How Computer Simulation Helps

to Design Induction Heating

Systems

Dr. Valentin Nemkov

Centre for Induction Technology, Inc.

Auburn Hills, MI USA

Overview

• What’s New in Computer Simulation of

Induction Heating Processes – Hardware

– Software

• Computer Simulation of Large Diameter

Pipe Coating

• Conclusions

What’s New Since ASM ‘99 in

Computer Simulation?

• Computer Hardware

• Computer Software Improvement

• Market Demand

• Material Properties?

Computer Hardware Available for Less

than $12,000 USD

• 2-2.0 GHz Processors

with 400 MHz Buss

• 4 GB RAM with 800

MHz speed

• 4-73 GB, 10000 RPM

Hard Drives

• 4.7 GB DVD Drives

• 1-400 MHz Processor

with 100 MHz Buss

• 256 MB RAM with

100 MHz speed

• 2-10 GB, 5600 RPM

Hard Drives

• 100 MB Zip Drives

1998 Fall 2001

Process Control

Machine Operating Mode Power Supply Circuits

Thermal Process (Heating) Electromagnetic Process

Cooling Quenching Stresses

Structural Transformations Distortions

Specific Features of Induction Heating

Computer Simulation

Rule of Pyramid

3D

2D, Electromagnetic or Thermal

1D, Electromagnetic + Thermal

2D, Electromagnetic +

Thermal

Computer Software

Improvements

• New Applications (1D and 2D Scanning)

• Coupled 3D for Some Types of Systems

• More User Friendly (Flux 2D Windows based)

• Post Processors and Graphics (Videos of 2D

coupled process simulation with Flux 2D)

• Faster and More Precise Solvers

• 16 X’s Memory Capacity in 3D Simulation

• Cubic and Prismatic Elements for 3D

1D Scanning Application

Scanning Simulation Using

ELTA

New Flux 2D Windows Interface

3-D Simulation of Heat

Exchanger Joint Brazing

Computer Simulation of Large

Diameter Pipe Coating

Steel Tube

Copper

Cables

Case Study Conditions

• Tube: 1030 Steel

– 1100 mm Diameter with 20 mm Wall

– 600 mm to be coated

• Frequency 3 kHz

• Heating Time 200 seconds

• Required Temperature 180 – 210 C

• Delay after Heating 50 s, Curing Time 120 s

Magnetic Field Lines and

Temperature Color Shade at the End

of Heating for Uniform Pitch

Surface Temperature at 200, 250 and

370 s for Uniform Pitch

Magnetic Field Lines and

Temperature Color Shade at the End

of Heating for Variable Pitch

Surface Temperature at 200, 250 and

370 s for Variable Pitch

Results of Study on Pipe Coating

• With Uniform Wire Distribution, the Induction

Coil Would Need to Be Much Longer than the

Treated Zone

• By Using Variable Turn Positioning, the Induction

Coil Length Can Be Significantly Reduced at the

Same Time Providing Energy Savings of 25-30%

• Computer Simulation Is a Good Tool for Design

and Optimization of Large Diameter Pipe Coating

Applications

Conclusions

• There are continuous improvements to both

the hardware and software for induction

heating computer simulation

• Computer simulation is an effective tool for

induction system design and optimization,

as well as a powerful educational and

business tool