CHAPTER ONE

INTRODUCTION

1.1 INTRODUCTION

Induction heating is a process which is used to bond, harden or soften metals or other conductive

and non-conductive materials. For many modern manufacturing processes, induction heating

offers an attractive combination of speed, consistency and control. The basic principles of

induction heating have been understood and applied to manufacturing since the 1920s. During

World War II, the technology developed rapidly to meet urgent wartime requirements for a fast,

reliable process to harden metal engine parts. More recently, the focus on lean manufacturing

techniques and emphasis on improved quality control have led to a rediscovery of induction

technology, along with the development of precisely controlled, all solid state induction power

supplies.

Induction heating relies on the unique characteristics of radio frequency (RF) energy -

that portion of the electromagnetic spectrum below infrared and microwave energy. Since heat is

transferred to the product via electromagnetic waves, the part never comes into direct contact

with any flame, the inductor does not get hot, and there is no product contamination. When

properly set up, the process becomes very repeatable and controllable.

The operation of an induction heater can be achieved when PVC is inserted into the

varying magnetic field; currents are setup in the conductor by influence of the induced voltage.

Electromagnet induction which is the bases of all induction heating system was discovered by
Micheal Faraday in 1831. The basis of this method of coil design is the reduction of the

induction heater coil and workpiece to their equivalent resistance and inductance.

The practical example of this process is the induction process that happens when only the

primary side coil of a transformer is used and the heating element is serving as the secondary coil

placed in the magnet field to induce the magnetic current that transform into eddy current.

1.2 STATEMENT OF THE PROBLEM

Electricians do encounter difficulty in bending of PVC pipes during conduit wiring installation

on site, as they result to use of physical fire which have lead to fire outbreak, injury and even

death.

1.3 AIM

The aim of this research project work is the design and construction of an induction heater for

PVC materials.

1.4 JUSTIFICATION AND SIGNIFICANCE

The use of induction heater for PVC pipe become necessary as it will help reduce risk of fire

outbreak on site and help the electricians in achieving desired bending of PVC pipes to suit

purpose during installation.

1.5 SCOPE

This research project work of induction heater for PVC pipe is limited to pipe range of 20mm

and 25mm.
1.6 LIMITATIONS OF THE PROJECT

a. Funding – There was no enough fund finance the project.

b. Availability of certain component – Some of the electronic components are not

available in the local market.

c. Timing – The researcher needed more time in designing and constructing the project

and put it into test. The final exams took much of the time.

1.7 PROJECT OUTLINE

Chapter one

Introduction

Statement of the problem

Aim

Justification

Scope

Limitation of the project

Chapter two – Literature review

Introduction

Review of fundamental concept

Review of related works

Comparative analysis

Stabilizing and regulatory circuit

Switching circuit

Feedback circuit

Battery
 Coil

Chapter three – methodology

Introduction

Push-pull topology

Push-pull design

Chapter four

Implementation

Testing

Chapter five

Conclusion

Recommendation

Suggestions

Appendix

References
 CHAPTER TWO

LITERATURE REVIEW

2.1 INTRODUCTION

2.2 REVIEW OF FUNDAMENTAL CONCEPTS

The study of different types and categories of induction heater had given the researcher a

wider knowledge on induction heaters in relation to the components used. Many of them use AC

in triggering and powering their operations and in view of non regular availability of AC at site,

the need for design and construct an induction heater that use battery as such of input power.

The researcher uses a simple circuit with fewer components but still achieves a desired

regulated and stabilized electromagnetic current. The complex circuit in existence makes

maintenance more difficult due to non-availability of the Integrated Circuit (IC) in our local

market.

The DC source (Battery) triggers the regulatory and switching circuit. The switching and

regulatory circuit comprises of resistors, diode and metallic oxide semi-conductor field effect

transistor (MOSFET). The resistors are use to limit the flow of current to a suitable level of

demand, diodes for directional flow of current and backward direction when it reaches the zener

voltage in the case of zener diode. Both resistor and zener diode connected in parallel also serves
as stabilizer enhances the current and half the resistance. It prepare the DC that flows into the

MOSFET for switching operation that produces its input inform of square waves that form the

alternating current (AC) that feed the working coil.

At the working coil, the alternating current passes through the coil; it produces magnetic

current in the coil which produces magnetic field or flux surrounding the coil. Work piece place

within the magnetic field will causes induction of magnetic current into it thereby creating eddy

current in the object or work piece. The resistance of the object against the flow of eddy current

introduces heat required. The feedbacks which function are to sense error in the signal going to

the work piece through the working coil. If any, it feed its observation back into the switching

circuit for correction purposes.

The induction heater related research work available take its input source from main (AC) which

goes straight to the switching circuit supply the electric current to the working coil that convert

the electric current into magnetic current produced by coil. The EMF generate magnetic current

that passes through the PVC and create an eddy current which in result generate heat that melt

the PVC into bending point

2.3 COMPERATIVE ANALYSIS

more efficient. Instead of using bipolar joint transistor (BJT) in switching circuit, the researcher

uses MOSFET transistor because of its high rate of switching.

A stabilizing circuit is also incorporated into the research project in other to produce a

regulated current. Resistor and zener diode is used.

A feedback loop is also introduced into the research work to ensure a regulated and stable current

that goes to the working coil.

2.4 LIST OF COMPONENTS

S/NO COMPONENTS QUANTITY

1. Casing 1

2. Battery 1

3. Soldering lead 2

4. Capacitor 750/1100V 2

5. MOSFET IR44N 2

6. Coil 1

7. Cable 4mm twin 1 yard

8. Heat sink 4

9. Fan 12VDC 2.5Amp 1

10. Zener diode 2

11. Jumper wire 6

12. Input terminal 1

14. Inductor 200uF 2

15. Cable luck 4

16. Resistor 10K 4

17. Diode FR207 1

18. Vero board 2

19. Capacitor 0.33uF 1

20. Resistor 11K 2

Table 1 List of components

2.5 STABILIZING AND REGULATORY CIRCUIT

In trying to achieve a regulated and stabilized current, the researcher made use of a zener

diode which provides a reference voltage. The zener diode conduct at a certain required voltage

and will conduct as much current as possible to hold its terminal voltage by grounding excess

current. A relatively low value resistor is used to dissipate the excess energy. Most of the

induction heater available dose not encompasses a stabilizing circuit in other to output a

regulated current.

2.5.1 ZENER DIODE

when a certain set reverse voltage known as the zener voltage is reached. Maximum current of

zener diode is given as

I = P/V

Where: P = Power

V = Zener voltage

I = Current

2.5.2 RESISTOR

Resistor is an electrical component that limits or regulates the flow of current in an

electrical/electronic circuit. Resistors are of different types and categories to suit purpose.

TYPES OF RESISTOR
Types of resistor include:

a. Carbon composition resistor

b. Wire wound resistor

c. Variable resistor

d. Light dependable resistor

e. Carbon film resistor

f. Metal film resistor

g. Thermistor

h. Varistor

2.6 SWITCHING CIRCUIT

In switching mode, MOSFET is one of the components used, because at its efficient

switching ability to turn “ON” (saturated) and ÖFF” (cut off) faster and slower or passes

high/low currents when the MOSFET is fully ON and conducting current, the voltage drop

across it is at minimal value and when the MOSFET is fully OFF there is no current flow

through it, the transistor is acting like an ideal ON/OFF switch. This ability makes it better than

bipolar junction transistor which is commonly used other researcher.

The MOSFET (Metal Oxide Semiconductor Field Effect Transistor) is a semiconductor device

that is widely used for switching purposes and for amplification of electrical signals in electronic

devices. A MOSFET either a core or integrated circuit designed and fabricated into a single chip.

It is a uni-polar, voltage controlled, tri-terminal, and high input impedance device.

The main principle of the MOSFET device is to be able to control the voltage and current flow

between the sources and drain terminals.

2.6.3 P - CHANNEL MOSFET

The p-channel MOSFET has a p-channel region located in between the source and drain

terminals. It is a four-terminal device having the terminals as gate, drain source and body. The

drain and source are heavily doped P+ region and the body or substrate is of n-type. The flow of

current is in the direction of positively charge holes.

2.6.4 N – CHANNEL MOSFET

The N-channel MOSFET has an n-channel region located in between the source and drain

terminals. It is a four-terminal device having the terminals as gate, drain, source body. In this

type of Field Effect Transistor, the drain n+ region and the substrate or body is of p-type.

2.6.5 MOSFET REGION OF OPERATION

The operation of this device happens mainly in three regions which are:

a. Cut-off region

b. Saturation region

c. Linear/Ohmic region

a. Cut-off region - It is the region where the device will be in the OFF condition and

there is zero amount of current flow through it. At this region, the device functions as

a basic switch and is employed as when they are necessary to operate as electrical

switches.
 b Saturation region - In this region, the device will have their drain to source

current value as constant without considering the enhancement in the voltage across

the drain to source. This happens only when the voltage across the drain to source

terminal increases more than the pinch-off voltage value. In this scenario, the device

functions as a closed switch where a saturated level of current across the drain to the

source terminals flows. The saturation region is selected when the device is supposed

to perform switching.

C. Linear / Ohmic region - It is the region where there the current across the drain to

source terminal enhances with the increment in the voltage across the drain to source

path. When the MOSFET devices function in this linear region, they perform

amplifier functionality.

2.7 FEEDBACK CIRCUIT

At this circuit, a portion of the output signal to the working coil was returned to the input

of the induction heater, the signal returned (the feedback signal) at same phase as the input signal

regarded as positive or regenerative. It is used to compare the actual output of a system with the

desired output. The task of this loop is to measure the output voltage or current compared it to a

desired value and use the error or difference between them to adjust the switching pattern of the

switching unit until the error become zero or close enough to zero.

The combination of capacitor and diode at this circuit are to jointly perform the task of

feedback and error correction in the system. The diode is to protect and prevent the regulated

signal (current and voltage) from being reversed when input supply voltage is switched off.
While the output supply remain “ON” or active for a short period of time. The capacitor is to

ensure that portion of signal to perform the feedback operation is kept constant throughout the

feedback exercise.

2.7.1 DIODE

A diode is an electrical component that allow current to move or flow it in one direction with far

greater ease than in other component. It is a two terminal electronic component that conducts

electricity primarily in one direction. It has high resistance on one end and low resistance on the

other end. Diodes are to protect circuit by limiting the voltage and to also transform AC into DC.

such as cabl