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How Computer Simulation Helps to Design Induction Heating Systems ASM 2001

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Fluxtrol Inc.
Fluxtrol Inc.

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 shows how variable coil positioning optimized large diameter pipe coating by reducing coil length and energy use by 25-30% compared to uniform positioning. The conclusion states simulation is an effective design, optimization, and educational tool for induction heating.

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

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How Computer Simulation Helps to Design Induction Heating Systems ASM 2001

  • 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
  • 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