A Modular Three-Phase Induction Heating Generator with Enhanced Power Factor

This paper presents a novel modular and interleaved solid-state induction heating generator designed for induction casting machines, particularly for jewelry casting applications. The proposed system addresses challenges related to power factor correction, harmonic compliance, and scalability by employing modular single-phase solid-state inverters integrated with Power Factor Correction (PFC) units. Each inverter utilizes advanced 600-700V Silicon Carbide (SiC) power MOSFETs and a custom gate-driver card, ensuring high efficiency and reliability. The control strategy employs phase shift control for power regulation and automatic frequency control for maintaining zero voltage switching at all loading conditions. The system’s modular design allows for easy scaling of power levels in multiples of 6 kW while maintaining compliance with international standards such as IEEE-519-2014 for harmonics and EMI/EMC regulations. The use of a high-frequency impedance matching transformer and a common series resonant LC tank circuit ensures efficient power distribution. This paper discusses the design, implementation, and advantages of the system, highlighting its potential for various industrial induction heating applications beyond jewelry casting.