Design and Testing of DC Powered Induction Cooker PDF

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TRIBHUVAN UNIVERSITY INSTITUTE OF ENGINEERING PULCHOWK CAMPUS THESIS NO.: M-09-MSESPM-2014/2016 Design and Testing of DC Powered Induction Cooker by Bikal Adhikari A THESIS SUBMITTED TO THE DEPARTMENT OF MECHANICAL ENGINEERING IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF MASTER OF SC...

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TRIBHUVAN UNIVERSITY INSTITUTE OF ENGINEERING PULCHOWK CAMPUS

THESIS NO.: M-09-MSESPM-2014/2016 Design and Testing of DC Powered Induction Cooker

by Bikal Adhikari

A THESIS SUBMITTED TO THE DEPARTMENT OF MECHANICAL ENGINEERING IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF MASTER OF SCIENCE IN ENGINEERING IN ENERGY SYSTEMS PLANNING AND MANAGEMENT

DEPARTMENT OF MECHANICAL ENGINEERING LALITPUR, NEPAL

OCTOBER, 2016

COPYRIGHT The author has agreed that the library, Department of Mechanical Engineering, Pulchowk Campus, Institute of Engineering may make this thesis freely available for inspection. Moreover, the author has agreed that permission for extensive copying of this thesis for scholarly purpose may be granted by the professor(s) who supervised the work recorded herein or, in their absence, by the Head of the Department wherein the thesis was done. It is understood that the recognition will be given to the author of this thesis and to the Department of Mechanical Engineering, Pulchowk Campus, and Institute of Engineering in any use of the material of this thesis. Copying or publication or the other use of this thesis for financial gain without approval of the Department of Mechanical Engineering, Pulchowk Campus, Institute of Engineering and author’s written permission is prohibited. Request for permission to copy or to make any other use of the material in this thesis in whole or in part should be addressed to:

Head Department of Mechanical Engineering Pulchowk Campus Pulchowk, Lalitpur Nepal

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TRIBHUVAN UNIVERSITY INSTITUTE OF ENGINEERING PULCHOWK CAMPUS DEPARTMENT OF MECHANICAL ENGINEERING The undersigned certify that they have read, and recommended to the Institute of Engineering for acceptance, a thesis entitled "Design and Testing of DC Powered Induction Cooker" submitted by Bikal Adhikari, 071 MSE 555 in partial fulfillment of the requirements for the degree of Master of Science in Engineering in Energy Systems Planning and Management.

________________________________________ Supervisor, Jagan Nath Shrestha, PhD Professor (Visiting), Center for Energy Studies, Institute of Engineering, Tribhuvan University

_______________________________________ Supervisor, Shree Raj Shakya, PhD Assistant Professor, Department of Mechanical Engineering, Pulchowk Campus

________________________________________ External Examiner, Rajib Subba, PhD DIGP, Nepal Police Headquarter

_______________________________________ Committee Chairperson, Rajendra Shrestha, PhD Head, Department of Mechanical Engineering, Pulchowk Campus

Date: 3

ABSTRACT Cooking is an important human activity. In urban sector of Nepal, cooking is highly dependent on LPG. In the recent energy crisis of Nepal, there was LPG shortage. To fulfill the daily cooking needs, people switched to Induction Cooker. Faults were seen in the local distribution transformer due to the overloading in the peak hours causing substantial loss of money in repair and maintenance. A lot of people were looking for an alternative way to use induction cooker when there was no grid electricity. The only option available then was to use battery as a source with an expensive inverter. At that stage a lot of people had an interest and confusions in the possibility of using induction cooker directly with battery without the use of higher rated costly inverters. The main objective of this research is motivated by a desire to be able to run an induction cooker directly from DC supply. A detailed survey in 217 sample households of Lalitpur Sub Metropolitan City Ward Number 2, Nepal was conducted. From the survey it has been found that the average shade free area per HH is 58.01 m2 and average solar PV installable area per HH is 22.83 m2. Installation of solar PV in the area with 4.5 hour peak sun would generate 10.26 kWh per HH per day which is sufficient to cover the energy demand of a house in this ward. The efficiency of the selected commercially available induction cooker was experimentally measured to be 85.56 %. The efficiency calculated from the simulation of functional circuit diagram of existing induction cooker is 87.00 %. A solar electricity based induction cooker using quasi resonant topology is designed and simulated using circuit simulators Multisim and Proteus. The designed system is battery operated with 24 V DC as system voltage and is micro controller based for control operation. It runs on 24 V DC, 300Ah battery with 500WP solar PV panel. The system operates with the input power range from 46.4 W to 1500 W correspondingly drawing input current in the range from 1.93 A to 62.5 A. The output power is in the range from 40.8 W to 1310 W with an average efficiency of 90.10%. The performance parameters of the designed induction cooker show that the simulated system is technically possible to implement. The hardware realization of the design could not be achieved with the use of available components in the Nepalese market due to the component quality issues in low voltage high current condition for a given output power. This study has established a baseline for further research in the area of DC induction cooker.

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ACKNOWLEDGEMENTS I would like to express my sincere gratitude and appreciation towards my thesis supervisor Prof. Dr. Jagan Nath Shrestha whose ideas, guidance and motivation has been a major source of progress in this thesis work. His direct involvement in the survey, presence in the extended discussion as per my need, and his way of supervising thesis by giving a lot of resources has really motivated me in this thesis work. I would also like to express my deep gratitude to my thesis supervisor, Dr. Shree Raj Shakya, for his valuable insights, guidance and encouragement in this thesis work. Apart from supervision, he has helped me in every respect for my academic betterment. I would like to thank Ms. Shailaja Shrestha, on behalf of Ministry of Industry for providing financial assistance for my thesis research work. I would like to express my sincere thanks to respected sirs, Prof. Dr. Bhakta Bahadur Ale and Dr. Ajay Kumar Jha for providing me induction cookers for lab testing. I would like to thank Assistant Professor, Hari Rimal, Department of Electrical Engineering, Pulchowk Campus for providing me helpful insights into Power Electronics. I would like to thank Mukesh Gautam, Electrical Engineer at Ministry of Energy for providing me help in the circuit analysis. I would like to thank sir Ram Ekwal Yadav (Lab Instructor, Department of Electrical Engineering, Pulchowk Campus) for helping me in Lab tests despite his busy schedule. I would like to thank Ram Hari Puri for helping me set up Lab at Center for Energy Studies and assisting me in testing during off hours. I would like to thank Mr. Sashi Shrestha, Mr. Amar Adhikari, Mr. Saroj Dhakal, Mr. Bhoj Raj Kafle and Mr. Shankar Basnet for helping me in the survey works at ward number 2 of Lalitpur Sub Metropolitan City. Last but not least, I would like to thank my parents for their constant encouragement and guidance throughout my life.

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TABLE OF CONTENTS

 COPYRIGHT.................................................................................................................... 2 ABSTRACT...................................................................................................................... 4 ACKNOWLEDGEMENTS .............................................................................................. 5 TABLE OF CONTENTS.................................................................................................. 6 LIST OF FIGURES .......................................................................................................... 8 LIST OF TABLES .......................................................................................................... 10 ABBREVIATIONS ........................................................................................................ 11 CHAPTER ONE: INTRODUCTION ......................................................................... 12 1.1.

Background ...................................................................................................... 12

1.2.

Problem Statement ........................................................................................... 14

1.3.

Research Objectives ......................................................................................... 14

1.4.

Rationale .......................................................................................................... 15

1.5.

Scope of the Work ............................................................................................ 15

1.6.

Limitations ....................................................................................................... 16

CHAPTER TWO: LITERATURE REVIEW ............................................................ 17 2.1.

Research Gap ................................................................................................... 17

2.2.

The PN Junction ............................................................................................... 19

2.3.

Photovoltaic Cells (Solar Cells) ....................................................................... 19

2.4.

Induction Heating ............................................................................................. 24

2.5.

Modeling the coupling between the Pan and Coil: .......................................... 26

2.6.

Conventional SMPS Converters and Resonant Converters: ............................ 28

2.7.

Quasi Resonant Converter for induction cooker .............................................. 31

2.8.

Hardware Components Used............................................................................ 40

2.9.

Present Status of Solar PV in the World: ......................................................... 43

2.10. Present Status of Solar PV in the Nepal ........................................................... 45 2.11. Energy Consumption Pattern of Nepal ............................................................ 45 2.12. Issues with Solar PV in Nepal .......................................................................... 51 2.13. Environmental Concerns .................................................................................. 51 CHAPTER THREE: RESEARCH METHODOLOGY ........................................... 52 6

3.1.

Methodology: ................................................................................................... 52

3.2.

End-use Energy Survey: ................................................................................... 53

3.3.

System Design .................................................................................................. 54

3.4.

Flowchart of the system operation: .................................................................. 57

3.5.

Calculation of Solar Panel Size and Battery Size: ........................................... 58

3.6.

Temperature Control Circuit design: ............................................................... 58

3.7.

Power Supply Circuit ....................................................................................... 60

3.8.

Tank Circuit: .................................................................................................... 61

3.9.

Energy Considerations in Induction Cooker: ................................................... 63

3.10. Design of an inductive coil: ............................................................................. 64 3.11. Experimental Testing: ...................................................................................... 65 CHAPTER FOUR: RESULTS AND DISCUSSION ................................................ 66 4.1.

End use energy survey ..................................................................................... 66

4.2.

Simulation of Existing Induction Cooker using functional circuit: ................. 69

4.3.

Simulation of the system designed ................................................................... 70

4.4.

Simulation of System Circuit in Proteus .......................................................... 70

4.2.1. 4.5.

Simulation of Resonant Converter ............................................................ 71

Testing on the design: ...................................................................................... 73

CHAPTER FIVE: CONCLUSIONS AND RECOMMENDATIONS ..................... 78 5.1.

Conclusions: ..................................................................................................... 78

5.2.

Recommendations: ........................................................................................... 78

REFERENCES.............................................................................................................. 80 APPENDICES ............................................................................................................... 82



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LIST OF FIGURES Figure 2-1: Conventional Approach for powering an induction cooker from a battery . 17 Figure 2-2: Modern approach for powering induction cooker from Battery. ................. 17 Figure 2-4: PN junction solar cell with resistive load .................................................... 20 Figure 2-5: Current Voltage characteristics of a pn junction solar cell .......................... 21 Figure 2-6: Maximum power rectangle of solar cell IV characteristics ......................... 22 Figure 2-7: Circuit Symbol for solar photovoltaic cell ................................................... 22 Figure 2-8: Output Current Characteristics .................................................................... 22 Figure 2-9: Output Current Characteristics .................................................................... 23 Figure 2-10: Block Diagram of a typical induction cooker ............................................ 25 Figure 2-11: Induction Coil with a cooking pan ............................................................. 26 Figure 2-12: Transformer analogy for coil pan coupling ............................................... 26 Figure 2-13: Equivalent circuit of induction coil and pan coupling ............................... 27 Figure 2-14: Simplified R-L circuit for coil pan coupling.............................................. 27 Figure 2-15: A thought circuit for describing switching operation ................................ 28 Figure 2-16: Power Losses in conventional SMPS Converter ....................................... 28 Figure 2-17: Some topologies used in resonant converters ............................................ 30 Figure 2-18: Operating circuit topology for quasi resonant topology ............................ 31 Figure: 2-19: Quasi-resonant circuit with RL model of coil-pot coupling ..................... 32 Figure: 2-20: Various waveforms in the quasi-resonant circuit ..................................... 33 Figure 2-21: [t0, t1] inductor charging period .................................................................. 34 Figure 2-22: [t1, t2] LC Resonant stage: capacitor charging period ................................ 34 Figure 2-23: [t2, t3] LC Resonant stage: capacitor discharging period ............................ 35 Figure 2-24: [t3, t4] Inductor discharging period ............................................................. 36 Figure 2-27: Series R-L-C circuit excited by a DC source ............................................. 38 Figure 2-30: Current oscillation in series R-L-C circuit ................................................. 40 Figure 2-31: LCD external view ..................................................................................... 41 Figure 2-32: Pin configuration of LM 35 ....................................................................... 43 Figure 2-33: Cumulative installed Solar PV globally (EPIA, 2014) .............................. 44 Figure 2-34: PV Module Price per Watt ........................................................................ 44 Figure 3-1: Flowchart of the Methodology adopted ....................................................... 52 Figure 3-2: Block Diagram of the System ..................................................................... 54 Figure 3-3: Block Diagram of DC induction cooker ...................................................... 55 8

Figure 3-4: Flowchart for the system operation.............................................................. 57 Figure 3-5: Basic architecture of PWM based temperature controller circuit ................ 59 Figure 3-6: An arbitrary PWM signal at the microcontroller’s pin. ............................... 59 Figure 3-7: Power supply circuit .................................................................................... 61 Figure 3-8: LC based tank circuit ................................................................................... 62 Figure 3-9: Bundled or stranded wires ........................................................................... 63 Figure 3-10: Outside view of spiral induction coil ......................................................... 64 Figure 4-1: Percentage use of fuels for cooking in 217 sample households................... 66 Figure 4-2: Daily Cooking energy consumption by different fuel types per HH ........... 67 Figure: 4-5: Willingness to pay for 24 x 7 Solar Electricity ........................................... 68 Figure 4-6: Functional Circuit Diagram of Existing Induction Cooker.......................... 69 Figure 4-7: Circuit for simulation in Proteus .................................................................. 71 Figure 4-8: Simulation of quasi resonant converter in Multisim .................................... 71 Figure 4-9: PWM Signal for driving IGBT .................................................................... 72 Figure 4-10: Current waveform across the cooking pot ................................................. 72 Figure 4-11: Voltage waveform across the cooking pot ................................................. 73 Figure 4-12: Schematic diagram of circuit tested ........................................................... 74

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LIST OF TABLES Table 2-1: Difference between Weber (2015) and this thesis research .......................... 18 Table 2-2: Pin Description of LCD LM 016L ................................................................ 41 Table 2-3: Energy Consumption by Fuel types ............................................................. 45 Table 2-4: Energy Consumption by Economic Sectors ................................................. 47 Table 2-5: End-use energy consumption pattern in residential sector ........................... 48 Table 2-6: Total residential energy consumption for cooking in Nepal ....................... 49 Table 2-7: Total cooking energy consumption in Urban Residential of Nepal ............. 50 Table 2-8: Total cooking energy consumption in Rural Residential of Nepal ............... 50 Table 4-1: Efficiency, Output Power, Input Power and Input Current at Different Control Voltage............................................................................................................... 70 Table 4-2: Variation of power, current and efficiency with duty cycle ................