Maximum Voltage Gain Tracking Algorithm for High-Efficiency of Two-Stage Induction Heating Systems Using Resonant Impedance Estimation

A boost power factor correction (PFC) circuit has replaced the diode rectifier to improve its poor power factor performance, low efficiency, and output power limitation for conventional induction heating (IH) applications. Accordingly, many studies have been conducted, but they considered only the efficiency of the boost PFC rather than the entire IH system, or their control and design were complicated. In this paper, an algorithm tracking the maximum voltage gain of the resonant network is proposed to improve the entire efficiency of the two-stage IH system based on an exact online resonant frequency estimation. It can make the resonant network operate at the maximum voltage gain point which can improve the efficiency of the series-resonant inverter (SRI) included in the IH system with low circulating current, the minimum switching frequency, and zero voltage switching (ZVS) capability. The proposed algorithm also induces the minimum output voltage of the boost PFC, which can reduce its switching losses and total harmonic distortion (THD). The validity of the proposed algorithm is experimentally verified using a 2.4-kW prototype IH system, including the boost PFC and the IH-SRI controlled by a digital signal processor (DSP).