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The domestic induction heating appliance:

an overview of recent research


J. Acero, J.M. Burdio, L.A. Barragán, D. Navarro, R. Alonso J.R. García, F.Monterde, P. Hernández, S. Llorente, I. Garde
Universidad de Zaragoza Bosch-Siemens Home Appliances Group
María de Luna 1, Ada Byron Building Avda. de la Industria 49
50018 Zaragoza, SPAIN 50016 Montañana (Zaragoza), SPAIN

Abstract-In this paper several research topics pertaining to the


design and modeling of domestic induction appliances are Domestic induction
reviewed. Each topic is summarized, stressing its most significant heating technologies
advances and pointing to its future tendencies. A bibliographic
review showing some of the published papers during the last years
is included. The emphases and relative contributions of some of Power Digital Inductor-load
them are also discussed. electronics control system

I. INTRODUCTION Inverter Closed-loop Wire losses


topologies power control analysis
On January 2008, the Moreland’s paper “The Induction Modulation Spread-spectrum Inductor-load system
Range: Its performance and Its Development Problems” [1] strategies implementation impedance analysis
turned thirty five of its publishing, being one of the earliest
references on the domestic induction heating field. During Fig. 1. Technologies involved in induction heating appliances, specifying
these years, the domestic induction hobs have been becoming the different aspects of them.
increasingly popular, due to its specific features of safety,
cleanliness, quick warming and high efficiency. Some of these II. INVERTER TOPOLOGIES AND MODULATION STRATEGIES
features derive of the fact that the heating is directly generated
in the vessel, unlike the traditional contact heating methods. Induction appliances take the energy from the mains voltage,
Specially, the later feature is attracting the attention of which is rectified by a bridge of diodes. A bus filter is designed
researchers devoted to highly efficient power electronic to allow a high voltage ripple, getting a resultant input power
systems. factor close to one. Then, an inverter topology supplies the
Induction cookers constitute the domestic application of the alternating current (between 20 kHz to 100 kHz) to the
induction heating phenomena. In such devices, the desired induction coil. Nowadays, burners of domestic induction
heating is produced in metallic vessels by a varying magnetic appliances are designed to deliver up to 5.5 kW. A schematic
field, which in its turn is generated by a planar coil fed by a diagram of the power stage of a domestic induction apparatus
power electronics inverter. Basically, a domestic induction is shown in Fig. 2.
arrangement consists of a planar turn winding situated below a Formerly, the power electronics was located in a forced-air
metallic vessel and supplied by a medium-frequency power cooled separate box placed on the floor; however, in the later
source, normally operated between 20 kHz and 100 kHz. nineties the application of the resonant inverter topologies
Therefore, domestic induction heating appliances encompass a causes the integration of the electronics and the inductors in a
variety of technologies traditionally grouped in converters, compact hob whose housing is compatible with the
digital control and magnetic components, as it is shown in Fig. conventional resistive cookers. Having in mind that hobs are
1. In this paper some of the recent research carried out in these normally placed over an oven, an environment temperature of
topics is reviewed, as well as some remarkable milestones 75 ºC (167 ºF) is usually considered for electronics design
since publishing [1] are listed. purposes and a highly efficient energy conversion is mandatory.
The paper is organized as follows. Section II introduces Nowadays, resonant inverter topologies are commonly used for
some of the background concepts and recent advances about induction hobs. The most used topologies have been the full-
the power converters used in induction hobs. Section III bridge [2]-[3], half-bridge [4]-[8] and two single-switch
describes the research tendencies in the digital controllers inverter topologies: a ZVS one [9]-[10] and a ZCS one [11]. At
included in such appliances. Section IV summarizes the present, the half-bridge topology is the most popular one due to
concepts involved in the planar windings design, and finally its robustness and its cost savings [12].
Section V draws conclusions and future tendencies. Multiple-burner appliances including two or four inductors
are commonly manufactured. In a multiple-burner induction
cooker, the easiest approach is to use one inverter per burner

978-1-4244-1874-9/08/$25.00 ©2008 IEEE 651


AC-DC converter DC-AC converter Load Q1 Q3 Q5
Mains Cs1 Cs3 Cs5
vGS1 Load 1 vo1 vGS5
50/60Hz iL vGS3 iL1
Rectifier Filter Resonant inverter Leq1 Req1 Cr1
im VDC + + -
vm VDC vo S1 S2

Q2 Q4 i
+ Leq2 Req2 C - Q6
Cs2 Cs4L2 r2 Cs6
vGS2 vGS4 Load 2 vo2 vGS6
vm VDC vo
im

iL
Fig. 3. Two-output full-bridge resonant inverter implementation.
f = 50Hz - 60Hz DC f = 20 kHz - 100 kHz

Fig. 2. Schematic representation of the power electronics of an induction


cooker.
vo1 iL1
[2], [5], [9], or one inverter for two or more burners [13]-[16]
vo1 iL1
as other usual approaches, with some benefits as lower overall
cost and higher utilization ratio of electronics. In the last case,
a common technique uses a single-output inverter multiplexing vo2 iL2
the loads along the time periodically by means of
electromechanical switches [13], causing a very low frequency
switching with power distribution and acoustic noise not
completely satisfactory. Recent solutions [14]-[15] trying to
avoid these problems have been proposed, although there are (a) (b)
still some limitations as lower efficiencies due to two solid- Fig. 4. Experimental waveforms of the output voltages (vo1 , vo2 ) and currents
(iL1 , iL2 ) for the implemented two-output inverter. (a) Both loads operated with
state switches in series with load [14], restrictions in power
output powers P1=1150 W and P2=820 W. (b) One load operated with output
control when all loads are operated [15]. power P1=1650 W.
Recently an upgraded full-bridge inverter with two outputs
(Fig. 3) has been proposed [16] and this concept has been also intervals in which the current is supplied into the inductors.
applied to the half-bridge inverter. It is a cost-effective The main drawback of this strategy is that the power is
proposal that provides new benefits as a quick heating function supplied in pulses of low frequency, which entails some
with an optimum utilization of electronics. problems like not compliance with flicker regulations and a
The full-bridge two-output inverter is based on the sharing a non optimal vessel heating.
common leg and it is also based on adding two low-cost relays Other strategy, still under research process, is the
(S1, S2) for paralleling the independent legs when only one Discontinuous Mode Control (DMC) [21]-[23], which consists
output is required. Thus, the converter can be configured to of forcing a zero inductor current (discontinuous mode) with a
supply either both outputs or only one. In addition, the circuit reduction of the power delivered into the load. In this strategy
in Fig. 3 includes some resonant capacitors Cr1, Cr2, and some the dead time existing between the gating signals of the
snubber capacitors Cs1-Cs6, in order to get a zero-voltage switches placed in the same leg is considered like a control
switching operation of main switches. Fig. 4 shows some variable (see Fig. 3 and Fig. 5). Considering an inverter leg,
typical waveforms including the output voltages vo1, vo2, and when it is operating in discontinuous mode at steady state both
the load currents iL1, iL2 for several operation conditions. transistors and antiparallel diodes are off, the inductor current
Domestic induction cookers must control a delivered power (iL) is zero and the output voltage (vo)is smaller than VDC/2.
ranging between 50 W to 5.5 kW. In a series resonant load, the The DM permits to switch at low frequencies controlling the
supplied power can be controlled by means of the operating delivered power at the lowest range. Therefore, with this
frequency of inverter. Therefore, above the resonant frequency, control an improvement of the efficiency with respect to the
the higher the frequency is, the lesser the power is delivered. In traditional controls, specially at the lowest power range, (see
addition, some modulation strategies are typically used in Fig. 6) is achieved. Moreover other aspects of the converter, as
domestic induction heating, for example the Square Wave (SW) the semiconductor stress and the balance of losses in the
control and the Asymmetrical Duty Cycle (ADC) control [17]- devices remains similar as those achieved with the other
[18]. In these controls, the output power is decreased when the strategies.
switching frequency is increased; consequently, at the lowest
power range the efficiency is appreciably lesser than at the III. DIGITAL CONTROL IMPLEMENTATIONS
highest power range. The increasing performance and cost reduction of digital
To overcome this problem, the switching frequency has been circuits have made possible their application for power
restricted at the highest efficiency range, and the Pulse Density converters control. Induction heating appliances follow the
Modulation (PDM) strategy has been used [19]-[20]. The present trend on increasing the digital controllers of the power
power regulation with the PDM is achieved by varying the converters. The control circuit generates the gating signals,

652
C1
+VCC

+VCC FPGA
iL CT vX R1 –
+ FF1 FF2 QI
SDII
RT D Q D Q
+

CLK CLK

VREF VREF
R1 SDIO

Current ΣΔ modulator CLK ÷100 CLKV


VDC
C2
RS +VCC
– R2 –
+ vY + FF3 FF4 QV
+ SDVI
D Q D Q
RI –
CLKV CLK
Fig. 5. Experimental waveforms corresponding to a half-bridge inverter
VREF
delivering 150 W inductor with DMC. vGS1 and vGS2 are the gating signals, iL is R2 SDVO
the current inductor and vO the half-bridge voltage.
Voltage ΣΔ modulator

Fig. 7. Implemented ΣΔ modulators.

achieve an efficient and useful product. Usually, a power


reference level is done by a knob or a capacitive sensor user
interface. In a commercial appliance, the user expects a reliable
and repetitive output power for a done reference.
Power control requires an accurate real time power
measurement. Moreover, multiple-output converters present
the drawback of sharing the same bus DC and therefore, the
power must be measured in each burner, which entails sensing
and processing signals at the medium-high frequency range
(from 20 kHz to 100 kHz) [20], [24]-[25].
Thus, voltage and current are sensed in each inductor using
Fig. 6. Efficiency comparison between SW, ADC and DMC. first-order sigma–delta (ΣΔ) analog-to-digital converters
implemented in the ASIC [26], instead to use conventional
measures the input current and voltage and the load currents discrete ADCs which require high sampling rate and resolution.
and voltages. In digital controllers, theses signals are sampled Fig. 7 shows the signal conditioning block and the first-order
through A/D converters. ΣΔ modulators used to convert to digital the load current iL and
The design of an application specific integrated circuit the input voltage VDC. The load current is sensed through a
(ASIC) is particularly attractive because induction home current transformer (CT). The current is converted to a voltage
appliances are manufactured in enough quantities to justify the through resistor RT . The modulator D flip-flop is implemented
non-recurrent engineering costs. In this case, the digital in the FPGA. The current ΣΔ modulator sampling frequency
functionality can be tested in prototypes implemented into an fCLK is the FPGA clock frequency. Besides, the voltage in the
FPGA. load is estimated by measuring the DC bus voltage VDC, which
The main advantage of the last digital approach is flexibility. needs the previous knowledge of the modulation strategy.
Besides, well-established and automated digital design tools It is also worth to mention another facility allowed by the
can be applied to shorten the design cycle. The design is digital controller. In order to reduce the conducted
described at the functional level using a hardware description Electromagnetic Interference (EMI) in the A frequency band (9
language (HDL). Starting from HDL-based design, synthesis, kHz–150 kHz) caused by resonant inverters, a frequency
simulation and verification tools are available to target the modulation, as the spread-spectrum technique, is used and
design to standard-cell ASIC or FPGA implementation. The implemented in the ASICs [27]-[28]. This technique allows a
design can then be easily moved to a different process, cost-free noise reduction that, otherwise, must be accomplished
integrated with other digital systems, or modified to meet a with EMI suppression filters.
new set of specifications. Following this trend, we present The digital modulator has been modeled in synthesizable
some digital VLSI implementations of a controller of resonant VHDL and it generates the gating signals of the power devices.
inverters for induction-heated cooking appliances. Fig. 8 shows the gating signal generator block diagram. It
Perhaps the most popular feature of the digital control is the generates two complementary signals QH and QL with
automatic detection of the presence of vessel, which is allowed programmable dead time to prevent switching overlap. The
in fact by the induction technology. Lately, some specific gating signal parameters are stored in configuration registers.
features are also implemented in the ASIC. Among these REG_TS stores the switching period, REG_D the pulse width,
features, one of the most appreciated by the users is a reliable and REG_DT the dead time. QH and QL are generated using
power control. Power control is an important goal in order to counters and a finite state machine (FSM) RAMA. It has four

653
MR

RST FSM RAMA


CNT_DT 4 A CMP
MCON
Config.Registers
A≥B EndDT EndDT and MR
4 B S0 S1
REG_DT

REG_D 9 B CMP QH
EndSC
10 A≥B EndSC
CNT_TS A EndC
REG_TS QL
A CMP EndDT
10 A≥B EndC S3 S2
B

Fig. 8. Gating signal generator block diagram.

fsw

Ajittter
fbase
t

Tjittter
Fig. 9. Frequency modulation parameters.

states. QH is activated in state S1 and QL in state S3. The


transitions between states are determined by comparing the
counters with the values stored in the configuration registers.
MCON is the control register. The FSM remains in reset state
until the MR bit of the control register MCON is set.
The modulation strategies are implemented by dynamically
varying REG_TS, REG_DT and REG_D, according to some
frequency modulation schemes. One of the most popular and
easy to implement is the triangular modulation, which consists
of varying the switching frequency around the working point
according to a triangular law. Therefore, this modulation has
time dependence. Fig. 9 shows the ratio between the triangular Fig. 10. Experimental results without frequency modulation and applying the
amplitude and its period, the EMI reduction depends on the triangular frequency modulation.
triangular frequency modulation parameters.
Fig. 10 shows the spectral analysis of a practical induction
appliance delivering 3500 W at 25 kHz. It can be observed that The efficiency of the heating system, ηind , is the ratio of the
a peak of 82 dBμV occurs at 50 kHz, which it is just twice the power transferred to the load, Pl , to the total power supplied,
switching frequency. Applying a triangular of parameters Pt , that is
fbase=25 kHz, Tjitter=6.4 ms, Ajitter=1.72 kHz, a peak reduction of
3,51 dBμV is achieved. Pl Pl
ηind = = (1)
IV. INDUCTOR DESIGN Pt Pw + Pl
Induction coils transfer the electrical power delivered by the where Pw represents the power dissipated in the windings,
inverter into the vessel through a magnetic coupling. The which causes a non-desirable warming up of the inductor.
windings for domestic induction heating must fulfil several Therefore, two ways could be followed to improve ηind : on the
conditions as sizing restrictions, power ratings, and high
efficiency in the transmission of the electromagnetic energy. one hand, improving Pl ; on the other hand reducing Pw with
Normally, flat-type spiral windings are used for cooking an adequate yarn design.
purposes [29]-[30], with an external diameter defined by the In this way, traditionally two topics have been covered: the
size of the burners. The number of turns of an inductor is analysis of the equivalent impedance of the coupled inductor-
determined once the required nominal power, the inverter vessel system, and the analysis of the winding losses. The first
topology and the mains voltage are known. Therefore, analysis is useful designing the resonant inverter, the second
designing an inductor the main degree of freedom is the one is essential to manufacture safe and efficient appliances. In
winding yarn, which is closely related with the induction order to carry out these analyses, accurate numerical three-
efficiency [31]. dimensional (3-D) finite element analysis have been often used;
however, analytical studies were addressed by some authors

654
ηind

Twisted
Litz

Round

Tapes
cost
Fig. 12. Schematic cost-efficiency representation for an inductor wound with
different cables.

Fig. 11. Typical arrangement of an inductor system comprising the vessel


bottom, the cooking surface, the winding, and the magnetic substrate. (FEA) methods, which traditionally had been used to design
the domestic induction systems, become unpractical, specially
because numerical methods require long computation time and
for wires with a high number of fine strands. This fact has
they are more appropriate for design verification than the
implied the development of hybrid methods [43]-[45], which
design of an induction system.
combine a FEA calculation of the magnetic field needed to
Then, on the basis of some solutions where real conductors
estimate analytically the proximity losses in the wires. These
are replaced by filamentary currents [29]-[30], an analytical
methods have been also applied to study the effect of the
model of the equivalent impedance of the simpler planar
temperature on the coupled inductor-vessel system [46].
induction system (consisting of a bulk material representing the
The hybrid methods provide a resistance Ro representing the
vessel over a planar inductor) was developed [32]. This
solution was extended to cover a more general scenario, in losses in the wire. Therefore, in order to verify experimentally
which the winding is located between two multilayer media the theoretical models, the measured frequency-dependent
[33]. The later result has allowed the study of the effect of the resistance of a coupled inductor-load system must be
magnetic substrate shown in Fig. 11 on the performance of the coincident with the sum of both ΔR and Ro . This parameter is
system [34]. named the equivalent resistance (see Fig. 3) of an inductor
These models provide two electrical magnitudes related with system and it is defined as follows
the parameters involved in the induction-load coupled system
Req = ΔR + Ro (2)
(number of turns, frequency, electromagnetic properties of the
materials, geometrical parameters). The first one is a resistance, Fig. 13 shows the calculated and measured frequency-
ΔR , representing the power transferred into the load for dependent equivalent resistances corresponding to a 23-turn
heating purposes through the induction phenomenon. The other planar inductor designed to deliver up to 3500 W. The inductor
one is an inductance Leq representing the ratio between the was wound with a 20-starnd litz wire, and in this experiment
total magnetic flux and the excitation current. three different materials was tested as loads: copper, aluminum
Designing a domestic induction system, it is also essential to and ferromagnetic steel. The resistance was measured with a
define the yarn which minimizes the self-losses in the inductor. commercial RLC impedance analyzer (Agilent 4284A).
Throughout the time, different kinds of copper-wire profiles Similarly, Fig. 14 shows the frequency-dependent equivalent
have been used for domestic inductors: foils or tapes [35]-[36], inductance for the same experimental setup and loads. In this
round wires [37], and multi-stranded wires. The last ones are case, the equivalent induction is defined as
often divided in litz wires (those constructed according to a
Leq = ΔL + Lo (3)
careful strand-transposition pattern) having up to tens of
strands [38]-[40], and twisted wires (those with the strands where L has been separated in a self inductance of the
eq
simply twisted or bunched) that they can group up to thousands
of fine strands [41]-[42] A schematic representation of the winding Lo , and a contribution of the load ΔL . The origin of
comparative cost of an inductor wound with each kind of wire ΔL is the induced currents in the load, due to the nature of the
is shown in Fig. 12. induction phenomenon, ΔL is typically a term which tends to
Nowadays, litz wires are extensively used because a good reduce the self inductance of the windings.
ratio between the cost and the performance is achieved; Moreover, considering (1) and taking into account that both
furthermore, the number of strands of the cable and its Pl and PT are caused by the same driven current, which it is
diameter can be designed to maximize ηind at a specific assumed to be sinusoidal with an amplitude I , the efficiency
φ
working frequency [31]. However, the Finite Element Analysis can be rewritten as follows

655
Fig. 15. Calculated and measured induction efficiency for the tested loads:
Fig. 13. Calculated and measured frequency-dependent equivalent aluminum (Al), copper (Cu), and ferromagnetic steel (Fe).
resistance for different loads: aluminum (Al), copper (Cu), and
ferromagnetic steel (Fe). The different contributions of the calculated
equivalent resistance are also shown.

Fig. 16. Optimum number of strands with ferromagnetic load at 25 kHz.

Fig. 14. Calculated and measured frequency-dependent equivalent Nowadays, induction hobs have become a sophisticated device
inductance for the considered loads: aluminum (Al), copper (Cu), and but it is progressively appreciated by a growing number of
ferromagnetic steel (Fe). The different contributions of the calculated users. However, more research and development effort is still
equivalent inductance are also shown.
necessary in some aspects: the efficiency of the power
electronic stages still can be upgraded by reduction of the
1
⋅ ΔR ⋅ Iφ2 ΔR ΔR diode rectifier losses. For this purpose, direct AC/AC
ηind = 2
= = (4)
1
2 ⋅ Req ⋅ Iφ2 Req ΔR + Ro conversion could represent an interesting alternative. On digital
controllers, System on Chip (SoC) implementations is being
Last equation shows the above mentioned models can be evaluated in order to reduce peripheral components. The
used to estimate the efficiency of the electromagnetic coupling reduction of inductor losses and the design of inductors
between the winding and the vessel. Applying this result to the creating a uniform heating profile are still pending challenges.
previously calculated resistances provides the induction Finally, it is still necessary an effort to reduce customer price
efficiency shown in Fig. 15. In this figure clearly is appreciated without sacrificing performance and reliability.
that induction efficiency achieved with the ferromagnetic steel
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