Practical Use of Computer Simulation for

Advanced Induction Coil and Process Design

Dr. Valentin Nemkov

Mr. Robert Goldstein

Centre for Induction Technology

Auburn Hills, MI

Overview

• Benefits of Computer Simulation

• Special Features of Induction Heating

Computer Simulation

• Induction Heating Computer Simulation

Software

• Rule of Pyramid

• Computer Simulation Examples

Computer Simulation Rules of Thumb

• Works for Any

Geometry and

Conditions

• Demonstrate the

Entire Dynamics of

the Process

• Leaves a Record for

Future Study

• Limitless Accuracy

• Good for Simple

Geometries

• Don’t Provide a Good

Understanding of the

Process

• Experience Isn’t

Passed On

• Case Dependent

Accuracy

Accuracy of Computer

Simulation

• Mainly Depends upon Description of

Material Properties

• Number, Distribution and Type of Elements

• System Description

Why Isn’t there One Comprehensive

Computer Simulation Software Package for

Induction Heating?

• Induction heating simulation involves a set of mutually

coupled non-linear phenomena

• Many induction applications are unique and may require

individual program structures

• Powerful personal computers with high processing speeds

and large available memory only recently became available

• The induction heating market is small compared to other

industrial sectors

• It is difficult to make an induction coil that doesn’t heat at

all and some users don’t care about design optimization

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

Types of Programs for Induction Heating

Computer Simulation at CIT

PC simulation programs

Type Example

1D coupled Elta

2D Electromagnetic QuickField

2D Thermal Flux2D

2D Coupled Flux2D

3D Electromagnetic Flux3D

3D Thermal Flux3D

ELTA, 1-D Software Features

• User Friendly Interface with Very Fast

Solver

• Electromagnetic + Thermal

• Axisymmetrical or Plane Parallel

Geometries

• Database with Non-Linear Properties of

Materials

• Automatic Report Generation

QuickField, 2-D Software

Features

• User Friendly Interface

• Electromagnetic Only

• Linear Materials Only

• Fast Solver

• Inexpensive

Flux 2D, Software Features

• Less Friendly User Interface

• Electromagnetic + Thermal

• Material Database with Non-Linear

Properties

• Can Work in Conjunction with Other

Software (AutoCad, MatLab, Atila, etc.)

Flux 3D, Software Features

• Less Friendly User Interface

• Electromagnetic or Thermal

• Material Database with Non-Linear

Properties

• Tetrahedral, Cubic and Prizmatic Elements

Rule of Pyramid

3D

2D, Electromagnetic + Thermal

1D, Electromagnetic + Thermal

2D, Structural + Thermal

Axle Fillet Geometry

A

B

Fluxtrol

Concentrator

Coil Copper

Water Passage

Axle Flange

Magnetic Field Lines and Power

Density, 3 kHz

Temperature Profile and

Austenitized Zone, 3 kHz

Austenitized Zones

10 kHz 3 kHz without Concentrator

Conclusions

• There are Many Advantages of Using

Computer Simulation

• The Specific Features of an Induction

Heating System must be Considered for

Computer Simulation

• The Rule of Pyramid is a Strategy for

Limiting the Time Required for Simulation