A SOLID STATE CONTROLLER FOR INDUCTION LOADS by George Havas Submitted in Partial Fulfillment of the Requirements for the Degree of Master of Science in Engineering in the Electrical Engineering Program Adviser De n of the Gra uate School YOUNGSTOWN STATE UNIVERSITY August, 1972 ABSTRACT A SOLID STATE CONTROLLER FOR INDUCTION LOADS George Havas Master of Science in Engineering Youngstown State University, 1972 This thesis presents the results of an investigation concerning a thyristor controller with an induction heating load. Approximate and exact methods of analysis are utilized to predict system behavior. Unstable regions and an interesting jump phenomenon are predicted and experimentally verified. Extensive use has been made of a digital computer in predicting system performance. ii ACKN~DGEMENTS The author wishes to express his gratitude to Professor M. Siman of the Department of Electrical Engineering, Youngstown State University, for his continuous guidance and encouragement in the preparation of this thesis. The financial assistance of Ajax Magnethermic Corporation is also gratefully acknowledged. iii iv TABLE OF CONTENTS PAGE ABSTRACT ? ? . ? ACKNOWLEDGEMENTS TABLE OF CONTENTS LIST OF FIGURES CHAPTER ii iii iv vi Mode B Operation. A PRACTICAL STEADY STATE ANALYSIS Discussion . Assumptions INTRODUCTION ? ? . ? . DEFINITION OF TERMS 1 3 3 4 5 6 7 9 10 11 11 13 18 19 19 20 21 23 29 ? ? ? ? ? " 0 Equivalent Circuit Models Analysis Using Circle Diagrams ? Basic Controller Control Scheme . . Basic Operation Representation of Load . Definition of Terms Conclusions . . ? . . Discussion . Methods of Analysis Mathematical Derivations . Mode A Operation. EXACT ANALYSIS . I. II. IV. III. v PAGE CHAPTER IV. EXACT ANALYSIS (Continued) Voltage and Current Expressions in the Circuit ? 31 Determination of Rms Circuit Quantities 31 Power and Power Factor ? 32 Harmonic Analysis 32 Prediction of System Performance ? 33 Conduction Angle vs. Firing Angle 34 . . . . 46 63 72 78 83 84 85 Line Current Harmonics ? Power, Input Power Factor, Rms Line Current and Load Voltage. 0 ????? Experimental Verification Comparison of Approximate and Exact Theoretical Results ? ? ? ? Conclusions V. CONCLUSIONS REFERENCES ? ? . ? . LIST OF FIGURES vi FIGURE PAGE 1. Basic Controller Schematic ? ? ? ? ? ? ? ? 3 2. Modes of Operation and Symmetrical Phase Control 4 3. Basic Model of Parallel Compensated Induction Load 6 4. Controller Circuit Diagram ? 10 5. Harmonic Model of Controller 12 6. Fundamental Model of Controller 12 7. Circle Diagram, XL = .2, PF = 1.0 15 8. Circle Diagram, XL = .2, PF = .9 16 9. Circle Diagram, XL = .2, PF = -.9 17 10. Complete Controller Circuit 22 11. Equivalent Circuit for Mode A Operation 23 12. Equivalent Circuit for Mode B Operation 29 13. Conduction Angle vs . Firing Angle for Q = 1.0 and XL = . 0714 . ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? 35 14. Conduction Angle vs. Firing Angle for Q = 1.0 and XL = .1 . ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? 36 15. Conduction Angle VS. Firing Angle for Q = 1.0 and XL = .2 . . ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? 37 16. Conduction Angle VS. Firing Angle for Q = 1.0 and XL = .286 ? ? ? ? ? ? ? ? ? ? ? ? ? 38 17. Conduction Angle vs. Firing Angle for Q = 2.0 and XL = .0714 ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? 39 18. Conduction Angle VS. Firing Angle for Q = 2.0 and XL = .1 ? ? ? ? ? ? ? ? ? ? ? 40 19. Conduction Angle vs. Firing Angle for Q = 2.0 and XL = .2 ? ? ? ? ? ? ? ? ? ? ? ? ? ? 41 vii FIGURE PAGE 20. Conduction Angle vs. Firing Angle for Q = 5.0 and XL = .1 ? ? ? ? ? ? ? ? ? ? 42 2l. Conduction Angle vs. Firing Angle for Q = 5.0 and XL = .2 ? ? ? ? ? ? 43 22. Conduction Angle vs. Firing Angle for Q = 10.0 and XL = .1 ? ? ? ? . ? ? ? ? 44 23. Conduction Angle vs. Firing Angle for Q = 10.0 and XL = .2 ? ? ? ? ? ? ? ? 45 24. Rms Line Current vs. Firing Angle for Q = 5.0 and XL=?l 47 25. Average Output Power vs. Firing Angle for Q = 5.0 and XL = .1 ? ? ? ? ? ? ? ? ? ? ? 48 26. Rms Output Voltage vs. Firing Angle for Q = 5.0 and XL = .1 ? ? ? ? ? ? ? ? ? ? ? 49 27. Input Power Factor vs. Firing Angle for Q = 5.0 and XL = .1 ? ? ? ? 0 ? ? ? ? ? ? ? . ? 50 28. Rms Line Current vs. Firing Angle for Q=5.0 and XL=?2 . 51 29. Average Output Power vs. Firing Angle for Q = 5.0 and XL = .2 ? ? ? ? ? ? ? ? ? ? ? . ? . 52 30. Rms Output Voltage vs. Firing Angle for Q = 5.0 and XL = .2 ? ? ? ? ? ? ? ? ? ? 53 3l. Input Power Factor vs. Firing Angle for Q = 5.0 and XL = .2 ? ? ? ? ? ? ? ? ? ? 54 32. Rms Line Current vs. Firing Angle for Q= 10.0 and XL = .1 ? ? ? ? ? ? ? ? ? ? ? ? 55 33. Average Output Power vs. Firing Angle for Q = 10.0 and XL = .1 ? ? ? ? ? ? ? ? ? ? . . 0 ? ? ? . . 56 34. Rms Output Voltage vs. Firing Angle for Q = 10.0 and XL = .1 ? ? ? ? ? 0 ? ? ? ? ? ? ? ? . 57 35. Input Power Factor vs. Firing Angle for Q = 10.0 and XL = .1 ? " ? ? ? ? ? ? ? ? ? ? ? ? ? ? 58 36. Rms Line Current vs. Firing Angle for Q = 10.0 and XL = .2 ? ? ? ? ? ? ? ? ? ? ? . . ? ? ? ? 59 viii FIGURE PAGE 37. Average Output Power vs. Firing Angle for Q = 10.0 and XL = .2 ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? 60 38. Rms Output Voltage vs. Firing Angle for Q = 10.0 and XL = .2 ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? 61 39. Input Power Factor vs. Firing Angle for Q = 10.0 and XL = .2 ? ? ? ? ? ? ? ? ? ? ? ? ? 62 40. Line Current Harmonics vS.Firing Angle for Q = 1.0, XL = .1 and PF = .9 ? ? ? 64 41. Line Current Harmonics vs. Firing Angle for Q = 1.0, XL = .2 and PF = 1.0 ? ? ? ? ? 65 42. Line Current Harmonics vs. Firing Angle for Q = 1.0, XL = .2 and PF = .9 ? ? ? ? ? ? ? ? ? 66 43. Line Current Harmonics vs .Firing Angle for Q = 2.0 , XL = .1 and PF = 1.0 ? ? ? ? ? ? ? ? ? ? 67 44. Line Current Harmonics vs. Firing Angle for Q = 2.0, XL - .1 and PF = .9 ? ? ? ? ? ? ? ? ? 68 45. Line Current Harmonics vs. Firing Angle for Q = 2.0, XL = .2 and PF = -.9 ? ? ? 69 46. Line Current Harmonics vs. Firing Angle for Q = 2.0, XL = .2 and PF = 1.0 ? ? ? ? ? ? ? ? ? 70 47. Line Current Harmonics vs. Firing Angle for Q = 2.0, XL = .2 and PF .9 ? ? ? ? ? ? ? ? ? ? 71 48. Rms Line Current vs. Firing Angle for Q = 5.0 and XL = .2 ? ? ? ? ? ? ? ? ? ? ? 73 49. Average Output Power vs. Firing Angle for Q = 5.0 and XL = .2 ? ? ? ? ? ? ? ? ? ? ? 74 50. Rms Output Voltage vs . Firing Angle for Q = 5.0 and XL = . 2 ? ? ? ? ? ? ? ? ? ? ? ? ? ? 75 51. Conduction Angle vs. Firing Angle for Q = 1.0, XL = .1 and PF = 1.0 ? ? ? ? ? ? ? ? ? ? 76 52. Conduction Angle vs. Firing Angle for Q = 1.0, XL = .2 and PF = -.9 ? ? ? ? . ? ? ? 77 53. Output Power vs. Firing Angle for Q = 1.0, XL = .2 and PF = 1.0 ? ? ? ? ? ? . . . ? ? ? ? ? ? ? 79 FIGURE 54. 55. 56. Output Power vs. Firing Angle for Q = 10.0, XL = .2 and PF = 1.0 ..??.. Real vs. Reactive Fundamental Input Power for Q = 1.0, XL = .2 and PF = 1.0 . . . . Real vs. Reactive Fundamental Input Power for Q = 10.0, XL = .2 and PF = 1.0 . . . . ix PAGE 80 81 82 1 C~PITR I INTRODUCTION The phenomenal development in the past few years of the four layer semiconductor device, the thyristor, more commonly known as an SCR (silicon-controlled rectifier), opened a brand-new dimension in efficient and economical switching and controlling of large blocks of electrical power. SCR's have been used for controlling rotating equip ment, as switching devices in frequency converters and in many other industrial and commercial applications. In this thesis, the use of SCR's in switching and controlling power supplied to large induction heating or melting loads is in vestigated. The utilization of SCR's has the following inherent advantages over conventional electromechanical or magnetic means of power control: 1. Higher Efficiency. 2. No moving parts. 3. No component deterioration. 4. Small physical size. 5. Transient-free starting. 6. Half-cycle fault protection. 7. Extremely fast response time. However, the use of SCR's requires a deeper and better under standing of the complete system so that its performance under various load conditions can be predicted. The prediction of system performance is 2 not straight-forward due to the non-sinusoidal nature of the SCR currents during the controlled mode of operation. In the following chapters, the definition of basic terms, a method of approximate analysis, the derivation of equations necessary for exact analysis, digital simulation of the system and the comparison of predicted performance versus experimental results is given. In choosing the method of analysis for the digital simulations, the following factors were of primary concern: 1. Accuracy of calculations. 2. Limited computer working core capacity (8K). 3. Limited computer time available. In other words, the highest degree of accuracy was desired with short computational time using a computer (IBM 1130) with limited working core capacity. An attempt has been made throughout this study to consider cases of practical importance and to link the theoretical results meaningfully to practical considerations. 3 CHAPTER II DEFINITION OF TERMS This chapter introduces the basic controller configuration, its control scheme and operation and gives a definition of the basic terms used throughout the following chapters, as well as a short dis- cussion of the general nature and range of the load. Basic Controller Th.l L I --------I iL .I I Th.2 Vc Lo I v C I 1.0 Ro I L- ------- _-.J Load Fig.l Basic controller schematic Fig.l is a schematic diagram of the controller. It consists of a series inductance L, antiparallel connected thyristor switches Th.l, Th.2, and a parallel-tuned tank circuit which is a simplified lumped parameter representation of an induction load with its power factor correcting capacitances. 4 Control Scheme Stepless, continuous control of the power delivered to the load can be obtained by the use of a sYmmetrical phase control. Th.l in Th.2 in Th.l in Th.2 in I? cond., I I- condo a I I?condo I?condo I I I I I ( I I I I , II I I I I~\T+e:p I 0 I" I , "51\ I 1 'ModeI kde IGPI Mode Mode Mode Mode A B A- A A- I I I I I I I UJtI I , GP~l I I0 D ?vst. Fig. 2 Modes of operation and sYmmetrical phase control Fig.2 illustrates the principle of sYmmetrical phase control. The input sinusoid v represents the time reference source. Gating pulses GPI and GP2 are derived and controlled in such a manner that for any integral cycle they have a fixed interval between the zero ? 5 crossing of the reference supply and the start of the gate pulses. The interval between the start of each gate pulse and the previous zero crossing of the reference supply is defined as the firing angle ~ ? Symmetrical control of the load voltage, current or power is achieved by continuously varying the firing angle on an integral cycle basis. The symmetrical operation of the controller is extremely important in eliminating direct current and even harmonics from the supply lines. Basic Operation The steady state operation of the controller can be described as a repetition of two transient modes. Fig.2 illustrates these modes. Let us assume that Th.l is connected so that it conducts current during the positive half cycle. Mode A starts when Th.l is rendered conductive at firing angle ~ by gate pulse GPI. During this mode, current flows from the supply to the load. When the current through Th.l goes through zero, Th.l opens. This is when Mode B begins. During this mode, both Th.l and Th.2 are open, that is, the load is disconnected from the supply. The load now proceeds to resonate due to the charge on the capacitor and current in the load inductance from the previous mode. Mode B continues until UJ1:.=1T-t-ep, when Th.2 is rendered conductive, repeating Mode A for the negative half-cycle. The steady state operation of the system then consists of the repeti tion of Modes A and B in the positive and negative half-cycles. 6 Representation of Load The true reflected impedance of an induction heating load is a complicated function dependent on the coupling between load and work coil and on the resistivity, permeability and temperature of the load. The frequency of operation and the geometry of the load also contribute to the reflected impedance. However, if one considers the total net effect of all the factors mentioned above, the induction heating load can be represented by a series RL network where R is the reflected resistance and L is the reflected inductance of the load. Since the typical induction load has a low power factor typical values are .1 .3, with occasional values up to .7 parallel power factor correcting capacitors are used for better supply current versus power utilization. Normally, an induction heating load is corrected to nearly unity power factor. The basic model of the load is shown in Fig.3? ? c Fig. 3 Basic model of parallel compensated induction load 7 Definition of'Terms characterized by: power factor. The parallel load as shown in Fig.3 consists of the basic (1) ( 2) fundamental supply frequency Lo Ro C ::= Q Req and The quality factor Q is defined by the equation uJLo::= "R;"" f is the The equivalent impedance of the load at unity power factor is Req - the impedance of the load to fundamental frequency at unity parameters Ro, Lo and C. In the following chapters, the load will be P.E the load power factor. Q - the quality factor of the load. given by the equation In general, Req will be normalized to unity. where YJ=2.:ttf in rad/sec in Hertz. In a practical circuit, the load power factor is held close to unity by periodic adjustments of the parallel capacitors. However, due to the rapid changes of the load, the power factor is held within a fixed lead-lag band. To simulate these conditions, the value of the parallel capacitance C is varied,with Ro and Lo held constant until the desired load power factor is obtained. The normalized magnitude of the load impedance at any operating power factor is then given by the equation 1 nl..U C 0--------1 In 12 Fig. 5 where n = 3, 5, 700. Harmonic model of controller Fig. 6 Fundamental model of controller 13 A brief numerical example using the harmonic representation of the compensated load illustrates well the shunting effect of the load power factor correcting capacitor. For a load whose Q =: 3, it can be shown that at the fundamental frequency, Ro(l) 1 =: 1 =: .1- Q2+1 10 XLo(l) =: Q Ro =: 3 =: 03 and10 Xc(l) =: 1 =: 1 . 033Q 3 At the third harmonic frequency, Ro(3) =: 1 =: .110 XLo(3) =: 9 =: .9 and10 Xc(3) =: 1 =: .119 . The above simple calculations show that at the third harmonic frequency the capacitance has about one ninth the impedance of the in- ductive load. It is not difficult to see that for higher harmonics the capacitance acts nearly as a short circuit compared to the inductive load. Analysis Using Circle Diagrams Making use of the fundamental model, the controller's behavior under various load conditions can be analyzed with the help of circle diagrams. The following figures show the controller behavior from full conduction to
+ cos u..J t sin eP ) and the Laplace transform of v is: (11) (12) 1- (v) = A (t.u cos ef:> + s sin.q,)s2 +L.U 2 (13) Taking the Laplace transform of equation (10) and solving for x(s) with all possible initial conditions, we have !(s) == [s,!, - ~J -1 ~(O+) + [s,!, - ~] -1 ~(s) ~(s) (14) Written in terms of the circuit componenmof Fig.ll, equation (14) is: 25 l L(s) s2 + Ro + 1 1 s(-1) Ro iL(O+)s- -- ---Lo LoC LC L LLo 10 (s) = 1 s2 + 1 s ....L io(O+)LoC LC Lo Vc(s) s 1 Ro 1 s2 Ro Vc(O~C LoC C Lo det (sI - !] s2 + s Ro 1 1 s(-l) _ Ro-+-L o LoC LC L Lto + 1 s2 + 1 1LoC LC Lo s l Ro 1 s2 + Ro+-- s - s -C LoC C L o 1 L o o x [-s""'2-+;;';;~'--""'2- det [SI - AJ (\.0 cos cj> + s sin
+ X)
Bl~ = Bl - B2 (Y
Z [(Y -
jZ) + B3 (Y
jZ)Z +t..U 2J jZ) 2 - B4 (Y jZ)3
-YtE.= CL ) + Cl - C2X + C3X2 -Xtsin (Zt +0' (Y _ X)2 +Z2 ?..
Dl - D2X tcE.. -X
+ (X2 +lJ.J Z) [(Y - X)Z + z2J
+ CB sineUJ t + o%,) + DeE -Yt sin(Zt +d) (18)
where
CL~ + Cl - C2 (Y - jZ) + C3 (Y - jZ) 2
Z (X - Y + jZ)
Dl + D2 (jW)CB~=
W [(j LU + Y) Z + Z2J (jW + X)
27
Did = Dl - D2 (Y - jZ) (X - Y +
jZ)
Vc Yt El - E2X + E3X2 t:. -XtEL c. - sin(Zt +t=") + (Y _ X)2 + Z2
+ Fl - F2X + F3X2 -Xt
(X2 +lJ..)2) [(Y - X) 2 ..(. Z2J E.
+ EB sin(LtJ t +f'L) + F e. -Yt sin (Zt + E5 ) ( 19)
where
El - E2 (Y - jZ) + E3 (Y - jZ) 2EL\P, =
Z (X - Y + jZ)
Fl - F2 (jUJ) + F3(jL.U)2
EBlf':z. = luw + y)2 + z2]
(jUJ + X)
Fl - F2 (Y - jZ) + F3 (Y - jZ) 2FlSL
=
Z [(Y - jZ) 2 +UJ 2] (X - Y + jZ)
In the above equations, X is the real root of
det [s.! - A] = 0 and Y and Z are the real and imaginary parts
of the complex conjugate roots of det [s.! - A] = 00 The subscripted
constants in terms of the circuit constants are:
Al
A2 = 1
L
A3 = iL(O+)
Bl A UJ cos pLLoC
B2 = A <.u cos 1> Ro + A sinpLL
o LLoC
B3 = Au..> cos ep + A sin 4> Ro
L LLo
B4 = A sin 4>L
28
Cl
C2
C3
=
=
1
LC
Dl
D2
= A u.J cos c:I>
LLoC
A to sin ep=
LLoC
El
E2
=
=
Ro
LoC
E3
Fl = A U) cos cI> Ro
LLoC
F2 = A w cos ep Ro + A sin et> Ro
LLoC LLoC
F3
where
= A sin