R&D in Domestic Induction Heating

1

R&D in Domestic Induction Heating 1

R&D in Domestic

Induction Heating

J.M. Burdío

Universidad de Zaragoza

CEI-UPM Annual Meeting, March 23rd 2012


1. Induction Heating Technology

2. Research and Development Activities

3. Comments on R&D Strategy

OUTLINE

2





OUTLINE

IN


TRADITIONAL APPLICATION FIELDS

Contactless, fast and efficient heating of conductor materials

Industrial applications

3

IN


RECENT APPLICATION FIELDS

Domestic applications

Wireless power supply Biomedical applications

IN


DOMESTIC INDUCTION HEATING

Pan Ceramic glass

Inductor

Magnetic field

AC source

*1

2V

P dVJ J

Eddy currents conductor materials

J

H

B

Magnetic hysteresis ferromagnetic materials

1

4m

V

W dVB H

4

IN


Ceramic glass

Pan

Inductor system

Power system Control

system User interface

BASIC INDUCTION COOKTOP


IN


speed of heating

easy to clean

safety

high efficiency

speed of heating

safety

high efficiency

advanced control

easy to clean

advanced control

MAIN ADVANTAGES OF INDUCTION

5

IN


EJEMPLO DE PLACA DE INDUCCIÓN IN CLASSICAL INDUCTION HOB PLATFORM

3.4 kW

1.8 kW 2.5 kW

2.5 kW

Induction hob range

IN


TOTAL ACTIVE SURFACE PROJECT

Inductor

Power

& Control

Circuit

230 VAC

Bus

Data

Network

Interface

MULTI-INDUCTOR SYSTEM

ONE OF THE NEW INDUCTION HOB PROPOSALS

6

IN


Inductor

Power

& Control

Circuit

230 VAC

Bus

Data

Network

Interface

Master Control




IN


Inductor

Power

& Control

Circuit

230 VAC

Bus

Data

Network

Interface

Master Control




7

IN


Inductor

Power

& Control

Circuit

230 VAC

Bus

Data

Network

Interface

Master Control




IN


Inductor

Power

& Control

Circuit

230 VAC

Bus

Data

Network

Interface

Master Control




8

IN


Inductor

Power

& Control

Circuit

230 VAC

Bus

Data

Network

Interface

Master Control




IN


Inductor

Power

& Control

Circuit

230 VAC

Bus

Data

Network

Interface

Master Control




9




3. Comments on R&D Model

OUTLINE

IN


RESEARCH LINES

Domestic Induction Heating Technology

Project Research line

Project 1

Project 2

Project 3

Project 4

Project 5

Project 6

Magnetics x x x

Power Conversion x x x x x

Digital Control x x x

EMC x x x

Magnetics Power Conversion Digital Control EMC

10

IN


MAGNETICS: INDUCTOR SYSTEM

1. Load (pan)

2. Ceramic glass

3. Insulator

4. Winding (round / rectangular / litz / twisted wire)

5. Ferrites

6. Aluminium shielding

IN


MAGNETICS: MODELING AND DESIGN

Electromagnetic modeling of inductor system with load

Theoretical EM analysis, FEM simulation and equivalent circuit synthesis

Aluminium Plate Ferrite

Coil Pan

Aluminium Plate Ferrite

Coil Pan

1 1, 1

1z d

0z

1' 1', 1'

1'z d

1a

ia

na

2

2 2,

2 '

2 ' 2 ',

2

0 1 1

1 1 0

( ) ( ) ( ) ( )N N

kd

j i i j i

j i

R a a k e J ka J ka dk

2

0 1 1

1 1 0

1 ( ) ( ) ( )N N

kd

j i r j i

j i

L a a e J ka J ka dk H

L RL RL R

Research on

multilayer structures

Inductor system

3D FEM simulation

11

IN


Analysis and design of multi-inductor systems

11 12 13 141 1

21 22 23 242 2

31 32 33 343 3

41 42 43 444 4

Z Z Z ZV I

Z Z Z ZV I

Z Z Z ZV I

Z Z Z ZV I

V Z I

Electromagnetic coupling analysis

PCB planar windings with litz structure

ViaB

ViaA EntrelazadoA

EntrelazadoB

TramaA

TramaB

entrelazadoA

tramaB

I

entrelazadoA

tramaA

entrelazadoB

tramaB

tramaA

entrelazadoB

MAGNETICS: MODELING AND DESIGN

IN


Experimental efficiency and thermal analyses for optimum design

Cu

Fe

Al

Cu

Fe

Al

MAGNETICS: EFFICIENCY ANALYSIS

12

IN


POWER CONVERSION: BASIC APPROACH

Inductor-load

System

Filter Inverter

Mains Voltage

50/60Hz

VI

VI

Rectifier

V0

I0

V0

I0

AC-DC Rectifier DC-AC Inverter

f = 20 kHz-100 kHz

V

V

I

I

IN


U

C Req Leq

Full-bridge inverter

U

C/2 Req Leq

C/2

Half-bridge inverter

U

C Req

Leq

Single-switch ZVS inverter

U

C

Req Leq LS

Single-switch ZCS inverter

POWER CONVERSION: RESONANT INVERTERS

13

IN


Multiple-output resonant inverter load-adaptive topologies

POWER CONVERSION: MULTIPLE OUTPUT

Multi-inductor systems

Resonant multi-inverter load-adaptive

topologies

Concentric inductor systems

Duplex and triplex resonant

load-adaptive topologies

IN


Continuous / discontinuous modulation techniques for topologies

0 500 1000 1500 2000 250050

55

60

65

70

75

80

85

90

95

100

P (W)

Eficie

ncia

(%

)

Eficiencia (%)

ADCi11 H20N60 Cs=0nF

ADCi11 H20N60 Cs=0nF fpmax

ADCi11 H20N60 Cs=7.5nF

ADCi11 H20N60 Cs=7.5nF fpmax

ADCi11 H20N60 Cs=15nF

ADCi11 H20N60 Cs=15nF fpmax

SDDC1 H20N60 Cs=0nF

SDDC1 H20N60 Cs=0nF fpmax

SDDC1 H20N60 Cs=7.5nF

SDDC1 H20N60 Cs=7.5nF fpmax

SDDC1 H20N60 Cs=15nF

SDDC1 H20N60 Cs=15nF fpmax

FP = 0.5 L = 20uH C = 1400 nF

10 20 30 40 50 60 70 800

500

1000

1500

2000

2500

3000

3500

4000

4500

fs (kHz)

P (

W)

FP = 0.55 L = 25uH C = 1400 nF

SW1

ADC11

ADC13/ADC31

SDDC1

SDDC2/ADDC22

ADDC11

ADDC12/ADDC21

QDDC11

QDDC13

QDDC12/QDDC21

QDDC11+/QDDC1+1

Power range

SDDC1 QDDC1/1

iL

vGS1

vGS2

vo

Ts = 1 / fs

d1 = 0

d2 D1

D2

iL

vGS1

vGS2 vo

Ts = 1 / fs

D1

iL

vGS1

vGS2

vo

Ts = 1 / fs

D1 =D2

d1 =d2

d1 d2 D1

D2

ADCi1/3

Efficiency

POWER CONVERSION: CONTROL TECHNIQUES

14

IN


Silicon Carbide (SiC) technology for power converters

POWER CONVERSION: EMERGING SiC DEVICES

60-80% Losses improvements over Si-IGBT

Reduced cooling requirements

Wide-band benefits in multi-inductor and all-metal

heating systems

+VDC

Driver DUT

Leq

Req

C1

C2

Filtro

EMI

Control

f variable

D variable

vD

vL

iD

iLEquivalente

inductor-recipiente

0

20

40

Transistor losses 700 W

Si-IGBT* SiC085 SiC045

-84%

Single-switch ZVS inverter with 1200V SiC JFET (normally-ON)

output power output power

IN


DIGITAL CONTROL: BASIC APPROACH

POWER

CONVERTER

Drivers

IGBTs

Control Param.

Power

Target Power

Power Measure

High-level low-frequency control

C

Low-level high-frequency control

ASIC

USER

15

IN


DIGITAL CONTROL: TEMPERATURE CONTROL

+ –

Touch Control

USER

Temperature (T) Power (P) Power (P)

Time

Temperature (T)

= 0 + K ·T

Adaptive control of pan temperature

Temperature Control with No External Sensor

IN


DIGITAL CONTROL: MODELING AND DESIGN

ASIC / FPGA based digital control system

VHDL modeling of control system and power converter

Power measure with sigma-delta A/D conversion method

Modulation algorithm for power converter

Spread-spectrum techniques for EMI reduction

ASIC

SPI

Communication

SPI

Timing

Block

F1

Modulator

F2

Modulator

F1 SD

Converter

F2 SD

Converter

Q1H

Q1L

Q2H

Q2L

SD1in

SD1out

SD2in

SD2out

C

ASIC

SPI

Communication

SPI

Timing

Block

F1

Modulator

F2

Modulator

F1 SD

Converter

F2 SD

Converter

Q1H

Q1L

Q2H

Q2L

SD1in

SD1out

SD2in

SD2out

C

16

IN


SoC (System-on-Chip) design

DIGITAL CONTROL: SoC APPROACH

Hardware Platform(VHDL)Hardware Platform(VHDL)

FPGA

Software Platform (C)Software Platform (C)

PowerConverter

PC interface

MicroBlazecore

MicroBlazecore

AXI Bus 32

IP Library CoresCustom HW

RS-232

SDII, SDVI

DPWM

Control Comms. Impedancecomputation

DFTS

ΣΔ ADCSDIO, SDVO

QH, QL

ZeroCQI, QV

Integration of microcontroller software and specific digital hardware in a single chip

Library core and customized hardware peripherals

IN


EMC modeling, design and test

ELECTROMAGNETIC COMPATIBILITY (EMC)

LISN EMC

FILTER INVERTER

CONTROL POWER SUPPLY

Z LISN (DM y CM)

150 kHz - 30 MHz

Z WIRE ( CM )

30 MHz - 1 GHz

MAINS

PAN

INDUCTOR

Z SYSTEM (DM y CM)

150 kHz - 1 GHz

IDM

ICM

ANALYZER BCK 1

BCK 2

17

IN





OUTLINE

IN


ASSUMED RESEARCH & DEVELOPMENT MODEL

RESEARCH

(R)

DEVELOPMENT

(D)

INNOVATION

(i)

RESEARCH DEVELOPMENT INNOVATION

unknown known

know-how is here

unknown

But in fact usually at University:

start

start

RESEARCH DEVELOPMENT INNOVATION

little know-how unknown unknown

start

Beginnings:

18

IN


PROPOSED D+R+i STRATEGY

RESEARCH DEVELOPMENT

INNOVATION

start

Cyclical Strategy

IN


COORDINATED RESEARCH & DEVELOPMENT

Applied Research Contracts

Public Research Projects

PhD Thesis

Master Thesis

Publications and Patents

Teaching Collaborations

Universidad de Zaragoza – BSH

Induction Technology

OPEN INNOVATION CONCEPT

(Bosch and Siemens Home Appliances Group)

19

IN


IMPACT OF TECHNOLOGY TRANSFER

BSH brands: Bosch, Siemens, Balay, Lynx, Neff, Gaggenau, Thermador

6 Generations of induction hobs for European and USA markets

All of them designed and manufactured in Zaragoza

BSH Worldwide Induction Competence Center located at Zaragoza

1992 1994 1996 1998 2000 2002 2004 2006 2008 2010

4.000

600.000Annual production evolution

1992 1994 1996 1998 2000 2002 2004 2006 2008 2010

4.000

600.000Annual production evolution


R&D in Domestic

Induction Heating

J.M. Burdío

Universidad de Zaragoza

CEI-UPM Annual Meeting, March 23rd 2012

Documents

R&D in Domestic Induction Heating