Design of the Half-Bridge, Series Resonant Converter for Induction Cooking

Henry W. Koertzent*, Jacobus D. van Wyk* and Jan A. Ferreira*

+Electrical and Computer Engineering Oregon State University Corvallis, Oregon, USA
Abstract - The forced commutated, half-bridge, series resonant converter is well suited for induction cooking. A detailed analysis is made of the operation of this converter to obtain the information needed for a complete design procedure. The values of the reactive components and the voltage and current requirements for all the power components can be calculated with this procedure for a given cooking vessel (experimental measurement of parameters needed), grid voltage and maximum output power. Experimental results are presented.
0

*Research Group: Industrial Electronic Technology Energy Laboratory, Rand Afrikaans University Johannesburg, South Africa No reactive components other than the heating-coil and the compensating capacitor, 0 No input or matching transformers, 0 Adequate degrees of freedom to obtain the desired power range for a practical frequency range, 0 Clamped switch voltage and/or current, 0 50% duty ratio, simplifying the control and gating circuits, 0 Zero current switching (ZCS) and/or zero voltage switching (ZVS) and 0 The use of an uncontrolled voltage source. 111. CHOICE OF CONVERTER The half-bridge, series resonant topology [1,2,3] (fig. 1) was chosen above the single-switch topologies [3,4,5,6]due to the following reasons:
0

I. INTRODUCTION
Induction cookers are designed to compete with conventional stove plates. The main advantages (+) and disadvantages (-) are:

+ The coil stays cool, and is therefore safer, + Constant output power,
- Higher initial cost and - Only cooking vessels with

+ Higher efficiency,i.e. lower electricitybills,

a high resistivity and relative permeability can be used.
To be successful these cookers must be as cheap and efficient as possible, but still meet the desired requirements. The first step is therefore to choose a well suited converter and then to do an optimal design.
11. REQUIREMENTS INDUCTION COOKERS FOR

The voltage across the semiconductors is clamped. Although two switches are needed, at least half the voltage blocking capability is required. Switchingis done at a duty ratio of 50%, and no feedback is therefore needed.

The requirements for induction cookers are as follows: Ultrasonic switching frequency, High efficiency, Low cost, Power factor close to unity, Wide power range (typically 10% to 100%) and Reliability.

Anti-parallel composite-switches (CS) must be used, as shown in fig. 1, consisting of a singular-switch (S) and an anti-parallel diode (D). Isolated gate bipolar transistors (IGBTs) are shown because they are well suited for this medium frequency application. Although an isolated gate drive is needed, a small isolationtransformer can be used due to the 50% duty ratio. The switching power loss in the semiconductors could be a disadvantage and is investigated later in this paper. ics S
2 1

vd

0 0

grid

Induction cookers arc usually designed to operate with a cooking vessel made from a specific material, mainly cast iron of fcrro-magneticstainless steel.
The following is therefore desired characteristics for the converter:
0-7803-2730-6195$4.00 0 1995 IEEE 729

1 r
S
Fig. 1. Half-bridge, series resonant circuit.
I
~~~

verb=

The are two possible switching strategiesfor this converter to obtain the desired power control without varying the input voltage, i.e. load commutation and forced commutation.
A. Load Commutation A typical composite-switch current (ics) waveform is shown in fig. 2. The power is decreased by decreasing the

The forced commutated converter was chosen due to the elimination of the reverse recovery current of the diodes and the maximum power being obtained at the lowest point of the switching frequency range, usually about 20 kHz. The following changes were made to the converters described by [l,2,3]:
0

switching frequency (fs) below the damped resonant frequency (fr), giving the following advantages and disadvantages:

+ No turn-off power loss for the singular-switches and no

-

turn-on power loss for the anti-parallel diodes. Turn-on power loss for the singular-switches and turn-off power loss and reverse recovery current for the anti-parallel diodes. Maximum power is obtained at the upper limit of the switching frequency.

Two resonant capacitors are used, as shown in fig. 1, so that current is drawn from the supply during each half cycle of the switching period, enhancing the power factor. Ci is reduced so that it only sinks the high frequency current of the anti-parallel diodes (no line frequency smoothing), resulting in a close to unity power factor and reduced cost.
IV. LOAD PARAMETIEM

E. Forced Commutation
A typical ics waveform is shown in fig. 3. The power is decreased by increasing fs above fr, giving the following advantages and disadvantages:

+ No turn-on power loss for the singular-switches and no

turn-off power loss or reverse recovery current for the anti-parallel diodes. + Maximum power is obtained at the lower limit of the switching frequency. - Turn-off power loss for the singular-switchesand turn-on power loss for the anti-parallel diodes.

A flat heating-coil is used for induction cooking, as shown in fig. 4. A thermal insulator is placed between the cooking vessel and the heating-coil to protect the coil from overheating and to support the vessel. Forced air coohg of the coil is usually necessary. A ferrite disc is sometimes used to enhance the coupling, but it also adds to the cost. The spacing between the vessel and the coil (b) should be as small as possible for maximum flux coupling, but large enough for sufficient support, insulation and airflow.

This structure can be seen as a transformer, where the cooking vessel acts as a short circuited secondary. The equivalent circuit for a transformer is shown in fig. 5. If the magnetizing inductance (LM) is neglected the heating-coil

ics
0

S & D blocking

ics

S & D blocking

Time

l/fs

Time

1S

Fig. 2. Composite switch current for load commutation.

Fig. 3. Composite switch current for forced commutation.

Cooking vessel
f

Thermal insulator Ferrite disc

Fig. 4. Structure of load circuit used for induction coolung.

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Fig. S. Equivalent circuit for transformer.

Fig. 6. Circuit for measuring load parameters.

and cooking vessel can be represented by an equivalent series inductance (Lr), and resistance (RI), given by RI = R,

+ N2 Rcs and
2

(1)
(2)

L = LIP + N ,

4 s

and the heating-coil and cooking vessel are represented by the series combination of R1 and L.SI is first closed, while S2 remains open, to obtain an initial voltage across G. S1 is opened and S2 then closed to obtain resonance between C , andb. The first (&) and second (&) peak values, eg. first positive and first negative peak value, and the oscillating frequency (f,) of the heating-coilcurrent can be obtained by measuring it with a storage oscilloscopeat the moment S2 is closed. This gives the information needed to calculate the damping factor

where N number of turns on heating-coil, R, resistance of primary (heating-coil), Rcs resistance of secondary (cooking vessel), Lip leakage inductance of primary and Lis leakage inductance of secondary. The vessel must therefore be made from a material of which the product of the resistivity and relative permeability is high enough to yield an acceptable efficiency. The heating-coil is usually made of Lit2 wire and forced air cooled. k and RI are Shown as a single symbol, as in fig-1,because the voltage across each of them cannot be measured separately. The parameters of fig. 5 can also be referred to the secondary, which is in effect a normalization of R and L with 1 , respect to N, giving R , n = R l / N = R c p / N +Rcs and
2

C, must be known, eg. measured with a bridge, and should be constant as a function of frequency and voltage if a polypropylene capacitor is used. The series inductance and resistance of the load structure can then be calculated with

b = (Cr ( ( 2 ~ ~ f , ) ~ + a ) ) -
R1=2a&

and

(6)
(7)

(3)
(4) . .

Cr should be chosen so that fo of the test circuit is equal to the desired minimum switching frequency (fs(min)) of the converter, where

fo= ( 2 x V T q - l
If Rcn and LIn is therefore know for a load structure where: the heating-coil has the same inner and outer diameter (any number of turns), xnw is the same and the cooking vessel is the same as to be used in the final product, a complete design can be done, as will be shown in the next section. R and L, of a certain load structure can be measured by 1 using the circuit shown in fig. 6. S1 and S2 are controllable switches, eg. MOSFETs with low on-state resistance, C, is the resonant capacitance, usually metallized polypropylene, Equations (3) and (4) are then used to calculate Lln and Rcn. Figs. 7 and 8 show measured results for a load structure for different values of x,. The decrease in R,, and the increase in Ls x, increases is due to the decrease in the as coupling between the coil and the vessel.
A cast iron cooking vessel with a diameter of 180 mm was used. The heating-coil had 24 turns with an outer diameter of 180 mm and an inner diameter of 40 mm.

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7

70F=F=T=7
- 0.9
fs I fo

1.5

Fig. 9. Normalized power \rs. normalizes switching frequency.

The combination of (3) and (13) then gives that

The number of turns on the heating-coil will therefore determine the maximum power output for a certain struc, , ture. If % fs(,in> and P is therefore chosen and Lln and R,, is measured, N, b, and Cr can be calculated using RI, (141, (4), (3) and ( ) 8.
3

* ("1
Fig. 8. R, vs.x, ,

v. DEIGN OF THE CONVERTER

An analytical model was used to investigate the operation of the converter, assuming ideal reactive and semiconductor components [7]. The important results (normalized) are shown in figs. 9 to 13, and are described below. The characteristic impedance and quality factor are respectively defined as

Fig. 9 also shows that the switching frequency range increases as the quality factor decreases for a certain power range. A very low Q can therefore lead to a large f, range for a certain power range, which is undesirable. The quality factor is not constant as a function of f,, but decreases as f, increases above fo, due to: The increase in RI caused by the skin effect, The increase in RI due to higher order harmonics as the waveform of the heating-coil current moves away from being sinusoidal and 0 The decrease in Lr caused by improved coupling.
0 0

Fig. 9 shows the normalized power as a function of the normalized switching frequency and depicts that the maximum power (P") is obtained when fs is equal to f,. ZCS is obtained when f, is equal to fr, where

To find an expression for Q as a function of f, is beyond the scope of this paper. If the decrease in Q over the switching frequency range can be estimated, fig. 10 can be used to obtain the f, range for the desired power range. The following are the important voltage and current ratings for each of the power circuit components:
I ) Diode bridge rectifier: The peak voltage (VB(~)) the and average current (IB(avg)) determine the requirements for the rectifier module.

= f, (1 - (2Q) -2)

Os

f, and fr are only significantlydifferent at low values of Q. The power is the main criteria and f,(,in) is therefore chosen to be equal to f,. According to fig. 9

2) Input capacitor.The main limiting factor will be the peak voltage (Vcib)). The rms voltage will not be a limiting factor due to the low grid frequency and the relatively small amplitude of the switching frequency ripple.

732

0.5 I

0.8

P -

0.6

Pmax 0.4
I
I
I
I

fs I fo

1.5

0.2

Fig. 11. Normalized VC~(,.,,,~) normalizes switching frequency. vs.

0.25

Fig.10 . Graph to determine switching frequency range.

3) Resonantcapacifors: Both the peak (VC,~)) therms and ( V C ~ ( ~ ~ ) ) are important. The rms voltage capabilivoltages ties of a capacitor decreases significantlyat high frequencies due to dielectric and conduction power loss. A dielectric material such as polypropylene is therefore usually used.
4) Heating-coil: The rms current ( I L ~ ( ~ ~ )determine will ) the cross sectional area needed for the conductors for operation at an acceptable current density. A single layer heating-coil is used, and therefore arcing between turns should not be a problem.

Is(avg) RI v d

fs I fo

1.5

Fig. 12. Normalized Is(avg) normalizesswitching frequency. vs.

0.5

5) Singular-switches: The voltage rating is determined by the peak voltage (VqP)). The average current (Is(avg)) (for IGBTs), turn-off current ( I q q ) and f, will indicate the current rating, on-state voltage and turn-off switching time required.

6 ) Anti-parallel diodes: The peak voltage (VD(~)) determines the voltage rating. The average current ID(^^^)), turnon current (equal to Iq0fg) and f, will indicate the current rating, on-state voltage and turn-on switchingtime required.

fs J fo

1.5

Fig. 13. Normalized Is(,,Q vs. normalizes switching frequency.

The voltage and current requirements for C, and the heating-coil respectively will be a maximum at Pmm,as illustrated in fig. 1 for VC,(?~). This is also the point of maxi1 mum as depicted m fig. 12. The maximum values for Is(ofg (fig. 13) and are at frequencies higher than fo. Table I shows that the required maximum voltages and currents can be normalized so that they are relatively constant as a function of the quality factor. Empirical equations similar to (13) can therefore be obtained to calculate the required ratings of the power components. Ci is needed to sink the negative ics. If Ci is too small the voltage spikes across it caused by the charge added by these

currents could cause failure of the semiconductor devices. The amplitude of the voltage spike can be calculated with
v s p = ID(avg) 1

(" fs ci)

(15)
(16)

= 0.0128 vd I fs C, RI

C, should therefore be large enough that an acceptable Vsp is obtaineti. Tables I1 and I11 give a summary of the design procedure. Safety factors must be added to the values oband vd(avg) are the rms, peak and tained. Vd(rms), vd@) average values of v respectively. Note that Vd@)is used to d calculate peak values and Vd(avg) to calculate average and
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--

TABLE 1
INFLUENCE OF Q ON MAXIMUM VALUE OF NORMALIZED 0UAIE.S

TABLE I1
CALCULATION OF CIRCUlT PARAMETERS
~

I I

Q
p,,,~,/d

1
0.206

2 0.204

0.203

10
0.203

20
0.203

Variable

Method obtained Practical considerations Fixed grid voltage

Value 6 mm

(0.203 da g (LPmax) as ( v ) 1

35
82.4pH

L
rms values, due to the unsmoothed Vd used. The values shown in the right column of these two tables are for the design of the experimental converter.
VI. EXPERIMENTAL RESULTS

b n
L N2
(4 n2

RI

3.55 P
746 nF 2.96 40 V

c ,
Q

2 L)-1

Cl ( C R )
Chosen

An experimental converter was constructed according to the design, using ultra-fast IGBTs. Fig. 14 shows the decrease in the input power (Pi) of the converter as the switching frequency is increased. A fs range between 20 H z and 100 kHz gave a power range from 100% to approximately 5%. Fig. 15shows that the efficiencyof the converter (determined with a calorimetric method) is always well above 95%. The n grid current (i@) at P,, and max ID(avg) is shown i figs. 16 and 17respectively, which is in phase with the grid voltage. The voltage across one of the resonant capacitors (vcr) and the current through the heating-coil (iLr) at fs(min>,i.e. at Pma, is shown in figs. 18 and 19 respectively. These two waveforms were measured at Vd equal to VQ). The design of the converter showed to be accurate within 10%.

G
TABLE 1 1 1

1.5pF

CALCULATION OF REQUIRED POWER COMPONEW RATINGS

VII. CONCLUSION
It is shown that the forced commutated, half-bridge, series resonant converter is well suited for induction cooking. A simple experimental procedure is used to measure the parameters of the load circuit which are needed for the design of the converter. Empirical equations for the design is obtained by means of an analytical model. If the desired maximum power and the grid voltage is therefore known a complete design of the converter can be done. Some minor modifications to the conventional converter gave a low cost experimental converter with a close to unity power factor and high efficiency.
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Pi ( 9
Fig. 14. Switching frequency vs. input power.

25

"0

Pi

(W)

2500

Fig. 15. Semiconductor power loss vs. input power.

10

-" 0
800
VCr

Time (ms)
Fig. 16 Grid current vs. time @ Pmm

20

-10 I 0

I I Time (ms)

20

Fig. 17. Grid current vs. time @ max ID(^^).

(VI
0

-400 0

Time (ps)

50
Fig. 19. Heating-coil current vs. time @ f, = 20 kHz..

Fig. 18. Resonant capacitor voltage vs. time @ fs = 20 kHz.

REFERENCES
[l] J.P. Ferrieux, J.P. Keradec and Y. Baudon, "A high-frequency con-

verter using COMFET transistor," IEEE-IAS Conference Record, pp. 717-723,1987. [2] L. Hobson, D.W. Tebb and D. Turnbill, "Dual-element induction cooking unit using power MOSFETs," International Journal of Electronics, Vol. 59, No. 6, pp. 747-757,1985. [3] A. Seelig, "Medium-frequency inverters for inductive cooking," Wiss. Ber. AEG-Telefunken, Vol. 55, No. 1-2, pp. 80-89,1982. [4] H. Omori, H. Yamashita, M. Nakaoka and T. Maruhashi, "Anovel type induction-heating single-ended resonant inverter using new bipolar Darlington-transistors,"IEEE-PESC Conference Record, pp. 590-599, 1985.

[5] J.M. Leisten and L. Hobson, "A parallel resonant power supply for induction cooking using a GTO," P E W Conference Record, pp. 224230,1990. [6] S . Hinchliffe and L. Hobson, "High-efficiencydc-ac converter suitable %r high frequency induction heating applications," IEEE-PESC Con.erence Record, pp. 1228-1235,1988. (71 H.W.E. Koertzen, "Variable load induction heating by medium frequency power electronic converters", Ph.D. Thesis, Rand Afrikaans University, November 1994.

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