Rp = N2A — resistance of inductor coil it­
self (ohms)
RS — N2B — resistance of load as reflected in
inductor coil (ohms)
R = N2(A +B) = N2F=resistance of inductor
coil with load (ohms)
XP — N2C—reactance caused by flux be­
tween inside and outside radius of
inductor coil (ohms)
Xs — N2D = reactance caused by flux within
the load as reflected in inductor coil
(ohms)
X0 = N2E =reactance caused by flux in air
gap between coil and load (ohms)
X = iV 2 (C+D+£)=iV 2 G=reactance of in­
ductor coil with load (ohms)
EL = voltage across inductor coil terminals
AA (volts)
IL = current through inductor coil (amperes)
PL = power input to inductor coil and load
(watts)
Ps = power dissipated in load (watts)
Paper 46-124, recommended by the AIEE subcom­
mittee on induction and dielectric heating for près"
entation at the AIEE summer convention, De­
troit, Mich., June 24-28, 1946. Manuscript sub­
mitted April 15, 1946; made available for printing
May 9, 1946.
J. T. VAUGHAN is a research and development
manager and J. W. WILLIAMSON is a research
engineer, both of the Tocco division of The Ohio
Crankshaft Company, Cleveland, Ohio.
887
 -*ii- change greatly during the heating opera­ and E, and for the calculation of the load
tion. However, if the air gap reactance resistance and reactance coefficients B
is small, the magnitude of this current and D at the end of the heating opera­

ö a
GENERATOR
CAPACITOR-
JÎI INDUCTOR
C0IL-^_,
L 0 A D
Figure 1 . Conventional induction heating
circuit using motor generator set
The required number of turns for any
given total power to the coil and for any
given terminal voltage may be calculated
by means of equation 2.
In analyzing the changes which occur
in a variable impedance circuit, it is con­
venient to represent the variation of re­
actance with resistance by a plot in rec­
tangular co-ordinates. Referring to Fig­
ure 2, the total resistance R and reactance
X of an induction heating coil with its
load at room temperature are represented
by the co-ordinates of point Pi. Since
Rp, Xv, and X0 are nearly constant, the
principal changes which occur in R and X
as the load heats are caused by variations
in the load resistance and reactance, Rs
and X8. When the power first is applied,
Rs and Xs increase because of the increas­
ing resistivity of the load with rising tem­
perature. The load impedance, there­
fore, follows a locus such as PiP 2 .
After a portion of the load reaches the
critical temperature, R and X drop off
rapidly. Let P 3 represent the impedance
calculated by taking the entire load to be
above the critical temperature and non­
magnetic with resistivity corresponding
to final conditions. The assumption will
may change sufficiently so that maximum
power to the coil occurs when the imped­
ance is less than the maximum value.
With the impedance locus shown in Fig­
ure 3, maximum power occurs when IL is
represented by Oh, where Q is the center
of the current locus and QI4 is parallel to
EL. By plane geometry 04 = ZQUO,
and 90 ° + « = Z QUO+ Z QOh=2 Z QUO.
Therefore,
04 = 45° + a:/2 (1)
The angle which 0 P 4 makes with EL
may be determined, therefore, by plotting
P2P3 and measuring the angle a which
this line makes with EL. The intersec­ B=l
tion P 4 of OP4 with P2P3 gives the values
of R and X for maximum power to the D = 0MB
coil. If 04 as defined by equation 1 is less
than 02 or greater than 03, the intersection
of OP4 with P2P3 extended does not repre­
sent an impedance which actually occurs
during the heating operation. If 04, or
45° + a/2, is less than 02, as in Figure 2,
maximum power corresponds to maximum
impedance. If 04 should be greater than
03, maximum power would occur at the K6 = v? K7
end of the heating operation where the
impedance is minimum.
Since F and G are proportional to the
total resistance and reactance of the coil
(R = i W a n d X = N*G), P2P3 in Figures
2 and 3 represents not only the locus of X
versus R but, to a different scale, the locus
of F versus G. The values of F and G
used to determine the number of turns
usually are based on conditions for maxi­
mum power to the coil. For 02 > 4 5 ° +
tion, if the load is in the nonmagnetic
state. The same limitations as given pre­
viously apply in the use of these formu­
las. These equations for resistance and
reactance coefficients for nonmagnetic
loads may be applied with reasonable ac­
curacy to SAE 1010 to 1045 steel above
1,600 degrees Fahrenheit. For conven­
ience, curves of resistivity versus tempera­
ture for SAE 1010 and SAE 1045 steels
are given in Figure 4.
For the load in the magnetic state and
at the temperature for maximum imped­
ance, B and D may be calculated by
/3.14MTA ..
D
-^—jVfKrXlO-* ' (5)
(6)
K7 is plotted against Ps/(3.14a<£) V/>
the watts per square inch of cylindrical
surface of load within coil divided by the
square root of frequency, in Figure 5.
The ranges of extrapolation are indicated
by dotted lines. For convenience the
function
(7)
is given as a function of P s /3.14 a0L for
/ = 10,000, 3,000, and 1,000 cycles per
second in Figure 6. To determine B and
D, it is first necessary to find Ps. The
portion of the total coil power input ab­
sorbed by the load is B/F = B/(A + B).
Therefore, the power to the load is
'-(Ä> (8)

be made that after the point of maximum
impedance is reached R and X follow the
straight line locus P2PS. This assumption
has been checked experimentally and
found to be reasonably accurate.
Suppose ELj the inductor coil terminal
voltage, is held constant as the load heats.
The locus of inductor coil current IL cor­
responding to impedance locus P2P3 is the
circular arc / 2 Ι 3 . 4 The center of the circle
0/2/3 lies on the line OQ, which makes the
same angle a with the vertical as P2P3
makes with the horizontal. The power
a/2 (Figure 2), maximum power to the
load corresponds to maximum impedance,
or the values of F and G plotted at P 2 .
For 02 < 45° + a/2 (Figure 3), maximum
power to the load occurs when F and G
are determined by the co-ordinates of P 4 .
Circuit Equations and
Their Limitations
For any given total power PL to the
coil and coil terminal voltage ELf the re­ > ROR f-

factor angle 0 is equal to the angle OP quired number of turns is

makes with EL. With conditions as
shown in Figure 2, maximum power to the N=EL^j (2)
\PL(F*+G*)
coil occurs at the point of maximum im­
pedance, represented by P 2 , since the By definition,
component of inductor current that is in
phase with EL is greatest at this point. F=A+B (3)
The current locus of Figure 2 would re­ G=C+D+E (4)
sult from a relatively large air gap react­
ance X0. Under this condition the cur­ Formulas are given in the authors' pre­ Figure 2. Impedance and current changes as
rent through the inductor coil does not vious paper 1 for the calculation of A, C, load heats

888 Vaughan, Williamson—Induction Heating Coils AIEE TRANSACTIONS

 B a n d F c a n n o t b e determined until
P8 is known. However, t h e r a t i o B/F
usually lies within t h e r a n g e 0.80 t o 0.95.
P8, therefore, m a y be calculated first from
equation 8 on t h e basis of a n y reasonable
value of this ratio. An a p p r o x i m a t e value
for \/f Ki or K6 t h e n can be obtained,
which m a y be s u b s t i t u t e d into equation 5
t o obtain a first approximation for B.
Actually, a three per cent error in estimat­
ing Ps results in only a one per cent error
in B, so t h a t this first approximation is
often sufficiently accurate for practical
purposes. However, if greater accuracy
is desired, t h e first approximation for B
Figure 3. Impedance and current changes as
load heats
m a y be used t o obtain a m o r e a c c u r a t e
value of B/(A + B) a n d t h e foregoing
process repeated.
LIMITATIONS
1. Taking the resistivity of the load as
4 0 X 1 0 - 6 ohm-inch at the temperature for
maximum impedance, the maximum depth
which magnetic flux and current penetrate
into the load, or the depth of zone in which
energy is induced (from equation 34) is
0.064
(inches) (9)
If the load is hollow, its wall thickness
should be at least* as great as δΜ for the
given equations to apply.
2. For an accuracy of plus or minus ten
per cent, the ratio α0/δΜ should be a t least
8.0.
3. The correction for coil shortness
should depend on the ratio of inside diameter
of the induction heating coil to its length,
the ratio of the outside diameter of the load
1946, VOLUME 65 Vaughan,
to the inside diameter of the coil, and prob­
ably the ratio
50
y/Ra*+Xa%/X0 = VB*+D*/E
of impedance associated with flux in the / /f
load to impedance associated with flux in /
the air gap. If this ratio is of the order of SAE 1045
magnitude of 1.0 or greater, the flux through Y
SAE 1010
the load is appreciable in relation to the
flux in the air gap, and the total flux is
therefore considerably greater than the flux
through the air gap alone. Consequently, a
larger number of ampere turns is required to
overcome the flux reluctance drop in the 5> l0
portion of the magnetic circuit external to
the coil, or for any given number of ampere
turns the magnetic intensity inside the coil
UJ
■X
L^f
0 400 800 1200 1600 2000
is less than would result with a nonmagnetic TEMPERATURE-DEG F
load of the same dimensions. However, in
the majority of applications in which a steel Figure 4. Resistivity versus temperature for
load is heated with a multiturn coil the ef­ S A E 1 0 1 0 and S A E 1045 steel
fect of coil shortness is so small t h a t it is
believed t h a t the equations given may be
used with reasonable accuracy. The con­
/ = f r e q u e n c y (cycles per second)
stant Ki, by which the actual ampere turns
per inch must be multiplied to obtain the ω=2ττ/
ampere turns per inch which would produce L = length of coil (centimeters)
the same average power density if the coil JV=number of turns
were infinitely long, is derived (for non­
magnetic loads) in the authors' previous T h e t o t a l flux within a circle of radius
paper. 1 r is, b y definition,
φ=2ττ£,\βά,γ (10)
Derivation of
Expressions for B and D B y O h m ' s law, w i t h positive directions
as indicated in F i g u r e 7,
T h e e q u a t i o n s for B a n d D given
in t h e foregoing t e x t a r e based on 2πΥρι ·-
οφ
(H)
experimental d a t a a n d relations derived òt
a n d checked experimentally u n d e r " M o r e Providing, as will b e assumed, t h a t t h e
E x a c t D e r i v a t i o n s , " b y m e a n s of which radius of t h e load is sufficiently great so
these d a t a m a y be extended t o other t h a t r is nearly equal t o t h e outside radius
frequencies. T h e " A p p r o x i m a t e T h e o r y " over t h e region in which β a n d i are a p ­
is included t o provide a n u n d e r s t a n d i n g preciable, equation 10 m a y b e w r i t t e n
of certain physical principles in t h e induc­ Φ=πα0£,Τ ßdr \
tion heating of magnetic materials a n d t o ao/2
^7ra0fs ßd5 ) (12)
establish limitations for small diameters
a n d wall thicknesses. T h e assumption where δ = a0/2 — r is t h e distance from t h e
m a d e in t h e l a t t e r section does n o t limit outside of t h e load. E q u a t i o n 11 m a y b e
t h e generality of t h e remainder of t h i s written
paper.
ρπα0ί = άφ/ òt (13)
Let
Consider only coils a n d loads of large
Subscript o refer to outside of load
Subscript M denote maximum values length t o d i a m e t e r ratios. T h e n , as in
δ = distance from outside of load (centi­ t h e induction heating of n o n m a g n e t i c
meters) materials, t h e magnetic i n t e n s i t y is equal
a0 = outside diameter of load (centimeters)
r = distance from axis of load (centimeters)
^ = instantaneous current density in load
(abamperes per square centimeter) -„^
Iins = instantaneous current in coil (ab­
amperes)
0.01
jT = rms current in coil (abamperes)
φ = instantaneous magnetic flux within pJJ
0.005
radius r (maxwells)
e = instantaneous voltage per turn to bring
about time rate-of-change of flux
within ΙοΛά = άφο/dt (abvolts)
β — magnetic flux density (maxwells per 0.001
0.005 0.01 0.05
square centimeter) i Ps(*w)
H — magnetic intensity \ff Tfa 0 L(SQIN.)
p = resistivity (abohms per centimeter)
/ = time (seconds) Figure 5. Load resistance coefficient K7
Williamson—Induction Heating Coils 889
 Equation 15 shows that at any instant the Substituting equations 23 and 21 for i

fisfîf^
*„
current density in the load varies with and equation 22 for δ+
^^.--^
1.0
s δ only where the flux density β is chang­
ing with time. By assumption, β can eMz sin ω/(1 — cos œt) (26)
^ ^ ,^Ω 'πLL
^ have only three values: βΜ, — βΜί and N 2ττ2ρα02βΜω
^π>^ rT4JJ
ΓΤΓ·^
0.5
~~Γ-
zero. At any given time, i can change e = 0 at œt = T. Therefore, from equa­
Γ>°[ Τ"*"' *■> 1 Mil only where β is going from one to another tions 17 and 13, άφ/ά1 = 0 and the cur­
iti ^ of these values. rent density i is zero; i was also zero
The magnetic intensity at the outside at t = 0. The conditions at ωΙ = τ, there­
0.1 of the load is fore, are identical (except for directions)
0.5 1.0
PS(KW) Ho = MN/L)Iins with the conditions assumed at / = 0.
(19)
TTa 0 L(SQ IN.) During the remaining half cycle a wave
Consequently, at the instant / = 0 at of negative magnetization enters the
Figure 6 . Load resistance coefficient K6 which the current in the coil becomes posi­ load. The phenomena of the first half
tive, the direction of magnetization at cycle are repeated with changes in polar­
to 4π times the total current per unit the outside of the load also becomes posi­ ity, as shown in Figure 9. The maximum
axial length outside the given radius. tive. Denote the depth of positive mag­ depth of penetration of electrical energy
The current per unit axial length in the netization by δ+. The total flux within is obtained by substituting ωί=π into
coil is (N/L) Iins. Therefore, the load is equation 22.
Φο=πα0[δ+βΜ+(δΜ-δ+)(-βΜ)] = ÒM — ^M^oßu^ (27)
H=±^Iins-f0lidò\ (14) ττα0βΜ{2δ+-δΜ) (20)
Equation 26 applies only t o the in­
The minus sign before the integral re­ Integrating equation 17 and substituting tervals during which e is positive. From
sults from the choice of positive direction equation 18 for e, equations 18 and 26, the instantaneous
for i (Figure 7). Differentiating equation input per turn to the load during the first
13 with respect to δ and substituting Φο — Jo edt+constant half cycle is
— —(eM/u>) cos oit+constant (21)
equation 12 for φ, —~~
L ΘΜΖ
sin2
ài laß elins =ΤτΊΓΙ—To—
N 2π2ρα 2β ω "^1 ~ cos ω
^ (28)
0 Μ
(15)
'pat
The average power per turn to the load
^I|NSe obtained from equation 28 is
Approximate Theory ~© Θ Θ Θ~
L eMz
(29)
Most induction heating applications ►Ρ,Η,Φ *-'»- N 4π2ρα02βΜω
require inductor coil current densities
such as to produce high saturations near From equation 26 the rms coil current
: ^Ρ,Η,φ
the outside of the load. Therefore, in the © Θ © Θ during the first half cycle, which is equal
present section assume the ß—H curve to the rms coil current, is found to be
shown in Figure 8, in which 0 = =±=/3M or
zero. Positive directions are indicated Figure 7 . Current and flux directions- ^ 7. ilk <* (30)
in Figure 7. Take the instant / = 0 when positive \ 8 N 2ττ2ρα02βΜω
the current in the inductor coil is zero Comparing equations 29, 18, and 30, the
after having been negative. Assume that ratio of abwatts t o abvolt-amperes or
at this instant the flux density ß is watts to volt-amperes is
Combining equations 20 and 21, and
negative (or to the left) between δ = 0
noting that δ+ = 0 at t=0t
and δ=δΜ, where δΜ is the maximum = Λ/0.8 = 0.895 (31)
0.707^/7
depth of penetration t o be determined δ+=(βΜ/2ττα0βΜω)(1- cos ωή (22)
later. Thefluxthrough the load at / = 0 is Solving equation 30 for CM and substitut­
δ+ is plotted against time in Figure 9. ing into equation 29, the power to the load
φ0[ί = ο = —πα0δΜβΜ; (16) The time rate-of-change of flux οφ/òt is per turn is
The portion of the voltage per turn uti­ independent of position for δ<δ+, and
/*~τ
lized in bringing about a time rate-of- zero for δ>δ+. Therefore, from equation N (32)
change of flux within the load is 13, w^S.maoVpßMwylj'I ·*" 1

1 άφ0 or the total power to the load is

i= - - p f o r δ<δ+
(17) ρπα0 dt (23)
' dt
= 0 for δ>δ+
Nw = 7Ma0J^.(Niy·* - (33)
Since φ0 is negatively maximum at t = 0,
e is zero at 2 = 0, but positive after this The total current per unit length in the
instant. Therefore, assuming this volt­ load is Table 1
age varies sinusoidally with time, which Λαο/2ίάδ=ίδ (24)
+
is the case at least if the voltage applied Ratio (Watts
Kilowatts Per Divided By
to the coil is sinusoidal and the air gap β is zero for δ > δΜ by assumption. There­ Square Inch x Volt-Amp er es)
between the coil and load is sufficiently fore, His also zero. Substituting δ = a0/2 to Load to Load
small, into equation 14, therefore, gives
Calculated 0.244 . , . 0.895
e — βΜ sin œt (18) Ιίη8 = (Σ/Ν)ΐδ+ (25) 0.802

890 Vaughan, Williamson—Induction Heating Coils AIEE TRANSACTIONS


P = PM
P = -PM
Figure 8. ß—H
curve assumed in
approximate theory
M a k i n g use of equations 27, 30, 33, 5,
and 7 and converting all quantities t o t h e
ohm-inch system, it can b e shown t h a t
δΜ = 1.595 Χ 1 0 3 ΐ τ (34)
For a given density of power t o t h e load,
the m a x i m u m d e p t h of penetration should
be nearly independent of t h e air gap.
Therefore, t h e expression used for K6 in
deriving equation 34 was obtained b y
p u t t i n g Ki = 1 in equation 5.
T a b l e I gives a comparison of experi­
m e n t a l results with theoretical calcula­
tions, t h e latter based on t h e approxi­
m a t e theory. An S A E 1015 steel load
was heated t o 210 degrees Fahrenheit b y
means of a closely fitting coil. T h e fre­
quency was 10,000 cycles per second.
T h e measured coil current was such as t o
produce 486 ampere t u r n s (rms) per inch
axial length of coil. I n t h e theoretical
calculation, t h e resistivity of S A E 1015
steel a t 210 degrees Fahrenheit a n d t h e
flux density ßM were t a k e n respectively
a s 6.75 X 10~ 6 ohm-inches a n d 18,500
lines per square centimeter.
T h e following conclusions m a y b e
d r a w n from t h e analysis so far presented :
1. The total depth of penetration of elec­
trical energy in the magnetic state is usually
small. Table I I gives values of δΜ corre­
sponding to two kilowatts per square inch
to the load and the temperature for maxi­
mum impedance with constant current ; p is
Figure 9. Inductor
current and depth of
penetration versus
time
1946, VOLUME 65 Vaughan, Williamson—Induction Heating Coils
taken as 4 0 X 1 0 - 6 ohm-inch, and K% in
equation 34 is obtained from Figure 6. 111 » a 1
2. The power density is approximately
proportional to the 1.5 power of current. V\ Vi­
This relation was observed by Rosen­ ert Λ-β-
1 * ' V {*
berg. 5 · 6 ' 7 As noted by Baker, 2 however, V \V I
Rosenberg's explanation is not very satis­ \Aif
v\
factory.
3. I t frequently has been assumed t h a t the
M λ
Ί
resistance and reactance of an induction
/ 7\\
heating coil with a magnetic load could be
calculated by assuming "some" constant
/ /
value of permeability. This is not strictly
true,since any constant value of permeability
would result in a ratio of watts to volt- 0.001
y
amperes to the load of 0.707 a t sufficiently 500
high frequencies. KiNI
4. With power densities as used in induc­
tion heating practice and with δΜ small Figure 10. Plot of experimental data
compared to the load diameter, the load
power caused by hysteresis is usually Θ—Coil 1, 10,000 cycles\
negligible. For instance, considering a +—Coil 2, 10,000 cycles I
1-inch diameter load of SAE 1020 steel χ—Coil 3, 3,000 cycles/
with a power density of 500 watts per square
inch of load surface at 10,000 cycles, the
power caused by hysteresis would be less
than 22 watts per square inch of load surface, M a k i n g use of equation 35,
or four per cent of the total power. This is ÒH
based on an assumed maximum flux density
Ο2#_4ΤΓ , ÒH
μ {Η) (37)
of 100,000 lines per square inch and a άδ* ~ p at
hysteresis energy of 0.05 joule per cubic
inch per cycle, 10 which is from data,with the where μ\Η)
is t h e differential permeability
steel a t room temperature. Further data defined b y
indicate a decrease in hysteresis loss as
temperature is increased, the hysteresis loss f_dB_
μ
approaching zero as the critical temperature ~dH "* (38)
is approached. 9
Since for a n y given distance ò from t h e
outside of t h e load a n d time, there exists
More Exact Derivations
one a n d only one value of H:
T h e saturation flux densities of carbon (39)
Η=Ψ(δ, t)
steels usually t r e a t e d b y induction heat­
ing are known a t present only at room As φ(δ, t) is a solution of equation 37, it
t e m p e r a t u r e . I n order t o design coils for can b e shown t h a t H' = \l/(ks} k*t) is also a
heating above t h e critical point, however, solution. At t h e outside of t h e load
t h e values of t h e load resistance a n d re­ Ψ(δ, ι) = Ψ(ο, t) a n d φ^δ, Μ)=Ψ(ο, kH). Sup­
actance coefficients B and D m u s t be de­ pose for a given p e a k magnetic intensity
termined a t t h e t e m p e r a t u r e of m a x i m u m H0M a t t h e outside of t h e load a n d a
impedance, a b o u t 1,200 degrees F a h r e n ­ given frequency fu H is represented b y
heit. T h e present section provides a \f/(st t). T h e n for t h e same m a g n e t i c in­
m e a n s of accomplishing this, a n d a t t h e tensity H0M a t t h e outside of t h e load
same time affords a more a c c u r a t e t h e o r y a n d a frequency k2fi, t h e m a g n e t i c in­
which avoids t h e assumption t h a t β = =*= t e n s i t y is represented b y ψ^δ, k*t).
constant. Use is m a d e of experimental W i t h a frequency fi,
information which is readily obtainable.
β=Φ(Η)==Φ(^(δ, 0 ) = Ω ( δ , t) (40)
Again consider loads of sufficient radius
so t h a t t h e distance from t h e axis m a y be W i t h t h e same p e a k m a g n e t i c intensity a t
t a k e n as t h e outside radius a 0 /2 a t all t h e outside of t h e load a n d a frequency
points for wThich t h e magnetic intensity k2fi,
/ / , t h e flux density β, a n d t h e current
density i are appreciable. Neglect hys­ β = Φ(Η') =Φ{φ{αδ, uh) =Ω(*δ,Λ*ί) (41)
teresis. T h e n for a n y given value of H Since t h e flux density is assumed negli-
there exists one a n d only one value of β
or, mathematically,
Table II
■£■=*(*) (35)
Differentiating equation 14 twice with Frequency in Depth of
respect t o δ a n d s u b s t i t u t i n g i n t o equation Cycles Per Penetration
Second in Inches
15,
10 000 0.066
» * - £ . * (36) 3,000 0.145
Ò52 p at
891
gible except for very small values of δ,
the upper limit in equation 12 may be
taken as infinity. Therefore,
Φο^ππαοΜ ° ° ^ δ (42)
Substituting equations 40 and 41 into
equation 42, with a frequency fu
= and bus losses between the wattmeter
^ ^ 0 Χ α Ώ ( δ , t)dò (43)
or, with a frequency &2/i,
<j>'0=Tra0J0 Q(h8,k*t')d8
CO
=ira0/kJ0 ü(s, icH')dh (44)
At corresponding times, kH' in equation
44 is equal to t in equation 43. Therefore,
the total flux in the load is proportional
to 1/k or 1/VT". The load impedance
is proportional to the product of the mag­
nitude of this flux multiplied by fre­
quency, or
(i/VT)f=Vf
Let
Wi = kilowatts per square inch to the load
Vi = reactive kilovolt-amperes per square inch
to the load
KiNI/L = effective ampere turns per inch
(rais)
Then from the foregoing reasoning, Wi
and vi may be written in the form
w^VfFiiK.NI/L) (45)
v^VfFi&NI/L) - (46)
where the functions Fi and F2 are inde­
pendent of frequency. To determine
these functions for SAE 1015 steel at the
load temperature for maximum imped­
ance and to show experimentally that
Wi/ V / and v\l y/J are independent of fre­
quency for any given ΚχΝΙ/L, data were
taken at 10,000, 9,600, and 3,000 cycles
per second. The results are' shown in
Figure 10. The variations in Wi/y/f and
vi/y/f between 9,600 and 10,000 cycles
per second w7ere negligible for a given
KiNI/L. Dimensions of coils and loads
are given in Tables I I I and IV. In each
reading the current through the induction
heating coil was held constant by varying
the voltage. This current was measured
through a current transformer by a dyna­
mometer type ammeter. Readings were
taken at the instant of maximum coil
terminal voltage. The power to the coil
also was found to be maximum at this
instant. To measure this power as ac­
curately as possible, the capacitor at BB
(Figure 1) was adjusted for approxi­
mately unity power factor at the generator
terminals CC for the instant readings were
taken. The generator output was meas­
ured by a wattmeter connected at CC.
The power to the load was obtained by
subtracting the calculated coil copper
loss.1 After making a slight correction
for conductor wall thinness at 3,000 cy­
cles per second (no correction was re­
quired at 10,000 cycles per second), the
maximum ratio of calculated coil PR loss
to generator output was 0.04. Capacitor
and coil terminals were negligible. The
voltage at the terminals of the induction
heating coil was measured by a voltmeter
connected at AA. It was assumed that
the reactive volt-amperes to the coil could
be determined from the watts and volt-
amperes by the usual method. Experi­
ence indicates that, after making allow­
ance for the reactance of the bus, the re­
active volt-amperes so calculated agree
closely with the volt-amperes of capaci­
tance required to balance to unity power
factor at the generator terminals, even
though the wave form of the current
through the inductor coil is not truly sinu­
soidal. The reactances associated with
the time rate-of-change of flux in the coil
copper and air gap are, respectively,
N2C and N2E. The reactive volt-am­
peres to the load were obtained by sub­
tracting PN2(C+E) from the reactive
volt-amperes to the coil. The watts per
square inch and vars per square inch t o
the load then were found by dividing the
power and reactive volt-amperes by the
load surface within the coil wa0L.
With a frequency of 9,600 cycles only,
the foregoing experiments were repeated
with SAE 1020 and SAE 1045 loads. No
significant differences could be detected
from the results with SAE 1015 steel. At
1200 degrees Fahrenheit, the difference in
resistivities between SAE 1015 and SAE
1045 steels is about three per cent. Ac­
cording to equation 33, if the magnetic
properties of the two steels were identical,
the load resistances should differ by
about two per cent. This variation
would be negligible in most induction
heating calculations.
By definition,
B= RS/N2=PRS/(NI)2
Table III. Description of Induction Heating
Coils
Coil 1
Total turns, N , 35 . .19
Inside diameter, inches 3.29 . . 3.20
Length over turns, L, inches 14.62 . . 7.05
Conductor:
Dimension parallel to^ axis of
coil, inches 0.375. . 0.297
Dimension perpendicular to
axis of coil, inches 0.25 . . 0.25
Wall thickness, inches 0.045. . 0.048
Resistivity, microhm inches 0.73 . . 0.73
Table I V . Description of Loads
Load 1 Load 2 Load 3
Outside diameter, inches.. . 2 . 5 1 . . . 2 . 5 0 . . . 2.50
Type steel, SAE n u m b e r . . . .1015. . . .1020.. ..1045
But PRS is the power to the load in watts.
Since wi is expressed in kilowatts per
square inch, PRs = TaoLwiXl03. There­
fore,
xa o L^iX10 3
5 =
(NI)2
ira0ki2
V/#7X10-3 (48)
where
wiX10Vv7
K7 = (49)
(KiNI/L)2
From equation 45 Wi/y/f is a function
of Ki(NI/L9 or KiNI/L is a function of
Wi/\/f. Therefore, K7 is also a function of
Wi/Vj"· Similarly, it may be shown that
where
_ _ViX10«/Vr
8
(KiNI/L)2
is a function of ΚχΝΙ/L or w\/ y/f. How­
ever, Figure 10 indicates that within the
range of K\NI/L covered by experiments,
the ratio of reactive volt-amperes to
watts is nearly constant and equal t o
0.65. Therefore, it is sufficiently accurate
at the load temperature for maximum
impedance to determine D from B by
means of equation 6.
References
1. DESIGN OF INDUCTION-HEATING COILS FOR
CYLINDRICAL NONMAGNETIC LOADS, J. T. Vaughan,
J. W. Williamson. AIEE TRANSACTIONS, volume
64, 1945, August section, pages 587-92.
2. INDUCTION HEATING OF MOVING MAGNETIC
STRIP, R. M. Baker. AIEE TRANSACTIONS, volume
64, 1945, April section, pages 184-9.
3. VACUUM-TUBE RADIO-FREQUENCY GENERATOR
—CHARACTERISTICS AND APPLICATION TO INDUC­
TION-HEATING PROBLEMS, T. P . Kinn. AIEE
TRANSACTIONS, 1944, volume 63, pages 1290-1303.
(47)
4. ELEMENTARY ELECTRIC CIRCUIT THEORY
(book), Richard H. Frazier. McGraw-Hill Book
Company, Inc., New York, N . Y. 1945, pages
246-9.
5. WIRBELSTROME I N MASSIVEM E I S E N , E. Rosen­
berg. Elektrotechnische Zeitschrift (Berlin, Ger­
many), May 31, 1923, pages 513-18.
Coil 2 6. EDDY CURRENTS IN IRON MASSES, E. Rosen­
berg. The Electrician (London, England), August
24, 1923, pages 188-91.
7. PROPERTIES AND TESTING OF MAGNETIC M A ­
TERIALS (book), Thomas Spooner. McGraw-Hill
Book Company, Inc., New York, N. Y., 1927, pages
98-103.
8. Reference 7, pages 138-9.
9. Reference 7, pages 174-6.
10. ELECTRO-MAGNETIC DEVICES (book), H . C.
Roters. John Wiley & Sons, Inc., New York,
N . Y., 1941, page 57.

892 Vaughan, Williamson—Induction Heating Coils AIEE TRANSACTIONS