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ПРИМЕНЕНИЕ МЕТОДИКИ МОДЕЛИРОВАНИЯ ИНДУКТОРОВ ДЛЯ ПРОЕКТИРОВАНИЯ
СЕРИИ ИНДУКЦИОННЫХ УСТРОЙСТВ
Тяпин А.А.
аспирант, ФГОУ ВО Сибирский федеральный университет, г. Красноярск, Россия
Кинев Е.С.
к.т.н., директор, ООО Тепловые электрические системы, г. Красноярск, Россия
APPLICATION OF THE INDUCTOR MODELING TECHNIQUE FOR DESIGNING A SERIES OF
INDUCTION DEVICES
Tyapin A.
Postgraduate student, Siberian Federal University
Kinev E.
Ph.D., director of Thermal Electrical Systems LLC
Аннотация
В статье рассмотрены особенности применения методики моделирования индукторов продольного магнитного поля для создания серии индукционных устройств. Средством моделирования служит программная среда, построенная на основе методов гибридного анализа. Моделирование выполняют по принципиальной схеме однофазной, двухфазной или трехфазной установки. Каждому классу устройств соответствует комплекс библиотечных моделей. В схемной модели учитывают компенсирующие устройства, вольтодобавочные трансформаторы, симметрирующее и иное оборудование. Электромагнитные связи обмоток и перенос мощности при искажении симметрии в моделях описывают с применением средств параметрического управления.
Abstract
The article discusses the features of the application of the method of modeling longitudinal magnetic field inductors to create a series of induction devices. The modeling tool is a software environment built on the basis of hybrid analysis methods. Simulation is performed according to the basic diagram of a single-phase, two-phase or three-phase installation. A set of library models corresponds to each class of devices. The circuit model takes into account compensating devices, booster transformers, balancing and other equipment. Electromagnetic connections of windings and power transfer with symmetry distortion in models are described using parametric control means.
Ключевые слова: индукционная система, электромагнитный индуктор, симметрирование нагрузки, электромагнитный режим, математическое моделирование.
Keywords: induction system, electromagnetic inductor, load balancing, electromagnetic mode, mathematical modeling.
Introduction. Induction complexes for heating aluminum before pressing are widely used in extrusion production [1]. The designs, circuitry of single-phase, two-phase and three-phase inductors, as well as the operating modes of the devices, can be very diverse. The calculation of asymmetric modes of induction heating installations, consisting of electromagnetic inductors, nonlinear transformer voltage regulators, adjustable capacitor banks, providing local resonances, is complex
[2]. General view of water-cooled induction heaters for extrusion of aluminum ingots is shown in Fig. 1. Three-phase inductors are rather long in design (Fig. 1, a). They are used for methodical heating [3]. Industrial inductors of periodic action (Fig. 1, b, c) are shorter. They are manufactured in single-phase and two-phase versions. Inductors for continuous heating of ferromagnetic materials can be of different lengths [4].
b
Figure: 1. General view of induction heaters
a
c
In the circuit for switching inductors, as a rule, capacitor banks are provided, which provide the mode of resonance of currents and a significant reactive current of the inductor [5]. During the heating of the ingot from 20 to 530 °C, the parameters of the loaded inductor change during heating and the resonance mode is maintained by switching the capacitance [3, 6]. In the simplest case, the control is relay, and with a significant project budget, the regulation of the induction heater mode is performed by the microprocessor of an industrial controller [7].
Formulation of the problem. When researching and designing induction devices, it is necessary to develop and apply a universal calculation and modeling tool that allows using a set of standard models. The calculation results should be presented in a convenient graphical form that allows one to evaluate the energy characteristics and a measure of the effectiveness of the electromagnetic regime. The order of the stages of using the modeling tools and the sequence of calculations should be formulated in the form of a methodology. This approach will allow designing a series of efficient induction devices for equipping extrusion shops of metallurgical enterprises.
Solution. To solve the modeling problem, you can use the software described in the literature [3, 8]. The software environment is built on the basis of hybrid matrix nodal analysis, programming topological and component equations for two-terminal and multi-terminal networks of circuit theory [9]. Mathematical modeling
is performed in the form of a multivariate computational project, relying on a complex of circuit models and libraries of computational methods [10]. The task description is generated as a file in ASCII code, by analogy with some versions of the Ansys software environment. The steady-state modes of inductors are usually calculated in the symbolic domain, transient states - in the time domain [11]. Parametric models are used to study steady-state modes when changing parameters, as well as starting modes of inductors [12].
The use of discrete control means makes it possible to calculate the set of steady-state modes during parameter drift and the dynamics of the inductor start-up in the distribution network. The modeling technique is based on the means of describing the circuitry of the induction complex in a universal software environment. When analyzing the switching circuit of all components of the induction device, methodological techniques are used to replace all multi-pole elements with equivalent models. Thus, a global digital description of the device is obtained. The structure of the circuit model for studying the modes of a single-phase inductor in a three-phase network is shown in Fig. 2. The circuit uses multi-pole models of the inductor and capacitor banks (Model). To control currents and voltages, voltage controlled EU voltage sources were used, which provide direct access to numerical arrays of simulation results [13]. Schematic models of single-phase, two-phase and three-phase inductors are built from standard modules. For each particular circuit, schematic models are generated from a set of built-in library components.
Figure: 2. Schematic model of a single-phase inductor in a three-phase network
The simulation results are displayed in the form of vector diagrams of currents and voltages of the induction system [3, 8]. To assess the drift of the parameters of inductors during heating in macromodels, discrete-analog parametric elements, implemented on the basis of voltage (current) controlled switches, can be used. The simulation results of asymmetric power consump-
tion modes are evaluated using the symmetric components analysis module. As a result, numerical data are obtained to plot the characteristics of the change in the current unbalance coefficient during heating for the specified drift boundaries of the parameters. The structure of the circuit model for studying the modes of an asymmetrical two-phase inductor in a three-phase network is shown in Fig. 3.
Figure: 3. Schematic model of a two-phase inductor in a three-phase network
Numerical arrays of calculation results are processed by tabular processors and exported to the graphical interface of the software shell. If necessary, an analysis of the dynamics of the induction system can be carried out using parametric models synthesized on the basis of time-controlled keys [12]. The most important stage of modeling in the course of studying dynamics can be considered overcoming conflicts when choosing and agreeing the duration of the integration step for dis-
crete models of reactive and nonlinear elements. Features of the construction and study of models for more complex - three-phase induction devices are presented in the literature [2, 10, 13].
For example, in fig. 4 in the form of a vector diagram shows the results of modeling in the symbolic area, the steady state of a three-phase induction system with resonant sections [2]. This form of presentation of the results of the steady state calculation can be considered very convenient.
Figure: 4. Results of simulation of currents of a three-phase induction device
Judging by the diagram, the investigated mode reflects the planned asymmetric distribution of currents Ii1, Ii2, Ii3 between the sections. The obtained state is typical for the methodical heating of the aluminum load with an increase in the output section power at a current of about 1.8 kA. During the simulation, special circuit solutions were used to optimize the circuitry of the induction heating installation. Changing the circuit allows you to simplify and reduce the cost of the device
by eliminating the transformers. However, a more significant consequence is the provision of symmetrical power consumption from the shop network at currents Ia = Ib = Ic, and the internal electromagnetic unbalance of the inductor itself [14, 15]. The modeling system provides for the possibility of studying transient modes of inductors using discrete models of reactivity and nonlinearities, as well as automated generation and solution of equations of state [9, 13]. In addition to the typical dynamic characteristics of voltage and current,
it is possible to evaluate the behavior of the power and energy of system elements over time. The open nature of the software allows you to get direct access to the information arrays generated during the simulation.
Industrial induction devices operate under the control of automated control systems (ACS) [16]. The results of modeling the control characteristics for tuning the automated process control system based on a microcontroller are given in [2, 8]. It should be noted that for inductors with a power of up to 200 kW, the equivalent reactances to be compensated are determined by the values of their own inductances of the order of 0.060.09 H, with resistive components of 0.03-0.06 Ohm. The analysis of modes according to circuit models showed that the range of variation of the inductor parameters corresponds to an increase in the current unbalance coefficient up to 15 to 25%. To compensate for the distortion of the symmetry of the mode, taking into account [3, 12], the means for controlling the regulators of the operating parameters were selected and the necessary switching ranges of the compensating capacitor banks were set. The proposed measures ensure the maintenance of the voltage unbalance coefficient in the connection node [11, 16], within the limits limited by the requirement of the GOST 32144-2013 standard.
Conclusion. The sequence and results of a numerical study of the energy characteristics of induction complexes presented here are a modeling technique that allows one to identify the electromagnetic mode of an inductor and to clarify the boundaries of changes in currents and powers in the presence of asymmetry. The use of parametric models in a numerical experiment makes it possible to predict the behavior of an inductive load under the influence of discrete controllers. Taking into account the influence of the dynamics of the mode on the parameters of the model, it becomes possible to quantitatively estimate the limiting values of the voltage unbalance coefficient of the distribution network. Based on the calculations, recommendations are developed to ensure the proper quality of electricity during the operation of powerful single-phase, two-phase and three-phase induction complexes.
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