An Enhancement Method for Induction Heating Efficiency Based on Ferrite Magnetic Circuit Optimization

doi:10.3969/j.issn.1004-132X.2026.05.014

Abstract

Abstract:

To meet the strict requirements of ground thermal experiments for advanced composite material performance testing， an efficient optimization scheme was proposed for a graphite induction heating system of non-conductive materials. The overall structure of the graphite induction heating furnace and two ferrite structures were designed， and the COMSOL simulation model was established covering the coupling of electromagnetic field， temperature field and thermal radiation multiphysics fields. The results show that under the working conditions of 20 kW input power and 20 kHz frequency of the coil， the number of coil turns is positively correlated with the temperature rise of the graphite， but the thermal radiation effect decreases nonlinearly with the increasing of the number of turns. After comprehensive evaluation， it is determined that the four-turn coil is the optimal parameter. The enhancement of the heating effectiveness by ferrite materials is the combined results of the overall structure's ability to gather the magnetic field and the power drop problem caused by the gathered magnetic field. The cylindrical structure is overall superior to the spiral structure， and the heating performance is the best at a coil-to-cylinder spacing of 4 mm. The high magnetic permeability ferrite cylindrical structure may significantly improve the heating performance of the induction heating furnace， providing a feasible strategy for high-demand ground thermal experiments.

Key words: multiphysics coupling, induction heating, radiative heating, structural design, optimization design

摘要：

为满足先进复合材料性能测试对地面热实验的严苛需求，提出一种面向非导电材料的高效石墨感应加热系统优化方案，设计了石墨感应加热炉整体结构和两种铁氧体结构，建立了涵盖电磁场-温度场-热辐射多物理场耦合的COMSOL仿真模型。研究结果表明，在线圈输入功率为20 kW、频率为20 kHz的工况下，线圈匝数与石墨温升成正相关，但热辐射效果随匝数增加呈非线性衰减，经综合评估确定四匝线圈为最优参数。铁氧体材料对加热效果的增强是整体结构对磁场的聚集能力和聚集磁场引发的功率下降问题的综合结果，圆筒形结构整体优于螺旋形结构，圆筒形结构与线圈间距为4 mm时的加热性能最佳。高磁导率铁氧体圆筒形结构可以显著提高感应加热炉的加热性能，为高需求地面热实验提供了可行方案。

关键词: 多物理场耦合, 感应加热, 辐射加热, 结构设计, 优化设计

CLC Number:

TH12

LI Yunlong, ZHANG Dahai, LU Fangzhou, LI Yanjie, XU Peifei, FEI Qingguo. An Enhancement Method for Induction Heating Efficiency Based on Ferrite Magnetic Circuit Optimization[J]. China Mechanical Engineering, 2026, 37(5): 1141-1149.

李昀龙, 张大海, 陆方舟, 李彦杰, 徐培飞, 费庆国. 基于铁氧体磁路优化的感应加热效率提升方法[J]. 中国机械工程, 2026, 37(5): 1141-1149.

Figures/Tables 15

Fig.1 Three-dimensional modeling diagram of the main structure of the graphite heater

Fig.2 Schematic diagram of the phenomenon of energy changes on the object surface

Fig.3 3D model for verification and temperature measurement points on the test specimen

Fig.4 Temperature rise curve at the center of the test piece

Fig.5 Two-dimensional model of graphite induction heating furnace

Fig.6 Overall grid and some major grids

Fig.7 Graphite radiant heating performance corresponding to the number of coil turns

Fig.8 Schematic diagrams of cylindrical ferrite structure and helical ferrite structure

Fig.9 Comparison of magnetic flux density between the original coil（left） and the cylindrical ferrite structure（right）

Fig.10 Magnetic induction line distribution diagram

Fig.11 Comparison of temperature field and external magnetic flux density between the original coil and the cylindrical ferrite structure

Fig.12 Comparison of current density between the original coil and the cylindrical ferrite structure

Fig.13 Comparison of magnetic flux density modulus， current density modulus distribution， and temperature rise curves under different ferrite structures

Fig.14 Impedance modulus of ferrite structure and temperature rise curves of cylindrical structure under different spacing

Fig.15 Temperature rise curves of different powers with and without ferrite structure

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