A universal induction heating system based on parametric simulation and its implementation method

Abstract

The present application belongs to the field of induction heating technology, and discloses a general induction heating system based on parametric simulation and its implementation method, including an induction heating furnace system model, a simulation platform, a sensor and monitoring module and a control unit; the induction heating furnace system model includes an induction furnace system and a crucible system, and the induction furnace system is modeled through the simulation platform to generate an alternating magnetic field; the alternating magnetic field and the crucible system are modeled through the simulation platform to simulate the heat energy generation and temperature changes caused by eddy currents; the sensor and monitoring module are used to detect heat energy and temperature, and transmit the data to the control unit; the control unit is used to debug the parameters of the induction heating furnace system model, and then run the induction heating furnace system model through the simulation platform to obtain the optimal parameters and the corresponding optimal heat energy generation and temperature changes.

Description

Technical Field

[0001] The present application belongs to the field of induction heating technology, and specifically relates to a universal induction heating system based on parametric simulation and an implementation method thereof. Background Art

[0002] Induction heating technology is a heating method that uses electromagnetic induction to generate eddy currents within conductive materials, thereby converting electrical energy into thermal energy. Since the early 20th century, induction heating has been widely used in industrial manufacturing and heat treatment fields, such as metal forging, welding, heat treatment, and food processing. An induction heating system typically consists of a high-frequency power supply, an induction coil, and the conductive material to be heated. Under the action of high-frequency current, the induction coil generates an alternating magnetic field, which causes eddy currents within the conductive material. The energy dissipated by the eddy currents is converted into thermal energy, thereby achieving heating. Induction heating has the advantages of high heating efficiency, fast heating speed, clean and environmentally friendly properties, and strong controllability. These advantages have led to the gradual expansion of the application of induction heating technology in modern manufacturing. However, due to the diversity of heating objects and application scenarios, existing induction heating systems still have shortcomings in adapting to different materials and geometries.

[0003] 1. Deficiencies of existing technologies in terms of multi-material adaptability:

[0004] Existing induction heating technologies are typically optimized for specific materials, such as steel, cast iron, or aluminum. The number of turns in the induction coil, operating frequency, and power configuration are typically tailored to the electromagnetic properties of a single material. This design has the following drawbacks:

[0005] Poor adaptability: When the material of the heating object is changed (such as from steel to aluminum), the existing system needs to redesign the current frequency, coil parameters or reconfigure the system, resulting in additional costs and time investment.

[0006] Insufficient energy efficiency: When heating materials with low magnetic permeability or high resistivity (such as aluminum and copper), existing systems have difficulty transferring energy effectively, resulting in energy waste and uneven heating.

[0007] Strong limitations: Existing technologies cannot provide a unified solution for the simultaneous or continuous heating of multiple materials.

[0008] 2. Deficiencies in geometric shape adaptability of existing technologies:

[0009] Existing induction heating equipment is optimized for containers of specific shapes (such as round or rectangular). However, when processing heating objects with irregular shapes or complex geometries, its main disadvantages are:

[0010] Uneven heating: Existing technologies usually assume that the shape of the container is simple and symmetrical. However, for complex shapes (such as polygonal or asymmetric containers), the eddy current distribution is difficult to calculate accurately, resulting in uneven power density in the heating area.

[0011] High computational complexity: Existing technologies lack a general model to simplify the effect of geometric shapes on electromagnetic properties, resulting in the need to model each shape separately, increasing design difficulty and computational cost.

[0012] 3. Deficiencies of existing technologies in multi-frequency and multi-configuration adjustment:

[0013] The efficiency and temperature rise rate of induction heating are strongly dependent on the current frequency and coil configuration. However, existing technologies are generally designed with a single frequency and a fixed number of winding turns, which has the following drawbacks:

[0014] Insufficient frequency flexibility: Fixed-frequency induction heating equipment is difficult to operate in multi-frequency scenarios, such as industrial applications that require both deep heating and rapid surface heating.

[0015] Difficulty in configuration adjustment: When the number of coil turns needs to be changed or the current intensity needs to be adjusted to accommodate heating objects of different thicknesses or conductivity, the existing system requires comprehensive modification of the hardware or control logic, which is costly.

[0016] 4. Deficiencies in existing technologies in simulation and emulation capabilities:

[0017] As industrial applications place increasing demands on the precision of induction heating system design, simulation technology has become an important means of optimizing design. However, existing technologies have the following shortcomings:

[0018] Lack of versatility: Existing simulation tools are usually developed for specific scenarios and are difficult to generalize to heating problems under different materials, geometries, and configurations.

[0019] Limited accuracy: The ability to model complex eddy current distribution and heat conduction processes is limited. Especially under high-frequency and asymmetric structural conditions, existing simulation methods have large errors and cannot accurately predict the actual application effect.

[0020] Insufficient dynamic adjustment capabilities: Existing simulation systems are usually based on static parameters and lack the ability to dynamically adjust parameters (such as frequency, number of coil turns, etc.) to optimize the design in real time.

[0021] 5. Limitations of existing technologies in cost and efficiency:

[0022] Many existing induction heating devices utilize high-performance materials and complex designs to improve heating efficiency. However, the high cost of these designs limits their widespread application in various scenarios. Furthermore, due to a lack of parameterized configuration capabilities, existing devices typically only operate at peak efficiency in specific scenarios, resulting in wasted energy in other scenarios.

[0023] In summary, existing induction heating technologies and models have significant deficiencies in adaptability, flexibility, high-frequency response, and simulation capabilities, failing to effectively meet the heating needs of modern industry for diverse materials and complex geometries. Therefore, designing a universal and adaptable induction heating furnace model that can simulate heating effects across different materials, geometries, and frequency configurations has significant practical significance and application value. Summary of the Invention

[0024] The purpose of this application is to solve the problems existing in the prior art and to provide a universal induction heating system based on parametric simulation and its implementation method.

[0025] In order to solve the technical problem, the technical solution of the present application is: a universal induction heating system based on parametric simulation, comprising an induction heating furnace system model, a simulation platform, a sensor and monitoring module and a control unit;

[0026] The induction heating furnace system model includes an induction furnace system and a crucible system. The induction furnace system is modeled through a simulation platform to generate an alternating magnetic field. The alternating magnetic field and the crucible system are modeled through a simulation platform to simulate the heat energy generation and temperature changes caused by eddy currents.

[0027] The sensor and monitoring module are used to detect heat energy and temperature and transmit data to the control unit;

[0028] The control unit is used to debug the parameters of the induction heating furnace system model, and then run the induction heating furnace system model through the simulation platform to obtain the optimal parameters and the corresponding optimal heat energy generation and temperature change.

[0029] Preferably, the simulation platform includes MATLAB Simulink and Simscape Electrical, and the Simscape Electrical module is used for modeling in the MATLAB Simulink environment.

[0030] Preferably, the induction furnace system includes a current source module and an electromagnetic conversion module, the current source module and the electromagnetic conversion module are connected by a wire, the parameters of the current source module include current intensity and current frequency, the parameters of the electromagnetic conversion module include the number of coil turns, coil shape, coil diameter, wire diameter and coil magnetic permeability, the current source module and the electromagnetic conversion module are configured in Simscape Electrical, the current intensity and current frequency of the current source module are parameterized with the number of coil turns, coil shape, coil diameter and wire diameter of the electromagnetic conversion module to generate an alternating magnetic field.

[0031] Preferably, the crucible system includes a crucible module, an eddy current module and a thermodynamic module. The parameters of the crucible module include material, material resistivity and shape, the parameters of the eddy current module include electrical conductivity and magnetic permeability of the crucible, and the parameters of the thermodynamic module include the mass of the workpiece to be heated and the specific heat capacity of the workpiece to be heated. The alternating magnetic field, the material and shape of the crucible module, the electrical conductivity and magnetic permeability of the eddy current module, and the mass of the workpiece to be heated and the specific heat capacity of the workpiece to be heated of the thermodynamic module are configured in Simscape Electrical to simulate the heat energy generation and temperature change caused by eddy currents.

[0032] Preferably, the simulation calculation formula of the induction furnace system is:

[0033] ;

[0034] in:

[0035] B is the magnetic induction intensity, T;

[0036] μ is the coil magnetic permeability, H / m;

[0037] N is the number of coil turns;

[0038] I is the current intensity, A;

[0039] is the magnetic field path length, m.

[0040] Preferably, the simulation calculation formula of the crucible system is:

[0041] ;

[0042] in:

[0043] P is the thermal power density per unit volume, W / m³;

[0044] ρ is the material resistivity, Ω·m;

[0045] B is the magnetic induction intensity, T;

[0046] ω = 2πf is the angular frequency, rad / s;

[0047] is the penetration depth, m;

[0048] ;

[0049] in:

[0050] f is the input current frequency;

[0051] μ is the magnetic permeability of the crucible;

[0052] σ is the conductivity of the crucible.

[0053] Preferably, the eddy current module is used to simulate the eddy current effect in the crucible module, and the shape factor method is used to accurately calculate the eddy current distribution of complex geometric shapes; when the crucible module is a uniform cylindrical workpiece, the shape factor When the crucible module is a flat workpiece, the shape factor It changes with the thickness, and its calculation formula is:

[0054] ;

[0055] in:

[0056] A is the thickness of the plate, m;

[0057] is the penetration depth, m.

[0058] Preferably, the temperature change simulation calculation formula of the thermodynamic module is:

[0059] ;

[0060] in:

[0061] ΔT is the temperature change, K;

[0062] P is the thermal power density per unit volume, W / m³;

[0063] t is the heating time, s;

[0064] m is the mass of the workpiece to be heated, kg;

[0065] C is the specific heat capacity of the workpiece to be heated, J / kg·K.

[0066] Preferably, a method for implementing a universal induction heating system based on parametric simulation is used for the above-mentioned universal induction heating system based on parametric simulation, and the method for implementing a universal induction heating system based on parametric simulation comprises the following steps:

[0067] Step 1: In the MATLAB Simulink environment of the simulation platform, use the Simscape Electrical module to build an induction heating furnace system model. The induction heating furnace system model includes an induction furnace system and a crucible system. The induction furnace system includes a current source module and an electromagnetic conversion module. The crucible system includes a crucible module, an eddy current module, and a thermodynamic module. Set the parameters of the current source module, electromagnetic conversion module, crucible module, eddy current module, and thermodynamic module respectively.

[0068] Step 2: Parameter adjustment: Ensure that the relative positions of the induction coil of the electromagnetic conversion module and the workpiece to be heated of the eddy current module are correct, and that the induction coil covers the upper half of the workpiece to be heated;

[0069] Step 3: Start MATLAB Simulink simulation, simulate the induction heating process of the induction heating furnace system model, monitor the power consumption, temperature change curve and temperature distribution diagram during the simulation process, and compare them with the requirements of the workpiece to be heated. If they do not meet the requirements of the workpiece to be heated, proceed to step 4; if they meet the requirements of the workpiece to be heated, proceed to step 6;

[0070] Step 4: Optimization and adjustment; by adjusting the number of turns and current frequency of the induction coil;

[0071] Step 5: Start the MATLAB Simulink simulation again, continue to simulate the induction heating process of the induction heating furnace system model, and continue to monitor the power consumption, temperature change curve, and temperature distribution diagram during the simulation process;

[0072] Step 6: Obtain the optimal parameters that meet the requirements of the workpiece to be heated, as well as the corresponding optimal heat energy generation and temperature change.

[0073] Compared with the prior art, the advantages of this application are:

[0074] (1) This application discloses a general induction heating system based on parametric simulation and its implementation method, including an induction heating furnace system model, a simulation platform, a sensor and monitoring module, and a control unit; the induction heating furnace system model includes an induction furnace system and a crucible system, and the induction furnace system is modeled by the simulation platform to generate an alternating magnetic field; the alternating magnetic field and the crucible system are modeled by the simulation platform to simulate the heat energy generation and temperature change caused by eddy currents. This application maximizes the conversion efficiency of electrical energy to thermal energy, reduces energy consumption, and improves the temperature rise rate and heating uniformity by optimizing the induction coil design and eddy current effect;

[0075] (2) The induction heating furnace system model of this application is applicable to heating objects of various materials (such as steel, cast iron, aluminum, etc.). By dynamically adjusting the conductivity, magnetic permeability and frequency response, the system can automatically optimize the heating effect according to the electromagnetic properties of different materials;

[0076] (3) This application supports the design of crucible containers of different shapes and sizes. By using a unified model of shape factor and equivalent conductance, the eddy current distribution under complex shapes can be accurately calculated to ensure heating uniformity and high geometric flexibility.

[0077] (4) This application supports induction coil configurations with multiple frequencies and different numbers of winding turns, adapting to high-frequency and low-frequency heating needs, and meeting specific heating requirements in different application scenarios (such as industrial heating, food heating, material melting, etc.);

[0078] (5) This application provides a universal induction heating simulation platform that can quickly predict the heating performance under different materials and configurations, thereby improving design accuracy and development efficiency. This application reduces hardware adjustments and additional development costs through unified modeling and parametric design, making the cost controllable and applicable to a variety of industrial application scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0079] Figure 1 , This application provides a structural block diagram of a universal induction heating system based on parametric simulation. DETAILED DESCRIPTION

[0080] The following describes the specific implementation of this application in conjunction with examples:

[0081] It should be noted that the structures, proportions, sizes, etc. shown in this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the conditions for the implementation of this application. Any structural modification, change in proportional relationship or adjustment of size should still fall within the scope of the technical content disclosed in this application without affecting the efficacy and purpose that can be achieved by this application.

[0082] This application discloses a universal induction heating system based on parametric simulation, including an induction heating furnace system model, a simulation platform, a sensor and monitoring module, and a control unit;

[0083] The induction heating furnace system model includes an induction furnace system and a crucible system. The induction furnace system is modeled through a simulation platform to generate an alternating magnetic field. The alternating magnetic field and the crucible system are modeled through a simulation platform to simulate the heat energy generation and temperature changes caused by eddy currents.

[0084] The sensor and monitoring module are used to detect heat energy and temperature and transmit data to the control unit;

[0085] The control unit is used to debug the parameters of the induction heating furnace system model, and then run the induction heating furnace system model through the simulation platform to obtain the optimal parameters and the corresponding optimal heat energy generation and temperature change.

[0086] Preferably, the simulation platform includes MATLAB Simulink and Simscape Electrical, and the Simscape Electrical module is used for modeling in the MATLAB Simulink environment.

[0087] Preferably, the induction furnace system includes a current source module and an electromagnetic conversion module, the current source module and the electromagnetic conversion module are connected by a wire, the parameters of the current source module include current intensity and current frequency, the parameters of the electromagnetic conversion module include the number of coil turns, coil shape, coil diameter, wire diameter and coil magnetic permeability, the current source module and the electromagnetic conversion module are configured in Simscape Electrical, the current intensity and current frequency of the current source module are parameterized with the number of coil turns, coil shape, coil diameter and wire diameter of the electromagnetic conversion module to generate an alternating magnetic field.

[0088] Preferably, the crucible system includes a crucible module, an eddy current module and a thermodynamic module. The parameters of the crucible module include material, material resistivity and shape, the parameters of the eddy current module include electrical conductivity and magnetic permeability of the crucible, and the parameters of the thermodynamic module include the mass of the workpiece to be heated and the specific heat capacity of the workpiece to be heated. The alternating magnetic field, the material and shape of the crucible module, the electrical conductivity and magnetic permeability of the eddy current module, and the mass of the workpiece to be heated and the specific heat capacity of the workpiece to be heated of the thermodynamic module are configured in Simscape Electrical to simulate the heat energy generation and temperature change caused by eddy currents.

[0089] Preferably, the simulation calculation formula of the induction furnace system is:

[0090] ;

[0091] in:

[0092] B is the magnetic induction intensity, T;

[0093] μ is the coil magnetic permeability, H / m;

[0094] N is the number of coil turns;

[0095] I is the current intensity, A;

[0096] is the magnetic field path length, m.

[0097] The calculation method of the magnetic field path length l includes:

[0098] 1) Distance from the induction coil to the workpiece to be heated: If there is a clear distance between the induction coil and the workpiece to be heated (such as the distance between the inner radius of the coil and the outer radius of the workpiece), then the magnetic field path length usually takes this distance into account.

[0099] 2) The relationship between the induction coil shape and the workpiece geometry: The length of the magnetic field path is related to the induction coil geometry (such as diameter, number of turns, shape, etc.) and the size of the workpiece to be heated. If the workpiece to be heated is cylindrical, the coil's magnetic field path length is the radius of the workpiece to be heated plus a certain coil spacing.

[0100] Approximate calculation method: In practical applications, due to complex geometries, the magnetic field path length is often estimated using simplified models. For example, considering the induction heating frequency and the shape of the heated object, the magnetic field path length l is the coil diameter or the distance from the coil center to the workpiece surface. For common induction heating scenarios, general empirical formulas also take into account the size of the workpiece and the expansion of the electromagnetic field.

[0101] Preferably, the simulation calculation formula of the crucible system is:

[0102] ;

[0103] in:

[0104] P is the thermal power density per unit volume, W / m³;

[0105] ρ is the material resistivity, Ω·m;

[0106] B is the magnetic induction intensity, T;

[0107] ω = 2πf is the angular frequency, rad / s;

[0108] is the penetration depth, m;

[0109] ;

[0110] in:

[0111] f is the input current frequency;

[0112] μ is the magnetic permeability of the crucible;

[0113] σ is the conductivity of the crucible.

[0114] Preferably, the eddy current module is used to simulate the eddy current effect in the crucible module, and the shape factor method is used to accurately calculate the eddy current distribution of complex geometric shapes; when the crucible module is a uniform cylindrical workpiece, the shape factor When the crucible module is a flat workpiece, the shape factor It changes with the thickness, and its calculation formula is:

[0115] ;

[0116] in:

[0117] A is the thickness of the plate, m;

[0118] is the penetration depth, m.

[0119] Preferably, the temperature change simulation calculation formula of the thermodynamic module is:

[0120] ;

[0121] in:

[0122] ΔT is the temperature change, K;

[0123] P is the thermal power density per unit volume, W / m³;

[0124] t is the heating time, s;

[0125] m is the mass of the workpiece to be heated, kg;

[0126] C is the specific heat capacity of the workpiece to be heated, J / kg·K.

[0127] Preferably, a method for implementing a universal induction heating system based on parametric simulation is used for the above-mentioned universal induction heating system based on parametric simulation, and the method for implementing a universal induction heating system based on parametric simulation comprises the following steps:

[0128] Step 1: In the MATLAB Simulink environment of the simulation platform, use the Simscape Electrical module to build an induction heating furnace system model. The induction heating furnace system model includes an induction furnace system and a crucible system. The induction furnace system includes a current source module and an electromagnetic conversion module. The crucible system includes a crucible module, an eddy current module, and a thermodynamic module. Set the parameters of the current source module, electromagnetic conversion module, crucible module, eddy current module, and thermodynamic module respectively.

[0129] Step 2: Parameter adjustment: Ensure that the relative positions of the induction coil of the electromagnetic conversion module and the workpiece to be heated of the eddy current module are correct, and that the induction coil covers the upper half of the workpiece to be heated;

[0130] Step 3: Start MATLAB Simulink simulation, simulate the induction heating process of the induction heating furnace system model, monitor the power consumption, temperature change curve and temperature distribution diagram during the simulation process, and compare them with the requirements of the workpiece to be heated. If they do not meet the requirements of the workpiece to be heated, proceed to step 4; if they meet the requirements of the workpiece to be heated, proceed to step 6;

[0131] Step 4: Optimization and adjustment; by adjusting the number of turns and current frequency of the induction coil;

[0132] Step 5: Start the MATLAB Simulink simulation again, continue to simulate the induction heating process of the induction heating furnace system model, and continue to monitor the power consumption, temperature change curve, and temperature distribution diagram during the simulation process;

[0133] Step 6: Obtain the optimal parameters that meet the requirements of the workpiece to be heated, as well as the corresponding optimal heat energy generation and temperature change.

[0134] Example 1

[0135] This example designs an induction heating furnace system model based on Simscape Electrical. This simulation model can be applied to induction heating systems of various materials, shapes, and configurations. By adjusting model parameters, the electromagnetic properties and eddy current heating effects of different materials (such as steel, cast iron, and aluminum) can be simulated, making it suitable for a wide range of industrial and manufacturing scenarios. The induction heating furnace system model consists of two main subsystems: the induction furnace system and the crucible system. The induction furnace system primarily simulates the electromagnetic field characteristics of the heating coil, while the crucible system describes the eddy current effects and temperature changes of the heated object.

[0136] Induction furnace system: includes current source module and electromagnetic conversion module, which are used to generate magnetic field and drive electromagnetic induction.

[0137] Objective: To generate an alternating magnetic field under high-frequency alternating current to achieve electromagnetic induction on the heating object.

[0138] Current source module: provides AC current of different frequencies and intensities. Parameters include current intensity and current frequency.

[0139] For example: providing 10A or 24A AC current with a frequency range from 10kHz to 50kHz to meet different heating effect requirements.

[0140] Electromagnetic conversion module: Contains a winding coil (induction coil) for converting current into magnetic field.

[0141] The number of turns of the induction coil (such as 15 turns or 25 turns) can be adjusted according to the penetration depth of the workpiece to be heated and the heating effect requirements.

[0142] By inputting high-frequency alternating current, a strong magnetic field is generated in space. The change of this magnetic field drives the generation of eddy currents in the workpiece to be heated.

[0143] Model implementation: Configure the current source module and electromagnetic conversion module in Simscape Electrical. The current intensity, current frequency, and number of coil turns can be parameterized using the following code:

[0144] set_param("InductionHob / CurrentSource", "ac_current", "24"); % Set the current intensity to 24A;

[0145] set_param("InductionHob / CurrentSource", "ac_frequency", "24000"); %Set the frequency to 24kHz;

[0146] set_param("InductionHob / ElectromagneticConverter", "Nw", "25"); % Set the number of coil turns to 25.

[0147] Crucible system: includes the crucible module, eddy current module, and thermodynamic module to simulate the heat energy generation and temperature changes caused by eddy currents.

[0148] Goal: To simulate the eddy current heating effect and temperature distribution in a crucible during induction heating.

[0149] Eddy Current Module: Simulates eddy current effects within materials and calculates penetration depth and conductance using the material's electrical and magnetic permeabilities.

[0150] The penetration depth δ is calculated by the following formula: ;

[0151] Where f is the input current frequency, μ is the magnetic permeability of the material, and σ is the electrical conductivity of the material.

[0152] Conductance value G expression: .

[0153] By configuring the electrical conductivity and magnetic permeability of different materials, it is possible to adapt to a variety of material properties. For example, for carbon steel and gray cast iron, the magnetic permeability is set to and , the conductivity is 6.99×10 6 S / m and 10 6 S / m.

[0154] The model’s parametric configuration supports dynamic adjustment of coil turns, current frequency, material conductivity, and magnetic permeability to accommodate different material and geometry requirements.

[0155] Thermodynamics Module: Simulates temperature changes in crucibles, including conduction and fluid heat transfer. Suitable for heating liquid or solid objects.

[0156] Configure parameters such as the mass of the workpiece to be heated and the specific heat capacity of the workpiece to be heated to describe the temperature rise during the heating process.

[0157] Use the "Constant Volume Chamber (2P)" module to define the temperature variation of the liquid in the crucible.

[0158] Model Implementation: Configure the conductivity parameters of the eddy current module and the material properties of the heating object in Simscape Electrical. The conductivity parameters of the crucible are set as follows:

[0159] set_param("Pot / EddyCurrent", "g", "136.55"); % For carbon steel crucible, set the conductivity to 136.55S.

[0160] Parameterized configuration and debugging:

[0161] To meet different industrial needs, the model allows users to freely set parameters such as coil turns, current frequency, material conductivity, magnetic permeability, etc. The following are several typical configuration examples:

[0162] Carbon steel (15-turn coil): The current frequency is set to 24 kHz, the number of coil turns is 15, and the eddy current conductivity is 136.55S.

[0163] Carbon Steel (25-Turn Coil): Change the number of coil turns to 25 to increase magnetic field strength and improve heating efficiency.

[0164] Gray cast iron (25-turn coil): The current frequency is 24kHz, and the material conductivity is set to 29.13S to achieve heating of the cast iron.

[0165] With the above configuration, the heating effects of different materials and different frequencies can be simulated in Simulink, and the power output and temperature changes can be viewed using the following command:

[0166] result1 = sim("InductionHobModel");

[0167] sscexplore(result1.simlog); % View the power loss and temperature changes of the eddy current module.

[0168] Continue to monitor the power consumption, temperature change curve and temperature distribution diagram during the simulation process to obtain the optimal parameters that meet the requirements of the workpiece to be heated.

[0169] Implementation and Application:

[0170] Industrial metal heating: In metal processing and heat treatment scenarios, rapid heating and precise temperature control can be achieved by adjusting the number of coil turns and current frequency.

[0171] Food processing: Use high-frequency induction heating to achieve uniform heating of food and reduce energy consumption.

[0172] Material melting: In material experiments and smelting applications, it is suitable for rapid heating and temperature control experiments of materials with different melting points.

[0173] Optimization and expansion:

[0174] The model supports switching between high-frequency and low-frequency modes, adapting to applications requiring high heating depth and surface uniformity. Future work will expand the model to include 3D structural simulations to accommodate heating requirements for more complex geometries and non-uniform materials.

[0175] Example 2

[0176] 1) According to the induction heating furnace system model provided in this application, configure the following parameters:

[0177] Induction furnace system:

[0178] Current source module:

[0179] Current intensity: 24A;

[0180] Current frequency: 24kHz;

[0181] Electromagnetic conversion module:

[0182] Coil turns: 15 turns;

[0183] Coil shape: round coil, diameter 50 cm, wire diameter 5 mm;

[0184] Crucible System:

[0185] Crucible module, eddy current module:

[0186] Crucible material type: carbon steel;

[0187] Conductivity (σ): 6.99×10^6 S / m;

[0188] Magnetic permeability (μ): 1.26×10^-4 H / m;

[0189] Crucible shape: cylindrical;

[0190] Diameter: 30 cm;

[0191] Height: 50 cm;

[0192] Thermodynamics Module:

[0193] Specific heat capacity of the workpiece to be heated: 500 J / (kg·K);

[0194] Density of the workpiece to be heated: 7850 kg / m³;

[0195] Initial temperature: room temperature (25°C);

[0196] Ambient cooling conditions: natural convection.

[0197] 2) Simulation steps:

[0198] Model construction:

[0199] In the MATLAB Simulink environment, the Simscape Electrical module is used to build an induction heating furnace system model.

[0200] Configure the current source module and set the AC current intensity to 24A and the frequency to 24kHz.

[0201] An electromagnetic conversion module is set up, with a coil number of 15 turns and a coil diameter of 50 cm.

[0202] In the Heating Object subsystem, select carbon steel as the material and enter its electrical conductivity and magnetic permeability parameters.

[0203] The geometric shape of the workpiece is set to a cylinder with a diameter of 30 cm and a height of 50 cm, and the corresponding thermodynamic parameters are input.

[0204] 3) Parameter adjustment:

[0205] Ensure that the relative position of the induction coil and the workpiece is correct, and the coil covers the upper half of the workpiece to ensure effective coverage of the magnetic field.

[0206] According to the size and material properties of the workpiece, the number of coil turns and current frequency are adjusted to optimize the eddy current distribution and heating efficiency.

[0207] Simulation run:

[0208] Start the Simulink simulation and run the induction heating process simulation.

[0209] Monitor power consumption, temperature profiles, and temperature distribution during simulation.

[0210] Result analysis:

[0211] Power output: Simulation results show that the total power loss in the carbon steel workpiece is 15kW at a 24kHz frequency and a 24A current.

[0212] Temperature change: The center temperature of the workpiece reaches 600°C after heating for 60 seconds, and the surface temperature is 650°C, achieving a relatively uniform temperature distribution.

[0213] Energy efficiency analysis: The conversion efficiency of electrical energy to thermal energy reaches 85%, which is about 20% higher than traditional heating methods.

[0214] 4) Optimization and adjustment:

[0215] Based on the preliminary simulation results, the coil design and operating parameters were further optimized:

[0216] Coil Turn Adjustment: Increasing the number of coil turns to 20 to observe the effect on magnetic field strength and temperature distribution. The results showed that the temperature rise rate increased by 15% and temperature uniformity was further enhanced.

[0217] Frequency Adjustment: Reducing the current frequency to 20kHz increases the penetration depth of the eddy currents, adapting to the heating requirements of thicker workpieces. Simulation results show that the temperature uniformity within the workpiece is significantly improved, the surface temperature decreases slightly, and the overall temperature distribution is more balanced.

[0218] 5) Practical application:

[0219] After determining the optimal parameter configuration through simulation optimization design, the configuration parameters are applied to the actual induction heating equipment:

[0220] Equipment settings: According to the simulation results, the current frequency of the actual induction heating equipment is set to 20 kHz, the current intensity is set to 24 A, and the number of coil turns is set to 20.

[0221] Process execution: Place the carbon steel workpiece in the induction heating furnace, start the equipment, and monitor the temperature sensor feedback to ensure that the temperature distribution during heating meets the design requirements.

[0222] Effect verification: During the actual heating process, the temperature distribution is highly consistent with the simulation results. The heating efficiency and temperature uniformity meet the expected goals, significantly improving production efficiency and product quality.

[0223] 6) Comparison between simulation and actual results:

[0224] The accuracy and practicality of the simulation model of this application are verified by comparing the simulation results with the actual heating effect:

[0225] Temperature distribution comparison: The temperature distribution predicted by the simulation model is basically consistent with the actual measurement results, with an error within ±5°C, meeting the accuracy requirements of industrial applications.

[0226] Energy efficiency comparison: The energy conversion efficiency in the simulation is highly consistent with the measured values ​​of the actual equipment, verifying the reliability of the simulation model in energy efficiency prediction.

[0227] Heating rate comparison: The simulation model accurately predicted the temperature rise rate of the workpiece. During the actual heating process, the temperature rise curve was synchronized with the simulation curve, ensuring the controllability of the production process.

[0228] 7) Implementation effect:

[0229] Through the application of this embodiment, the following effects are achieved:

[0230] Improved heating efficiency: The optimized induction heating system achieves higher energy conversion efficiency and reduces production energy consumption.

[0231] Enhanced temperature uniformity: Through simulation optimization design, the temperature distribution of each part of the workpiece is ensured to be more uniform, improving the quality of heat treatment.

[0232] Reduced production costs: Reduced material waste and substandard products caused by uneven heating, reducing overall production costs.

[0233] Shortened design cycle: Using simulation models for early design and optimization reduces the number of actual tests and shortens the product development cycle.

[0234] The present application discloses a general induction heating system based on parametric simulation and its implementation method, including an induction heating furnace system model, a simulation platform, a sensor and monitoring module and a control unit; the induction heating furnace system model includes an induction furnace system and a crucible system, and the induction furnace system is modeled through the simulation platform to generate an alternating magnetic field; the alternating magnetic field and the crucible system are modeled through the simulation platform to simulate the heat energy generation and temperature changes caused by eddy currents. The present application maximizes the conversion efficiency of electrical energy to thermal energy, reduces energy consumption, and improves the temperature rise rate and heating uniformity by optimizing the induction coil design and eddy current effect.

[0235] The induction heating furnace system model in this application is suitable for heating objects made of various materials (such as steel, cast iron, aluminum, etc.). By dynamically adjusting the electrical conductivity, magnetic permeability and frequency response, the system can automatically optimize the heating effect according to the electromagnetic properties of different materials.

[0236] This application supports the design of crucible containers of different shapes and sizes. By using a unified model of shape factor and equivalent conductance, the eddy current distribution under complex shapes can be accurately calculated to ensure heating uniformity and high geometric flexibility.

[0237] This application supports induction coil configurations with multiple frequencies and different numbers of winding turns, adapting to high-frequency and low-frequency heating needs, and meeting specific heating requirements in different application scenarios (such as industrial heating, food heating, material melting, etc.).

[0238] This application provides a universal induction heating simulation platform that can quickly predict heating performance under different materials and configurations, improving design accuracy and development efficiency. Through unified modeling and parametric design, this application reduces hardware adjustments and additional development costs, is cost-controlled, and is suitable for a variety of industrial application scenarios.

[0239] The preferred embodiments of the present application are described in detail above, but the present application is not limited to the above embodiments. Various changes can be made within the knowledge of ordinary technicians in this field without departing from the purpose of the present application.

[0240] Many other changes and modifications can be made without departing from the concept and scope of the present application. It should be understood that the present application is not limited to the specific embodiments, and the scope of the present application is defined by the appended claims.

Claims

1. A general induction heating system based on parametric simulation, characterized by: It includes induction heating furnace system model, simulation platform, sensor and monitoring module and control unit; The induction heating furnace system model includes an induction furnace system and a crucible system. The induction furnace system is modeled through a simulation platform to generate an alternating magnetic field. The alternating magnetic field and the crucible system are modeled through a simulation platform to simulate the heat energy generation and temperature changes caused by eddy currents. The simulation platform includes MATLAB Simulink and Simscape Electrical, and the Simscape Electrical module is used for modeling in the MATLAB Simulink environment; The induction furnace system includes a current source module and an electromagnetic conversion module, the current source module and the electromagnetic conversion module are connected by a wire, the parameters of the current source module include current intensity and current frequency, and the parameters of the electromagnetic conversion module include the number of coil turns, coil shape, coil diameter, wire diameter, and coil magnetic permeability. The current source module and the electromagnetic conversion module are configured in Simscape Electrical, and the current intensity and current frequency of the current source module are parameterized with the number of coil turns, coil shape, coil diameter, and wire diameter of the electromagnetic conversion module to generate an alternating magnetic field; The crucible system includes a crucible module, an eddy current module, and a thermodynamic module. The parameters of the crucible module include material, material resistivity, and shape. The parameters of the eddy current module include electrical conductivity and magnetic permeability of the crucible. The parameters of the thermodynamic module include the mass of the workpiece to be heated and the specific heat capacity of the workpiece to be heated. The alternating magnetic field, the material and shape of the crucible module, the electrical conductivity and magnetic permeability of the eddy current module, and the mass of the workpiece to be heated and the specific heat capacity of the workpiece to be heated of the thermodynamic module are configured in Simscape Electrical to simulate heat energy generation and temperature changes caused by eddy currents. The sensor and monitoring module are used to detect heat energy and temperature and transmit data to the control unit; The control unit is used to debug the parameters of the induction heating furnace system model, and then run the induction heating furnace system model through the simulation platform to obtain the optimal parameters and the corresponding optimal heat energy generation and temperature change; The simulation calculation formula of the induction furnace system is: in: B is the magnetic induction intensity, T; μ is the coil magnetic permeability, H / m; N is the number of coil turns; I is the current intensity, A; is the magnetic field path length, m; The simulation calculation formula of the crucible system is: in: P is the thermal power density per unit volume, W / m³; ρ is the material resistivity, Ω·m; B is the magnetic induction intensity, T; ω = 2πf is the angular frequency, rad / s; is the penetration depth, m; in: f is the input current frequency; μ is the magnetic permeability of the crucible; σ is the conductivity of the crucible; The eddy current module is used to simulate the eddy current effect in the crucible module and accurately calculate the eddy current distribution of complex geometric shapes using the shape factor method; when the crucible module is a uniform cylindrical workpiece, the shape factor When the crucible module is a flat workpiece, the shape factor It changes with the thickness, and its calculation formula is: in: A is the thickness of the plate, m; is the penetration depth, m; The temperature change simulation calculation formula of the thermodynamic module is: in: ΔT is the temperature change, K; P is the thermal power density per unit volume, W / m³; t is the heating time, s; m is the mass of the workpiece to be heated, kg; C is the specific heat capacity of the workpiece to be heated, J / kg·K.

2. A method for implementing a universal induction heating system based on parametric simulation, characterized in that: The induction heating parametric simulation is performed using the universal induction heating system based on parametric simulation according to claim 1. The method for implementing the universal induction heating system based on parametric simulation comprises the following steps: Step 1: In the MATLAB Simulink environment of the simulation platform, use the Simscape Electrical module to build an induction heating furnace system model. The induction heating furnace system model includes an induction furnace system and a crucible system. The induction furnace system includes a current source module and an electromagnetic conversion module. The crucible system includes a crucible module, an eddy current module, and a thermodynamic module. Set the parameters of the current source module, electromagnetic conversion module, crucible module, eddy current module, and thermodynamic module respectively. Step 2: Parameter adjustment: Ensure that the relative positions of the induction coil of the electromagnetic conversion module and the workpiece to be heated of the eddy current module are correct, and that the induction coil covers the upper half of the workpiece to be heated; Step 3: Start MATLAB Simulink simulation, simulate the induction heating process of the induction heating furnace system model, monitor the power consumption, temperature change curve and temperature distribution diagram during the simulation process, and compare them with the requirements of the workpiece to be heated. If they do not meet the requirements of the workpiece to be heated, proceed to step 4; if they meet the requirements of the workpiece to be heated, proceed to step 6; Step 4: Optimization and adjustment; by adjusting the number of turns and current frequency of the induction coil; Step 5: Start the MATLAB Simulink simulation again, continue to simulate the induction heating process of the induction heating furnace system model, and continue to monitor the power consumption, temperature change curve, and temperature distribution diagram during the simulation process; Step 6: Obtain the optimal parameters that meet the requirements of the workpiece to be heated, as well as the corresponding optimal heat energy generation and temperature change.

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