Inline induction heating for high-pressure fuel-based testing applications

Abstract

AbstractInduction heating offers numerous advantages over conventional methods for heating high-pressure fluids in hydraulic testing applications. It simplifies complex processes, mitigates the risks associated with high-pressure environments, and enhances overall safety. The design of an efficient induction heating system requires a clear understanding of its key components, including the resonant tank circuit, impedance matching and isolation stage, high-frequency inverter, driver circuitry, and controller. The configuration of the resonant circuit plays a crucial role in device ratings and control methods. To meet the demanding requirements of switching devices like IGBTs, the driver circuit must ensure high immunity to interferences and failure. Effective system design allows the heating circuit to operate close to resonant switching, minimizing switching losses and cooling requirements. This paper presents the design and development of a 4-kW induction heater specifically tailored for inline heating of aviation fuel under high pressure. The system aims to achieve a precise temperature profile for testing line-replaceable units (LRUs) used in aircraft. The design methodology encompasses the selection of the resonant tank circuit configuration, impedance matching and isolation stage, high-frequency inverter, driver circuitry, and control strategies. Through extensive simulations in LTspice and experimental measurements, power losses in different components of the power conversion circuits are assessed, and overall system efficiency is evaluated. The results demonstrate the proposed induction heating system’s remarkable energy efficiency, reduced switching losses, and improved reliability. Furthermore, a comprehensive comparison with existing designs and industry norms is presented, highlighting the distinct advantages of the proposed system in terms of cost-effectiveness, energy efficiency, material utilization, and processing time. This research contributes valuable insights into the design and optimization of induction heating systems for high-pressure fluid heating applications, providing a practical and efficient solution for the aviation industry.