This document discusses how computer simulation helps design induction heating systems. It outlines improvements in hardware and software that enable more advanced simulation. A case study uses simulation to optimize coating on a large diameter pipe, showing that variable coil positioning requires a shorter coil length and provides energy savings compared to uniform positioning. The conclusion states that continuous advances in simulation technology make it an effective design, optimization, and educational tool for induction heating systems.

1. How Computer Simulation Helps
to Design Induction Heating
Systems
Dr. Valentin Nemkov
Centre for Induction Technology, Inc.
Auburn Hills, MI USA

2. Overview
• What’s New in Computer Simulation of
Induction Heating Processes
– Hardware
– Software
• Computer Simulation of Large Diameter
Pipe Coating
• Conclusions

3. What’s New Since ASM ‘99 in
Computer Simulation?
• Computer Hardware
• Computer Software Improvement
• Market Demand
• Material Properties?

4. Computer Hardware Available for Less
than $12,000 USD
1998 Fall 2001
• 1-400 MHz Processor • 2-2.0 GHz Processors
with 100 MHz Buss with 400 MHz Buss
• 256 MB RAM with • 4 GB RAM with 800
100 MHz speed MHz speed
• 2-10 GB, 5600 RPM • 4-73 GB, 10000 RPM
Hard Drives Hard Drives
• 100 MB Zip Drives • 4.7 GB DVD Drives

5. Specific Features of Induction Heating
Computer Simulation
Process Control
Machine Operating Mode Power Supply Circuits
Thermal Process (Heating) Electromagnetic Process
Cooling Quenching Stresses
Structural Transformations Distortions

6. Rule of Pyramid
3D
2D, Electromagnetic +
Thermal
2D, Electromagnetic or Thermal
1D, Electromagnetic + Thermal

7. 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

8. 1D Scanning Application

9. Scanning Simulation Using
ELTA

10. New Flux 2D Windows Interface

11. 3-D Simulation of Heat
Exchanger Joint Brazing

12. Computer Simulation of Large
Diameter Pipe Coating
Steel Tube
Copper
Cables

13. 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

14. Magnetic Field Lines and
Temperature Color Shade at the End
of Heating for Uniform Pitch

15. Surface Temperature at 200, 250 and
370 s for Uniform Pitch

16. Magnetic Field Lines and
Temperature Color Shade at the End
of Heating for Variable Pitch

17. Surface Temperature at 200, 250 and
370 s for Variable Pitch

18. 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

19. 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