This presentation is a final report to my undergraduate capstone project. The conception of the problem and methodology of design has been explained in detail.

1. Induction Heater with safety features and
SD card data logging
G H Patel College of Engineering and Technology
Department of Electronics and Communication
Project By Devangsingh Sankhala
100110111011
Vivek Patel
100110111012
Krunal Patel
110113111005
Prof. Nilesh Desai
(EC)
Guided by
Prof. J J Patel
(EE)
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2. Block diagram
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3. Design Specifications
Parameter Value
Input Voltage 110-290VAC 50-60 Hz
110-400VDC (regulated DC preferred)
Input current 7 A max
Operating frequency range 0Hz-200kHz (optimum 100kHz)
Topology L-L-C inverter
Control strategy Phase Locked Loop
Microcontroller used dsPIC33EP512MC806
Galvanic isolation Full galvanic isolation of control card and
peripherals
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4. Progress in semester 7
• Selection of components
• Simulation in MATLAB® Simulink
• Learning the MPLAB X IDE
• Programming in MPLAB X IDE for PWM code
simulation
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5. Timeline of Semester 8
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Month Objective
January Hardware design
modifications and design of
tank circuit
February Implementation of power
inverter and control circuit
March Implementation of all
peripheral features

6. DESIGN MODIFICATIONS
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7. Use of Isolators
• Galvanic isolation was necessary for
protecting the control card from voltage
surges.
• High speed isolator used for trigger pulse
• Isolated ADC used for current measurement
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8. AMC1204-Q1
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9. ISO7240CF-Q1
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10. TANK CIRCUIT DESIGN
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11. LLC topology of inverter
To provide maximum efficiency, a controlled resonance is be created
using the LLC inverter topology.
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12. Coupling Transformer
• Magnetic field is dominated by current flow.
• A coupling transformer will be connected
between the inverter and the tank circuit so as
to provide impedance matching and higher
current output.
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13. Coupling Transformer
• The winding is done as
given below:
– Primary: 20 Turns
– Secondary: 1 Turns
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14. MMC Bank
• High amount of current will flow through the
tank circuit.
• To prevent high costs, an MMC (Multiple Mini
Capacitor) Bank will be designed using Axial
Metal Film Capacitors.
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15. MMC Bank
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16. LCR meter
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17. LCR meter(contd..)
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18. The design
• POWER CARD
• CONTROL CARD
• PCB LAYOUT (TOP)
• PCB LAYOUT (BOTTOM)
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19. References
Research papers
• N.S. Bayındır O. K.ukrer and M. Yakup DSP-based PLL-controlled 50–100 kHz 20 kW high frequency
induction heating system for surface hardening and welding applications [Conference]. - [s.l.] : IEEE, 2003.
• Soe Sandar Aung Han Phyo Wai, and Nyein Nyein Soe Design Calculation and Performance Testing of
Heating Coil in an INduction Surface Hardening Machine [Journal]. - 2008.
Books
• M D Singh, K B Khanchandani Power Electronics [Book]. - [s.l.] : Tata McGraw-Hill, 2010.
• Raj Kamal Embedded Systems: Architecture, Programming and Design [Book]. - [s.l.] : Tata McGraw-Hill.
• Valery Rudnev Don Loveless, Raymond Cook, Micah Black Handbook of Induction Heating [Book]. - [s.l.] :
Marcel Dekker Inc., 2003.
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20. References
Application notes and datasheets
• Microchip Technology Inc. dsPIC33EPXXX(GP/MC/MU)806/810/814 [Datasheet]. - 2012.
• STMicroelectronics AN3338: SLLIMM module. - September 2012.
• STMicroelectronics SAFETY PRECAUTIONS FOR DEVELOPMENT TOOL
TRIAC+MICROCONTROLLER. - April 2004.
• STMicroelectronics STGIPL20K60 - 2013.
• Billè Stello Matteo AN4076: Two or three shunt resistor based current sensing circuit
design
Web Pages
• http://www.richieburnett.co.uk/indheat.html
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