Project Report

On

INDUCTION HEATER USING ZVS (ZERO

VOLTAGE SWITCHING) DRIVER

Submitted By

Mr. Siddhesh V. Tekawade [B151142538] Mr.

Mandar S. Dhamal [B151142510]
Mr. Vaibhav G. Kuvar [B151142521]
Mr. Rushikesh P.Raul [B151142529]

Under the guidance Of

Prof. Y. N. Bangali

Jawahar
Education Society’s
Institute of Technology Management and Research, Nashik-
422222 Department of Electrical Engineering
Savitribai Phule Pune University
Academic
Year: 2021-2022
CERTIFICATE

This is to certify that following students from Second Year Electrical Engineering have
successfully completed project work on “ ” at
Jawahar Education Society’s Institute of Technology, Management and Research, Nashik in the
partial fulfilment of the Bachelor’s Degree in Electrical Engineering in the academic year 2022-
23.

Mr. Siddhesh V. Tekawade [B151142538] Mr.

Mandar S. Dhamal [B151142510]
Mr. Vaibhav G. Kuvar [B151142521]
Mr. Rushikesh P. Raul [B151142529]

Prof. S.A.Thete Prof.P.P.Wagh

External Examiner Project Guide

Prof.P.P.Wagh Prof. Mrs. S. A. Thete Prof. Dr. M. V. Bhatkar

PBL Coordinator Head of the Department Principal
ACKNOWLEDGEMENT

It is my privilege to express my sincerest regards to my Project guide Mrs. P.P.

Wagh, for her valuable inputs, able guidance, encouragement, whole-hearted cooperation
and constructive criticism throughout the duration of my project.
I highly indebted to Mrs. S. A. Thete and other faculties to help me with their
guidance and constant supervision as well as for providing necessary information regarding
the Project. I also thankful to staff of Electrical Department of Jawahar Education
Society’s Institute of Technology, Management and Research, Nashik for providing
valuable information to me.
I deeply express my sincere thanks to Head of Electrical Department Mrs. S. A.
Thete for encouraging and allowing me to present the Project on the
topic “ ”
at our department premises for the partial fulfillment of the requirements.
I would like to express my gratitude towards Dr. M. V. Bhatkar, Principal of
Jawahar Education Society’s Institute of Technology, Management and Research,
Nashik for his kind cooperation and encouragement which help me in research for this
Project.
I take this opportunity to thank all our lecturers who have directly or indirectly helped me
for the project. I pay my respects to my parents and others for their encouragement
throughout my seminar. Last but not the least I express my thanks to friends for their
support.

i
ABSTRACT

i
INDEX

Acknowledgement............................................................................................................... i

Abstract...............................................................................................................................ii

List Of Figure................................................................................................................... iv

List Of Table...................................................................................................................... v

1 Introduction.....................................................................................................................1

1.1 Introduction...........................................................................................................2

1.2 Problem statement................................................................................................2

1.3 Aim of Objective..................................................................................................4

1.4 Purpose of project................................................................................................4

1.5 Objective of project..............................................................................................5

1.6 Methodology........................................................................................................5

1.7 Scope....................................................................................................................5

1.8 Summary...............................................................................................................6

2 Literature Review...........................................................................................................7

2.1. Background information.......................................................................................8

2.2 Summary...............................................................................................................9

3 System Development.....................................................................................................10

3.1 Methodological approach.....................................................................................11

3.2 Methods of data collection / Components...........................................................11

3.2.1 Battery 11

3.2.2 LED 12

3.2.3 Registers… 12

i
3.2.4 Zener Diodes….........................................................................................12

3.2.5 Diodes… 13

3.2.6 Polypropylene Capacitor 13

3.2.7 Power MOSFET 14

3.2.8 Working Coil 15

3.2.9 Inductor 15

3.2.10 icture Of All Componants… 17

3.3 Block Diagram and methods of analysis.............................................................18

3.4 Operation of Circuit............................................................................................19

3.5 Summary..............................................................................................................20

4 Performance Analysis..................................................................................................21

4.1 Results..................................................................................................................22

4.2 Summary................................................................................................................22

5 Future Work................................................................................................................23

5.1 Advantages and disadvantage...............................................................................24

5.2 Applications….......................................................................................................24

5.3 Future Scope...........................................................................................................25

Conclusion..................................................................................................................26

Reference.....................................................................................................................27

i
List of Figures

3.2.1 Battery… 11

3.2.2 LED 12

3.2.3 Resistors… 12

3.2.4 Zener Diode 13

3.2.5 Diode 13

3.2.6 Polypropylene Capacitor 14

3.2.7 Power MOSFET… 14

3.2.8 Work Coil 15

3.2.9 Inductor… 15

3.2.10 Picture of Component… 17

3.3.1 Circuit Diagram… 18

3.3.2 Basic Circuit 19

4.1.1 Testing of the Prototype 22

v
List of Tables

3.1 Methodology… 11

3.2 Components… 16

v
CHAPTER 1
INTRODUCTIO
N

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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1.1 Introduction
Induction heating is the process of an electrically conducting object by electromagnetic
induction, through heat generated in the object by eddy current. An induction heater consists of an
electromagnet, and an electronic oscillator that passes a high frequency alternating current through
the electromagnet. The rapidly alternating magnetic field penetrates the object, generating electric
current inside the conductor called eddy currents. The eddy current flowing through the resistance of
the Material heat by joule heating. In Ferromagnetic material like iron, heat may also be generated by
joule heating. In ferromagnetic (and ferromagnetic) materials like iron, heat may also be generated
by magnetic hysteresis losses. The frequency of current used is depends upon the object size,
material type, coupling (between the work coil and object to be heated) and the penetration depth.
An important feature of the induction heating process is that the heat is generated inside the object
itself, instead of by an external heat source via heat conduction. Thus, objects can be heated very
rapidly. In addition, there need not be any external contact, which can be important where
contamination is an issue. Induction heating is used in many industrial processes, such as heat
treatment in metallurgy, Czochralski crystal growth and zone refining used in the semiconductor
industry, and to melt refractory metals which require very high temperatures. It is also used in
induction cooktops for heating containers of food; this is called induction cooking.

1.2 Problem Statement

Domestic purpose induction cookers are normally operated at a high frequency ranging
between 20 kHz to 50 kHz (Sadhu et al., 2005). The main parts of an induction cooker are the high
frequency inverter. Inverter selection:-

The induction cooker takes the energy from the mains voltage and this voltage is then rectified
by an uncontrolled bridge rectifier. A bus filter is designed to allow a high voltageripple and the
resultant power factor close to one. Then an inverter supplies high frequency alternating current to the
induction coil. Nowa-day, resonant inverter topologies are commonly used for induction cooker. The
most used inverter topologies are full bridge and half bridge.

Different full bridge topologies are described by Hobson and Tebb (1985) and Dawson and
Jain(1991). Different types of half bridges are also reported by Hobson et al., (1985); Koertzen et al.,
(1995); Kamli et al., (1996); Wang et al., (1998), Kwon et al., (1999) and Sadhu et al. (2004). One
cycle controlled half bridge series resonant inverter is used by Hsieh and Wang, (1997) for low
conduction loss. Two single switch inverter topologies Zero Voltage Switching (ZVS) and Zero
Current Switching (ZCS) are described by Omori et al., (1985); Leisten and Hobson 1990); Cohen
(1993). Comparison considering full bridge, half bridge has been made by Llorente et al., (2002).

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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They have made a conclusion that due to robustness, cost saving and simple circuit
configuration, half bridge inverter is most popular. Achara et al., (2007) analyzed the circuit of half
bridge inverter using the principle of positivenegative phase shift control under ZVS and non-ZVS
operation for small size and low voltage induction cooker.Dawson and Jain (1990) also made a
comparison between two inverter power supply topologies such as current source parallel inverter and
voltage source series inverter for induction heating and melting operation. The comparison is based on
the criteria such as input power factor, component ratings, maximum and minimum operating
frequencies, operation under varying load condition, inverter starting capability and control simplicity.
They have shown that voltage source series inverter provides better converter utilization over current
source parallel inverter at the frequency more than 1 kHz. Below that frequency, current source
parallel inverter plays better role. Moisseev et al., (2003) proposed a circuit topology with an
additional active inductor snubber for an edge resonant ZVS-PWM high frequency inverter using
IGBT which can achieve ZVS in all power regulation ranges. Multiple burner appliances including
two or four inductors are manufactured.

In multiple burner induction cookers, either one inverter per burner or one inverter for two or more
burners is used. A single output inverter multiplexing the loads along the time periodically by means
of electromechanical switches is developed by Rilly (1988). A few researchers such as Jung (1999)
and Forest et al., (2000) tried to solve these problems.

Their proposed schemes have some limitations such as low efficiency due to two solid state
switches as proposed by Jung (1999) and restrictions in power control when all loads are operated as
proposed by Forest et al., (2000). Full bridge inverter with two outputs has been proposed by Burdio et
al., (2005).

Some modulation strategies are used in domestic induction heating. Square wave control and
asymmetric duty cycle control has been reported by Burdio et al., (2004) and Barragan et al., (2005).
In these controls the output power is decreased when the switching frequency is increased. To solve
this problem.

Pulse Modulation strategy is proposed bySugimura et al., (2006) and Park et al., (2007). Here, the
switching frequency is restricted at the highest efficiency range. The pulse regulation is achieved by
varying the intervals in which the current is supplied into the inductors. In this case, the power is
supplied in pulses of low frequency which creates some problems like non-compliance with flicker
regulation and non-optimal vessel heating. Acero et al., (2008) had made an overall comparative study
on induction cooker. The series resonant based multi-inverter used for multiple induction heaters is
described by Lucia et al., (2010).

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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1.3 Aim and Objective
Understanding the gaps in the literature, aims and objective of thesis are framed as follows:

The primary objective of this thesis is to design an energy efficient induction cooker. Key to a successful
induction heater design is to select a well-suited inverter with suitable selection of semiconductor switches. A
comparative study can be made among the various semiconductor switches in terms of efficiency of the same
power rating inverter through PSPICE-based computer simulation and real time experiments.

A resonant inverter delivers maximum power to the load only when it works at resonant frequency. On the
other hand, material, shape and size of the heater affectthe resonant frequency, Q-factor and efficiency of the
inverter. Thus, it is necessary to optimizethe physical parameters of the cooker so as to get the maximum benefit
from it. It is possible only when the circuit is properly analysed. An attempt can be made to derive the voltage
and current across the induction heater analytically, through P-Spice simulator and from the real experiments.

Heating coil is considered as another main part of the induction cooker. The design of a heating coil
with its optimal parameters and the selection of the optimum operating switching frequency of the inverter for
different thickness of utensils / vessels are necessary to get the maximum efficiency. To avoid unwanted surface
heating of induction coil and to maintain the under-damped condition for R-L-C load circuit, the value of
resistance and inductance of the heating coil should be optimized. Variation of resistance and inductance with
the coil shape, size and operating frequency is non-linear. An attempt can be made to develop a Neural Network
(NN) - based model for accurately predicting resistance of an induction cookerIn this study an NNbased model
has been developed to predict the value of resistance of an induction coil for different values of operating
frequency, size of wire, number of strands, number of spiral turns, and number twists per feet of heating coil.

They have made a conclusion that due to robustness, cost saving and simple circuit configuration, half
bridge inverter is most popular. Achara et al., (2007) analyzed the circuit of half bridge inverter using the
principle of positive negative phase shift control under ZVS and non-ZVS operation for small size and low
voltage induction cooker. Dawson and Jain (1990) also made a comparison between two inverter power
supply topologies such as current source parallel inverter and voltage source series inverter for induction
heating and melting operation. The comparison is based on the criteria such as input power factor, component
ratings, maximum and minimum operating frequencies, operation under varying load condition, inverter
starting capability and control simplicity. They have shown that voltage source series inverter provides better
converter utilization over current source parallel inverter at the frequency more than 1 kHz. Below that
frequency, current source parallel 27 inverter plays better role. Moisseev et al., (2003) proposed a circuit
topology with an additional active inductor snubber for an edge resonant ZVS-PWM high frequency inverter
using IGBT which can achieve ZVS in all power regulation ranges.

1.4 Purpose of project

As in our conventional heaters there are numerous issues of optimized consistencies and qualities

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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where as induction heating overcomes above problems. Induction heating eliminates the

inconsistencies and quality issues associated with open flame, torch heating and other methods. Once
the system is properly calibrated and set up, there is no guess work or variation; the heating pattern is
repeatable and consistent. With modern solid-state systems, precise temperature control provides
uniform result; power can be instantly turned on or shut off. With closed loop temperature control,
advanced induction heating systems have the capability to measure the temperature of each individual
part

1.5 Objective of project

The primary objective of this thesis is to design an energy efficient induction cooker. Key to a
successful induction heater design is to select a well-suited inverter with suitable selection of
semiconductor switches. A comparative study can be made among the various semiconductor switches
in terms of efficiency of the same power rating inverter through PSPICE-based computer simulation
and real time experiments.

1.6 Methodology

● Background Study

● Designing of circuit and PCB build

● Mounting of components on PCB

● Testing of circuit

● Rectification of errors or failure

● Practical demonstration

● Result of project

1.7 Scope
The ZVS Driver circuit is a Royer-type push-pull oscillator with a resonated primary that is
implemented with FETs. This type of oscillator can be used to drive the ferrite core of a flyback
transformer to generate high voltage. It can also drive a high-current air-core "work" coil for an
induction heater. The high voltage driver was originally touted as an improved way of driving flyback
cores. Until the introduction of Mazilli's circuit, flybacks were typically driven with a single transistor
and a feedback winding or with a push-pull transistor configuration (e.g., using two 2N3055
transistors).It appears that component selection is not well understood because of the unique
characteristics of a resonant Royer-type oscillator. The component stresses are considerable with this

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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type of circuit because of the resonant operation of the primary which generates large voltages and
currents that can stress poorly-selected components.

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1.8 Summary
The Chapter introduce us with the Aim, Purpose, Objective, Methodology and Scope of the project
that we are making. From study of this chapter you will get a rough idea of what is induction heating
and why it is so important in Industries.

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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Chapter 2

Literature

Review

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2.1 Background Information
Domestic purpose induction cookers are normally operated at a high frequency ranging between 20
kHz to 50 kHz (Sadhu et al., 2005). The main parts of an induction cooker are the high frequency
inverter.

Inverter selection :- The induction cooker takes the energy from the mains voltage and this voltage
is then rectified by an uncontrolled bridge rectifier. A bus filter is designed to allow a high voltage
ripple and the resultant power factor close to one. Then an inverter supplies high frequency alternating
current to the induction coil. Nowa-day, resonant inverter topologies are commonly used for induction
cooker. The most used inverter topologies are full bridge and half bridge.

Different full bridge topologies are described by Hobson and Tebb (1985) and Dawson and Jain
(1991).Different types of half bridges are also reported by Hobson et al., (1985) Koertzen et al.,
(1995); Kamli et al., (1996); Wang et al., (1998), Kwon et al., (1999) and Sadhu et al. (2004). One
cycle controlled half bridge series resonant inverter is used by Hsieh and Wang, (1997) for low
conduction loss. Two single switch inverter topologies Zero Voltage Switching (ZVS) and Zero
Current Switching (ZCS) are described by Omori et al., (1985); Leisten and Hobson 1990); Cohen
(1993). Comparison considering full bridge, half bridge has been made by Llorente et al., (2002).

They have made a conclusion that due to robustness, cost saving and simple circuit configuration,
half bridge inverter is most popular. Achara et al., (2007) analyzed the circuit of half bridge inverter
using the principle of positive negative phase shift control under ZVS and non-ZVS operation for
small size and low voltage induction cooker. Dawson and Jain (1990) also made a comparison
between two inverter power supply topologies such as current source parallel inverter and voltage
source series inverter for induction heating and melting operation. The comparison is based on the
criteria such as input power factor, component ratings, maximum and minimum operating frequencies,
operation under varying load condition, inverter starting capability and control simplicity. They have
shown that voltage source series inverter provides better converter utilization over current source
parallel inverter at the frequency more than 1 kHz. Below that frequency, current source parallel 27
inverter plays better role. Moisseev et al., (2003) proposed a circuit topology with an additional active
inductor snubber for an edge resonant ZVS-PWM high frequency inverter using IGBT which can
achieve ZVS in all power regulation ranges.

Multiple burner appliances including two or four inductors are manufactured. In multiple burner
induction cookers, either one inverter per burner or one inverter for two or more burners is used. A
single output inverter multiplexing the loads along the time periodically by means of
electromechanical switches is developed by Rilly (1988).

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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A few researchers such as Jung (1999) and Forest et al., (2000) tried to solve these problems.
Their proposed schemes have some limitations such as low efficiency due to two solid state switches
as proposed by Jung (1999) and restrictions in power control when all loads are operated as proposed
by Forest et al., (2000). Full bridge inverter with two outputs has been proposed by Burdio et al.,
(2005).Some modulation strategies are used in domestic induction heating. Square wave control and
asymmetric duty cycle control has been reported by Burdio et al., (2004) and Barragan et al., (2005).
In these controls the output power is decreased when the switching frequency is increased. To solve
this problem, Pulse Modulation strategy is proposed by Sugimura et al., (2006) and Park et al., (2007).
Here, the switching frequency is restricted at the highest efficiency range.

The pulse regulation is achieved by varying the intervals in which the current is supplied into the
inductors. In this case, the power is supplied in pulses of low frequency which creates some problems
like non-compliance with flicker regulation and non-optimal vessel heating. Acero et al., (2008) had
made an overall comparative study on induction cooker. The series resonant based multi-inverter used
for multiple induction heaters is described by Luciaet al., (2010).

2.2 Summary
Induction heating is nothing but heating of material by means of electric current passing through it by
electromagnetic induction. The working principle of Induction Heating is the combined reciepe of
Electromagnetic Induction (Faraday’s Law of Electromagnetic Induction) and Joule’s Heating.

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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Chapter 3

System Development

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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3.1 Methodological approach

Sr. Methodological approach

no.
1 Components selection

2 Breadboard selection

3 Mounting of components on breadboard

4 Testing of circuit

5 Rectification of errors or failure

6 Practical demonstration

7 Result of project

Table 3.1 Methodology

3.2 Method of data collection / components

Types of components:

1) Battery:-

Used for generating pure DC Voltage for the operation of ZVS driver. In our project we use two
UPLUS new technology battery. In our project we connect two batteries in parallel giving current of
16.2 A at a constant voltage of 12 V

Having specification :-

US 12-7.2 12V 7.2 AH

Max Charging current:-2.16A

Value Regulated lead acid rechargeable Battery

fig 3.2.1 Battery

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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2) LED:-

6 V LED lamp is used for indication purpose which is connected in series with 4.7 kΩ After
glowing it gives indication of starting the circuit( ZVS Driver).It is connected in parallel with other
circuit.

fig 3.2.2 LED

3) Resistors:-
(4.7 kΩ, 10kΩ, 470 ohm) No of 4.7k Resistor : 2 It limits the current that charges the gates as too
much gate current can cause damage. A 4.7kΩ resistor is also connected across the LED Lamp so
that LED Lamp can glow effectively and without danger

Fig 3.2.3 Resistors

4) Zener Diodes:-

As noted earlier, the zener diodes limit the FET gate to source voltage to the maximum specified in
the spec sheet. A 15 Volt zener, rated at at least one Watt, is commonly used in most ZVS circuits.
The zener limiting resistors not only limit the maximum dissipation of the zeners but also drive the
gate to source capacitance of the FETs. A separate regulated gate supply voltage, should be set less
than the zener voltage and the nominal FET drain voltage. Or, the zener can be eliminated or

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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substituted with a reverse-biased diode. If the gate supply voltage is at the same voltage as the
supply voltage, the zener dissipation should be checked for the operating voltage.

Fig 3.2.4 Zener Diode

5) Diodes:-
The cross-coupling diodes should be Schottky types with a voltage rating consistent with the power
supply voltage and resonant rise considerations. Diodes rated at more than 200 Volts are commonly-
available and can be "pulls" from old switching power supplies.

Fig 3.2.5 Diode

6) Polypropylene Capacitors:-
The primary consideration for the resonating capacitance is that it be a high-quality capacitance
capable of handling large AC currents. Normally, this means selecting a "MKS" type metallized
polypropylene capacitor with a voltage rating at least as high as 4 times the power supply voltage.

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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Fig 3.2.6 Polypropylene Capacitor

7) Power MOSFET :- 40N60FD2PW1J02F :-

The metal-oxide-semiconductor field-effect transistor (MOSFET, MOS-FET, or MOS FET) is
a type of field-effect transistor (FET), most commonly fabricated by the controlled oxidation of
silicon. It has an insulated gate, whose voltage determines the conductivity of the device. MOSFET
having N channel region between source and drain is known as N channel MOSFET. It is a 4
terminal device, the terminal are gate, drain and source and substrate body. The drain and source are
heavily doped N+ region and the substrate is P type. The current flow due to flow of the negatively
charged electrons, that’s why it is known as N channel MOSFET. When we applied +ve gate voltage
the holes present beneath the oxide layer experiences repulsive force and the holes are push
downwards into the bound. Negative charges which are associates with the accepter atoms. The +ve
gate voltage also attract electrons from N+ source and drain region into the channel thus electron
reach channel is form, now if a voltage is applied between source and drain. The gate voltage
control the electron concentration in the channel N channel MOSFET is preferred over P channel
MOSFET as the mobility of electrons are higher than holes.

Fig 3.2.7 MOSFET 40N60FD2PW1J02F

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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8) Working coil:-
For this we used a copper tube of 1 cm diameter and make a 6 turn coil , turns can be reduced or
increased as per your System and also we can give the work coil any shape as per different size of
Work piece to be heated.

Fig 3.2.8 work coil

9) Inductor:-
inductor, also called a coil, choke or reactor, is a passive two terminal electrical component that
store electrical energy in a magnetic field when electric current flow through it and inductor
typically consist of an insulated wire wound into a coil around a core. When the current flowing
an inductor changes, the time varying magnetic field induces a voltage in the conductor,
describe by Faradays law of induction. According to Lenz’s law, the direction of induced EMF
opposes the change in current that created it. As a result, inductor oppose any the change in
current through them

Fig 3.2.9 Inductor

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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Componantas

NAME SPECIFICATIONS NOS

Resistor Resistor 470Ω, 5

4.7kΩ, 10kΩ

Mosfet 40N60FD2PW1J02F 2

Diode FR307 2

Zener Diode IN4742 2

Polypropylene Capacitor 0.33µF,400V 6

Ferrite Core 25mm 2

Copper Wire 1 mm 1 meter

LED 6V 1

Copper Tube - 5 Feet

Battery 12 V, 7.2 Ah 2

Table 3.2 Componants

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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Fig 3.2.10 Picture of all Components

3.3 Block diagram and method of analysis

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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fig 3.3 Circuit Diagram

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3.4 Operation of circuit

Fig 3.3.1 Basic circuit

A “ZVS driver” is a very simple circuit that can oscillate a large amount of power with about 90%
efficiency. To the right exists a simplified version of the oscillator, so take a good look!

When power is applied at +V current starts to flow through both sides of the primary and on to the
mosfets’ drains. Simultaneously that voltage appears on both of the mosfets’ gates and starts to turn
them on. Because no two components are exactly alike one mosfet turns on a little faster than the other
one and more current can then flow through that fet. The extra current flowing in that side of the
primary robs the gate current from the other fet and starts to turn it off. A condenser forms an LC tank
with the primary and the voltage proceeds to rise and fall sinusoidally. If it were not for that capacitor,
the current would continue to increase until the transformer’s core saturated and the mosfets exploded.

A keen eye will notice that this oscillator is zero-voltage switching (ZVS), meaning that the mosfets
switch when they have zero volts across them. This is good because it allows the mosfets to switch
when they are carrying the least power; something that for the most part eliminates the switching
losses which generate huge amounts of heat. This means only small heat sinks are needed, even when
oscillating 1000 watts.

Being a resonant oscillator the frequency that the mazilli will run at is determined by the inductance of
the transformer’s primary coil and the capacitor. You can use the following formula to figure this out:

f = 1 / ( 2π * √[L * C] )

f is the frequency in Hertz

L is the inductance of the primary in Henries

C is the capacitance of the capacitor in Farads

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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Now in reality mosfets are rather fragile components and if the gates are +/- more than 30V from the
source the mosfets will be destroyed, or at least degraded significantly. In order to prevent this
scenario from occurring we’ll need gate protection; something easily added with a few extra
components. See the schematic to the right.

The 470 ohm resistors limit the current that charges the gates as too much gate current can cause
damage.

The 10K resistors pull the gates down to ground to prevent latchup; a process in which the mosfet gets
stuck on.

The Zener diodes prevent the gate voltage from exceeding either 12, 15 or 18V depending on the
zeners you use. • The UF4007 diodes pull the gates down to ground when the voltage on the opposite
leg of the tank is at ground.

3.5 Summary
The Methodological approach that we used to develop this project along with all the components and
their specifications has been given in this chapter and also the detailed working process has been
mentioned above.

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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Chapter 4
Performance
Analysis

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4.1 Results
The aim of this project was to design, control and implementation of an Induction Heater using
the Half-Bridge Topology. The prototype developed fulfils this this brief in a safe, effective and stable
manner. Although many milestones and achievements were reached in this project, this in not a perfect
design. The design has the capacity to evolve into a very efficient and safe system and there is plenty
of room for improvements and added features. Induction heating is a very interesting subject and one
that is very topical in a society that is increasingly focused on safety and reducing wastage of energy
and time in peoples day to day lives. Induction heating marks a step improvement over other cooking
methods in all these areas and is without doubt going to become the accepted method of domestic
cooking in the future

The testing piece has to be inserted in the centre of working coil so that effective length and width
of the coil comes under the working coil results into flow of eddy current at very high frequency in our
project it is around 79.3 kilohertz results into very high eddy current losses. We use chromium
material : It is a high resistance material

Melting point:1900 DEGREE CELSIUS

Boiling point: 2672DEGREE CELSIUS

Due to the very high internal resistance it results into the very high eddy current losses .The material
get heated at only 30 seconds.

Fig 4.1 Testing Of The Prototype

4.2 Summary

All the detailed performance analysis, testing methods that we used to perform the working of the
prototype has been mentioned in the above chapter.

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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Chapter 5
Future
Work

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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5.1 Advantages and disadvantages

Advantages: -

● Due to skin effect of induction currents the heat can be confined to the surface of the object.
Hence induction heating is useful in surface hardening of steel.

● Very large heating ratio of the order of 5 kW/ cm² can be achieved.Controlled heating of
the surface area is achieved so it results in reduction of wasted heat.

● Total heat transferred to the work-piece can be very closely monitored and controlled with the
help of timers.

● Induction heating is possible in vacuum or in, inert gases as well as in presence of any other
gases also.

● Automatic temperature control with the help of feedback is also possible.

● The process is neat and clean so the working conditions are pleasant.

● As the operation is very simple, we can use relatively unskilled labours to operate it.

● The induction heating process does not produce any by products.

Disadvantages: -

● Cost of the equipment and the cost of the process are very high.

● Efficiency of heating is poor being less than 50% in many cases.

● Heating will be more in regions of the work piece closer to heating coil. That means heating
takes place in non-uniform manner.

● Generally, coil should have the shape of work piece which can prove to be
inconvenient practically.

● Heating will be more at corners of the work piece.

5.3 Application

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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1. Furnace

2. Welding
3. Manufacturing
4. Cooking
5. Brazing

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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6. Sealing

7. Heating to fit
8. Heat treatment
9. Plastic processing
10. Pyrolysis

5.4 Future scope

For the future of this project there are a number of areas in which the brief could be developed further:

● A safer more user-friendly control system could be developed using the Arduino or a more
powerful platform such as an FPGA

● The Design could be converted to run on mains voltage. This would add extra complications to the

design such as mains rectification and filtering not to mention the amplified concerns for personal
safety.

● Since this circuit cannot operate without the pot resting on the coil a future development might be

to create a pot detector circuit that would detect the presence or lack of a pot and turn the induction
heater on or off accordingly.

● The design of a Dual-Mode Half-Bridge Induction heater to improve the overall efficiency of the

system as described previously would be a great opportunity for the future development of this
project.

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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Conclusion

The aim of this project was to design, control and implementation of an Induction Heater using
the Half-Bridge Topology. The prototype developed fulfils this this brief in a safe, effective and
stable manner. Although many milestones and achievements were reached in this project, this in not
a perfect design. The design has the capacity to evolve into a very efficient and safe system and
there is plenty of room for improvements and added features. Induction heating is a very interesting
subject and one that is very topical in a society that is increasingly focused on safety and reducing
wastage of energy and time in peoples day to day lives. Induction heating marks a step improvement
over other cooking methods in all these areas and is without doubt going to become the accepted
method of domestic cooking in the future.

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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Reference

1) J. Acero et al., "The Domestic Induction Heating Appliance: An Overview of Recent Research,"
In Proc. Appl. Power Electron. Conf Expo, 2008.

2) Carlos Sagues Blazquiz and Gonzalo Lopez-Nicolas, "Reset observers and temperature control
for induction hobs," Universidad de Zaragoza, Spain, Zaragoza, Phd Thesis 2254-7606, 2011.

3) David Paesa Garcia, "Reset observers and temperature control for induction hobs,"Universidad
De Zaragoza, Zaragoza, Thesis 2011.

4) Richard Yi Zhang, "A Generalized Approach to Planer Induction Heating Magnetics,"

Department of Electrical Engineering, Massachusetts Institute Of Technology, Masters 2012.

5) D. C. Jiles and D. L. Atherton, "Theory of ferromagnetic hysteresis," Journal of Magnetism and

Magnetic Materials, 1986.

6) EFD Induction. www.efd-induction.com.

[Online]. http://www.efdinduction.com/en/Applications/Melting.aspx

7) Oscar Lucia, Jose M. Burdio, Ignacio Millan, Jesus Acero, and Luis A. Barragan, "Efficiency
Oriented Design of ZVS Half-Bridge Series Resonant Inverter With Variable Frequency Duty
Cycle Control," IEEE Transactions on Power Electronics, vol. 25, July 2010.

8) Renesas Technology Europe. (2008) University of Moratuwa. [Online].

http://www.ent.mrt.ac.lk/~thumeera/teaching/Note/Induction_Cooking.pdf

9) H. Sarnago, O. Lucia, A. Mediano, and J. M. Burdio, "Dual-ModeOperation Half-Bridge

Resonant Converter for Improved-Efficiency Induction Heating System," Department of
Electronic Engineering and Communications, University of Zaragoza, Zaragoza,.

10) S. Llorente, F. Monterde, J. M. Burdio, and J. Acero, "A Comparative Study of Resonant
Inverter Topologies Used in Induction Cookers," Univ4.

Electrical Engineering Department, J.E.S.I.T.M.R, Nashik, Year 2022-23

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