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This study involves the design and thermal simulation of an induction power controller (IPC) based on the perturb and observe method, aiming to enhance its performance and reliability for industrial applications such as induction hardening for metals, annealing, tempering. This work is focusing on the induction hardening for steel and iron. The IPC regulates the power supply to induction heating systems commonly used in welding, brazing, and other heat treatment processes. The investigation encompasses the formulation of design principles, computation of key components, and assessment of thermal behavior under various conditions using Finite Element Analysis (FEA). Additionally, optimization measures for IPC design are provided to ensure effective heat dissipation and temperature stability. The findings contribute to the development of dependable and long-lasting IPCs, offering enhancements such as increased performance and extended lifespan. The study also observes the impact of different components, such as using MOSFET and IGBT switches. Noting that the utilization of application of MOSFET resulted in presence of higher frequencies and temperature: when IGBT is run the frequency is 48 kHz, and when MOSFET is run it reaches about 72 kHz. The copper-liner copper output-voltage graph has an increasing tendency with voltage application. The thermal diagnostics expose that steel produces 681 degrees Celsius, and cast-iron yields 328 °C. MOSFT gave a result of 681 °C, IGBT being the prototype under consideration for its lifespan since the MOSFET needs a cooling system for the long-time usage.

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Numerical Study of the Design of a Thermal Induction Power Controller and Implementation of Its Thermal

  • 会议论文

  • 发表日期：

    2025年

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  • Noura Nail Ahmed,
  • Aseel Jasim Mohammd,
  • Mohammed Qasim Sulttan

摘要

This study involves the design and thermal simulation of an induction power controller (IPC) based on the perturb and observe method, aiming to enhance its performance and reliability for industrial applications such as induction hardening for metals, annealing, tempering. This work is focusing on the induction hardening for steel and iron. The IPC regulates the power supply to induction heating systems commonly used in welding, brazing, and other heat treatment processes. The investigation encompasses the formulation of design principles, computation of key components, and assessment of thermal behavior under various conditions using Finite Element Analysis (FEA). Additionally, optimization measures for IPC design are provided to ensure effective heat dissipation and temperature stability. The findings contribute to the development of dependable and long-lasting IPCs, offering enhancements such as increased performance and extended lifespan. The study also observes the impact of different components, such as using MOSFET and IGBT switches. Noting that the utilization of application of MOSFET resulted in presence of higher frequencies and temperature: when IGBT is run the frequency is 48 kHz, and when MOSFET is run it reaches about 72 kHz. The copper-liner copper output-voltage graph has an increasing tendency with voltage application. The thermal diagnostics expose that steel produces 681 degrees Celsius, and cast-iron yields 328 °C. MOSFT gave a result of 681 °C, IGBT being the prototype under consideration for its lifespan since the MOSFET needs a cooling system for the long-time usage.