EEPT - Kunjimon - High Efficiency IM

Invention Title ELECTRONICALLY CONTROLLED HIGH EFFICIENCY INDUCTION MOTOR
Publication Number 49/2018
Publication Date 07/12/2018
Publication Type INA
Application Number 201741039429
Application Filing Date 06/12/2017
Priority Number
Priority Country
Priority Date
Field Of Invention ELECTRICAL
Classification (IPC) B60L 11/00
Inventor
Name AddressCountryNationality
Thekke Peedikayil Kunjimon Thekkepeedikayil House Chalissery, PO Palakkad dist Kerala –

679536 INDIA India India
DESC:FIELD OF INVENTION
The present invention relates to a “Electronically controlled high efficiency induction motor” more
specifically an induction motor which is provided with an electronic module which has less power
consumption compared to the conventional induction motor having the same capacity. It is meant
for single phase motor with capacity of 1 to 10 hp.
BACKGROUND OF THE INVENTION
The world is moving towards a sustainable energy, with an emphasis on energy efficiency and energy
conservation. Energy has always been a vital resource in the development of any nation. We can no
longer support infinitely with the available source of energy as it is getting depleted day by day.
Hence all-out effort has to be made to find out renewal source of energy at the same time has to
conserve whatever energy is available. Here comes the relevance of the high efficiency induction
motors, the most commonly used motors in many applications from industry, agriculture etc. These
are also called as Asynchronous Motors, because an induction motor always runs at a speed lower
than synchronous speed. Synchronous speed means the speed of the rotating magnetic field in the
stator.
There are basically 2 types of induction motor depending upon the type of input supply - (i) Single
phase induction motor and (ii) Three phase induction motor out which the present invention is
limited to single phase motor. Or they can be divided according to type of rotor - (i) Squirrel cage
motor and (ii) Slip ring motor or wound type and our invention is related to squirrel cage motor.
Before going into details of the instant invention an effort is made to go into the working principle of
an induction motor. Here the stator winding is fed with an AC supply.
? Alternating flux is produced around the stator winding due to AC supply. This alternating flux
revolves with synchronous speed. The revolving flux is called as "Rotating Magnetic Field" (RMF).
? The relative speed between stator RMF and rotor conductors causes an induced emf in the
rotor conductors, according to the Faraday's law of electromagnetic induction. The rotor conductors
are short circuited, and hence rotor current is produced due to induced emf. That is why such
motors are called as induction motors. This action is same as that occurs in transformers, hence
induction motors can be called as rotating transformers.
? Now, induced current in rotor will also produce alternating flux around it. This rotor flux lags
behind the stator flux. The direction of induced rotor current, according to Lenz's law, is such that it
will tend to oppose the cause of its production.
? As the cause of production of rotor current is the relative velocity between rotating stator
flux and the rotor, the rotor will try to catch up with the stator RMF. Thus the rotor rotates in the
same direction as that of stator flux to minimize the relative velocity. However, the rotor never
succeeds in catching up the synchronous speed. This is the basic working principle of induction
motor of either type, single phase or 3 phase.
On a perusal of the prior art patents application/ granted patents and literature, it can be seen that
the “Electronically controlled high efficiency induction motor according to our invention is
completely different when it comes to consumption of electricity as well the load it can take
compared to the prior art induction motors.
In this connection reference is made to some of the prior art Patents/ Patent application in the field
of attention.
US6566778B1 discloses Cage-type induction motor for high rotational speeds comprising a rotor 10
has a structure with a rotor core 12 and rotor conductors 14, the rotor core 12 is made of a weakly
magnetic substance with a high permeability and a relatively low electrical conductivity, and the
rotor conductors 14 are composed of a conducting material with a low permeability and a relatively
high electrical conductivity. Also, the rotor core 12 and the rotor conductors 14 are formed into a
single body that has an entire-surface with a smooth cylindrical shape. Furthermore, a stator 20 is
composed of a plurality of stator sheets 22 laminated in the axial direction and a stator winding 24.
Each stator sheet is formed with a closed circular inner ring portion 22 a and an outer ring portion 22
b, with slots 23 that penetrate the sheets between the ring portions, and the stator winding is
housed in the slots.
US6700270B2 discloses a synchronous induction motor realizing a great reluctance torque by

concentrating a magnetomotive force generated by a rotor provided with a permanent magnet
having a two-pole structure, and having a high efficiency. The synchronous induction motor has a
stator provided with a stator winding, a rotor rotating within the stator, a cage-type secondary
electric conductor provided in a peripheral portion of a rotor yoke portion constituting the rotor, and
a permanent magnet inserted into the rotor yoke portion and having a two-pole structure, and the
magnetomotive force generated by one pole of the rotor is set to a value equal to or less than 10%
of a peak value in a predetermined range near an electrical angle of 0 degrees or 180 degrees.
US6331760B1 teaches an improved induction motor having at least one capacitive element
electrically connected in parallel with and tapped to each phase of a delta- or wye-wound stator
winding such that the capacitive elements are alternately charged or discharged during operation,
thereby storing energy from and releasing energy to the windings. This alternate energy storage and
release assists in controlling the level of magnetic core saturation and increasing motor efficiency
under all operating conditions due to reduced hysteresis and eddy current losses. Motor starting or
inrush current is also substantially reduced using this arrangement. In one embodiment, variable
capacitors and switch elements are used to provide the ability to dynamically “tune” the motor
winding for optimal efficiency.
US20120126741A1discloses a low-inductance, high-efficiency induction machine and method of

making same. The electric drive system includes an induction machine and a power converter
electrically coupled to the induction machine to drive the induction machine. The power converter
comprising a plurality of silicon carbide (SiC) switching devices. The electric drive system further
includes a controller that is electrically coupled to the power converter and that is programmed to
transmit switching signals to the plurality of SiC switching devices at a given switching frequency
such that a peak-to-peak current ripple is less than approximately five percent.
US5500581A relates to a high-efficiency power supply control apparatus for variable-speed induction
motor. The apparatus for controlling the supply of power to a variable-speed induction motor
converts an AC power source voltage to a motor supply voltage at a designated frequency, with the
amplitude of the motor supply voltage being controlled in accordance with the motor load such that
the degree of slip conforms to a predetermined optimum slip charactistic, whereby high efficiency
and stability are maintained over a wide range of load values. The motor supply voltage amplitude is
detected to provide an indication of the motor load, an optimum value of an operating parameter of
the motor which varies in accordance with degree of slip is derived based on the designated
frequency and the detected voltage amplitude, using a predetermined function corresponding to
that frequency, and the motor supply voltage amplitude is controlled such as to reduce an amount
of difference between the optimum value of the operating parameter and a detected value of that
parameter.
US6327524B1 discloses a device for high efficiency motor control includes an induction motor and a
controller. The induction motor generates a motor torque and has a given rotor resistance and
magnetizing inductance at a specific temperature. The controller is coupled to and controls the
induction motor. The controller includes control logic operative to maximize the motor torque using
a flux current and a torque current. The controller determines the flux current and torque current
based upon a requested torque, a requested speed, the magnetizing inductance, the temperature
and the rotor resistance.
US4971522A relates a control system for an AC motor driven cyclic load, such as a beam pumping
unit, includes a flywheel, transducer, tachometer, outside set point source, controller, and variable
frequency power supply. The flywheel is rotatably connected between the motor and the cyclic load
for receiving and storing rotational kinetic energy from the motor and the load during portions of a
cycle of the cyclic load when there is excess energy and returning the stored rotational kinetic
energy to drive the cyclic load during portions of a cycle when there is an energy demand by the
cyclic load. The transducer generates a transducer signal which is a function of the cycle speed. The
tachometer means generates a tachometer signal which is a function of the speed of rotation of the
motor's rotor. The outside set point source generates an outside set point signal representative of a
desired set point cycle speed of the cyclic load. The controller receives the transducer signal, the
tachometer signal and the outside set point signal and generates a control signal representative of
the adjustment to the power supply frequency of the motor needed to achieve the set point cycle
speed. The variable frequency power supply receives the control signal and adjusts the frequency of
the power supplied to the motor accordingly.
US3987324A discloses high efficiency induction motor with multi-cage rotor. Fractional horsepower
induction motors having a fixed number of poles (and, accordingly, a single no load synchronous
speed) that are particularly adapted for multi-speed operation when driving a fan load by changing
the field strength of the main winding. Induction motors of N fundamental poles have squirrel cage
rotor having a plurality of interrelated conductor bars and end rings that are arranged so that
multiple sets of the rotor bars establish a predetermined number of separately identifiable cage sets
such that the fundamental pole structure of the stator field is coupled with the rotor and such that
the third harmonic of the stator field is not coupled with the rotor. The rotor slot number and total
number of separately identifiable cage sets are selected so that a cage set pattern is provided that
has two-thirds of a fundamental pole pitch. In addition, the number of rotor cage end rings at one
end times the number of rotor cage end rings at the other end is greater than or equal to the
number of different cage types.
US3781616A relates to a control system for dynamically reenergizing a rotating induction motor. A
pair of inverters supply power to the windings of the induction motor through an inductive reactor.
A tachometer senses the rotational speed of the rotor of the induction motor and applies a signal to
a programmed logic circuit for pulse width modulating the power of the inverters over a constant
torque range and for step wave shaping the power of the inverters over a constant horsepower
range. In the event of an interruption of power, the reapplied power to the induction motor is
reduced and the frequency of the reapplied power is readjusted at or near the actual synchronous
speed of the induction motor so that little, if any, current surges occur upon reenergizing of the
induction motor.
US5294876A relates to a control system for an AC induction motor, comprising a stator, a rotor, at
least two stator windings and rotor windings. The control system comprises a first vector rotator for
rotating control signals with a first angle (a) for providing output signals connected to frequency
inverters for providing drive signals to each stator winding of the motor, said first angle (a) being the
time integral of a rotation frequency (w). Moreover, the control system comprises a second vector
rotator for counterrotating measured drive voltages and/or currents with a second angle (-a) which
is the inverse of said first angle (a). The rotation frequency (w) is controlled in dependence of said
counterrotated measured voltages and/or currents essentially for maintaining the amplitude of said
magnetizing currents (Im) of each stator winding constant which is a necessary condition for
obtaining Natural Field Orientation.
US4806838A relates to an A.C. induction motor energy conserving power control method and
apparatus. Electric power consumed by an a.c. induction motor is measured and sensed changes in
power factor are used to modulate the combined magnetic flux produced in the motor field by two
sets of RUN windings. A main RUN winding set, which normally couples fully with the a.c. power, is
engineered to have sufficient ampere-turns to produce just enough magnetic flux to operate the
motor with a light load and maintain a moderately high power factor. Motor driven load increases
are determined by sensing a corresponding increase in the power factor of the main RUN winding
set, whereupon power flow to a secondary RUN winding is proportionately increased. Considerable
energy savings occurs when the motor drives a fluctuating load due to reduced magnetic field
excitation under all but full load conditions, with the result that energy ordinarily wasted by eddy
currents, copper losses, and poor power factor operation is considerably lessened. Other possible
losses due to harmonic distortion of the a.c. power waveform brought about by the phase-delayed
thyristor control of the second run winding power are mostly swamped out and masked by the
parallel, always-on major power draw by the main run winding. A motor speed-sensitive switch or
relay may divert current around the thyristor and fully excite the second run winding during motor
start-up, thereby producing full available motor torque during start-up while negating any electrical
stress on the control thyristor.
Hence, in spite of the availability of a variety of induction motor according to prior art, having
varying degrees of efficiency, it can be seen that the novel features of our invention which makes the
induction motor according to the instant invention is unique having low power consumption which is
unparalleled, mainly due to different type of winding of the stator coupled with an electronic
module provided therein. Hence the present invention stands apart from the prior art system, due
to its overall efficiency with respect to power consumption.
SUMMARY
The present invention provides an electronically controlled high efficiency induction motor. One of
the main features of the state of the art induction motor is the method of winding the armature of
the stator coil which generates back emf and an electronic module connected to motor through
which electric power is supplied to the motor. Another feature of the electronic module is its
capacity to select the capacitor, from the capacitor bank having capacitors of varying capacitance
based on the quantum of load the motor is subjected to, which is reflected in terms of amperage
and measured by the CT coils of the electronic module and the relay switch provided therein.
Coming to the winding of the stator, there is provided an additional winding over the normal
winding, which develops what is known as back emf (BEMF), by which part of the power
requirement is met without drawing power from the electric main line. This is how the induction
motor of the present design is more power efficient than the prior art induction motor.
According to the invention the electronically controlled high efficiency induction motor is comprising
of a stator for generating a rotating magnetic field; a rotor disposed to rotate relative to the stator
and an electronic module coupled with the winding of the stator. Here the stator generates a
rotating magnetic field; and the rotor is disposed to rotate relative to the stator. The stator (1) is
having conventional main winding producing rotating magnetic Field and another additional winding
for producing the back EMF which in turn is fed back to the main winding through the electronic
module.
According to one aspect of the invention the electronic module attached to the induction motor
enables the selection of the capacitor, by means of relay switch (8), connected to the motor at a
given point of time while running the motor based on the torque/load taken by the motor which is
measured by the CT coil provided in the electronic module in terms of amperage of the motor and
thus stabilize the running of the motor.
According to another aspect of the invention, once the motor is switched on, in the electronic
module, the connection is made to capacitor C3 by means of relay1 (RL1), the motor starts rotating,
as the load increases, relay 2 (RL2) activates capacitor C4, as the load still increases, Relay 3( RL3)
activates the capacitor C5 and later Relay 4 (RL4) activates capacitor C6.
The electronic module is having i) a micro controller (6) that controls the voltage frequency and the
capacitance of the motor from lower to higher limit, ii) a variable frequency drive (7) that stabilize
the frequency at a constant limit; iii) relay switch(8) that helps for switching (on/off) the motor and
also controls the capacitor; iv) display (9) that displays the voltage, current and power consumption
of the motor; v) current transformer coil (CT- coil) (10) that sense the output current and transmit to
the microcontroller; vi) step transformer (11) that provides low voltage for the working of the
electronic module; vii) Integrated Circuit (12) that receives the output of the micro controller and
converts the output signal into analog signal and given to the input of the relay switch(8) and
capacitor bank (13) that stabilize the motor input and the power factor (pf) while the motor is
running on load.
According to yet another aspect of the invention, during the rotation in every segment of one full
rotation, produces the back emf and simultaneously said back emf produced during the rotation of
the specific segment is used in rotating the rotor in the succeeding segment and this cycle is
repeated in all the segment and as such alternate segment produces the back emf which in turn is
used in the rotation during the next segment.
According to another aspect of the invention, the CT Coil provided in the electronic module
measures the current consumption and passes to pre programed microcontroller (6), which in turn
actuates the relay (9), so as to select and connect the specific capacitor from the capacitor bank (13)
having different rating to suit the torque requirement.
BRIEF DESCRIPTION OF THE DRAWING
These and other features, aspects and advantages of the present invention will become better
understood when the detailed description is read with reference to the accompanying drawings.
Fig.1. View of the induction motors showing stator
Fig.2 Another view of the induction motor showing rotor
Fig.3 Induction coil showing the winding of the stator.
Fig.4 Shows the shortening of the induction coil between S2, H2 and J2 as shown in Fig.4
Fig.5 Shows the shortening of the induction coil between SS1, HH1 and JJ1 as shown in Fig.5.
Fig.6 depicts how back emf is developed during the single rotation of the rotor
Fig.7 Shows electronic circuitry of the Electronic module attached to the induction motor.
Wherein 1- Stator; 2- Rotor ; 3- Frame/yoke; 4- Shafts and bearing; 5- Fan; 6- Micro controller; 7-
Variable frequency drive; 8- Relay; 9- Display; 10- Current Transformer coil; 11- Step down
transformer; 12- Integrated Circuit; and 13- Capacitor bank.
DETAILED DESCRIPTION OF THE INVENTION
An electronically controlled high efficiency induction motor according to the invention is a self-
contained system wherein the electric power required for running the motor is partly being
generated by the motor itself due to the unique method of winding of the stator. Similarly, the
electronic module attached to the induction motor enables the selection of the capacitors, by means
of relay switch, connected to the motor at a given point of time while running the motor based on
the torque/ load taken by the motor which is measured by the CT coil provided in the electronic
module in terms of amperage of the motor.
Now the invention is being explained in detail. Like all the conventional induction motor and has
basically two parts – Stator and Rotor. The Fig.1 and Fig.2 shows rotor and displays a stator of motor
respectively.
The stator of an AC induction motor's magnetic structure, which does not rotate. It usually contains
the primary winding. The stator is made up of laminations with a large hole in the center in which
the rotor can turn. The stack of lamination is secured by end screws. There are slots in the stator in
which the windings for the coils are inserted. The Stator is made up of a number of stampings with
slots to carry windings. The windings are geometrically spaced 120 degrees apart. The stator (1)
rabbets and bore are machined carefully to ensure uniformity of air gap.
The stator (1) is installed with specially tailor- made stator winding, to meet our requirement of the
high efficiency induction motor as shown in Fig 1 and Fig.2. It carries two windings one is main
winding for producing rotating magnetic Field and another one is for producing the back EMF. This
back EMF is given to the electronic module. The electronic module controls the output of the motor
and this voltage is given back to the stator winding. The winding is wound for a definite number of
poles and the exact number of pole being determined by the requirement of speed. The greater the
number of pole, lesser the speed and vice versa as per the general concept. Synchronize Speed
directly proportional to frequency and inversely proportional to number of pols. Ns = 120f/P wherein
Ns is the synchronous speed and f is the frequency P is equal to number of poles.
The rotor (2) used here is squirrel cage type. In squirrel cage type rotor, copper bars or Aluminium
bars are placed parallel or approximately parallel to the shaft and close to the rotor surface. The
conductors are not insulated from the core, since the rotor currents naturally flow the path of least
resistance. At both ends of the rotor, the rotor conductors are short-circuited by the continuous end
rings of similar materials to that of the rotor conductors. The rotor conductors and their end rings
form a complete closed circuit itself. Carbon brushes are also provided like any conventional
induction motor. The frame / yoke (3) is made of close grained alloy cast iron or Aluminium alloy.
Shafts and bearing (4) used here are like any other conventional induction motor. Ball bearing of
suitable size is used to reduce rotational friction and support radial and axial loads. Fan (5) is
provided to help for adequate circulation of air to cool the windings and it is securely keyed into the
rotor shaft. The bearing is housed in the end plates and they are fixed to the frame/ yoke.
According to our invention, the rotor used is the conventional one. But there is design modification
with respect stator winding. The specialty of the winding design in the stator is the additional
overlapping parallel winding over the normal winding, which develops what is known as back emf
(BEMF). Referring to the Figure.3 which depicts the windings of the stator, the details of windings is
as under.
J1 and J2 refers to two end of the first motor winding coil over which an additional winding is made
to produce back emf, the ends of the additional coil is indicated by JJ1 and JJ2.
Similarly, H1 and H2 refers to two end of the motor winding coil over which an additional winding is
made to produce back emf, the ends of the additional coil is HH1 and HH2.
In the same way, S1 and S2 refers to two end of the motor coil over which an additional winding is
made to produce back emf, the ends of the additional coil is SS1 and SS2.
The winding connection inside the Motor is as under according to the present invention.
J1 is connected to Motor
H1 is connected to motor
S1 is connected to Motor
Shorting is done between S2, H2 and J2 as shown in Fig.4
Shorting is done between SS1, HH1 and JJ1 as shown in Fig.5

The Fig.4 and Fig.5 show the shorting for connecting the winding prior to connecting the board.
The other end of the main winding which is not shorted as well that of the additional windings which
is also not shorted are connected to the electronic module.
Electronic module is one of the most important part of the motor which does the control
functionality of the motor. The main components of the electronic module are as under:
Micro controller (6) controls the voltage frequency and the capacitance of the motor from lower to
higher limit.
Variable Frequency Drive (7) varies and stabilize the frequency at a constant limit. It is controlled by
the micro controller.
Relay switch (8) provided in the electronic module helps for switching (ON/OFF) the motor and also
controls the capacitor.
Display (9) provided therein shows the voltage, current while running the motor and power used in
the circuit.
Current Transformer Coil (CT coil) (10) of the electronic module controls the output current and
stabilize the current.
A step down transformer (11) is provided to give low voltage for the working of the electronic
module.
An IC (12) is provided therein to which the output of the micro controller is given. (eg IC TLO 2001). It
converts the output signal into analog signal and it is given to the input of the relay.
8-capacitor bank (13) stabilize the motor input and the power factor (PF) of the line. While the
motor is running on the load, based on load the electronic module selects the required capacitance
from the capacitor bank.
Stator winding connection with the electronic module is as under:
Power input is first given to the Electronic module
1. The entry of the Electricity input (phase) is to the capacitor bank of the board.
2. From capacitor bank the connection goes to S1 and SS2 of the Motor.
3. The entry of the Electricity input (Neutral) goes to the board as well as to H1-HH2 of the
motor
4. The Control relay of the board is connected to J1- JJ2
How the induction motor works according to the instant invention is briefly explained below.
It works similar to any other induction motor, but is more energy efficient. As a general rule,
conversion of electrical power into mechanical power take place in the rotating part of electric
motor.
In DC motor, the electrical power is conducted directly to the armature (rotating part) through
brushes and commutator. In this sense a dc motor can be called as a conduction motor. However, in
AC motor the, rotor does not receive electric power by conduction but by induction in exactly the
same way as the secondary of 2 winding transformer receives its secondary power from the primary.
That is why such motor are known as induction motor. In fact an induction motor can be treated as
rotating transformer.
One of the main feature of the induction motor is the method of winding the armature of the stator
coil, which generates back emf and an electronics module connected to motor through which
electric power is supplied to the motor. Another feature of the electronics module is its capacity to
select the capacitor, from the capacitor bank having capacitors of varying capacitance based on the
quantum of load the motor is subjected to, which is reflected in terms of amperage and measure by
the CT coil of the electronics module and the relay switch provided therein.
An electronically controlled high efficiency induction motor according to the invention is a self-
contained system wherein the electric power required for running the motor is partly being
generated by the motor itself due to the unique method of winding of the stator. Similarly, the
electronic module attached to the induction motor enable the selection of the capacitor, by means
of relay switch, connected to the motor at a given point of time while running the motor based on
the torque/load taken by the motor which is measured by the CT coil provided in the electronic
module in terms of amperage of the motor.
Once we switch on the motor, in the electronic module, the connection is made to capacitor C3 by
means of relay1 (RL1) and the motor starts rotating. As the load increases, the relay 2 (RL2) will
activate capacitor C4. As the load still increases, Relay 3(RL3) will activate capacitor C5 and later
Relay 4 (RL4) will activate capacitor C6.
Assume hypothetically that one rotation is divided into 4 equal segments/ sectors as shown in the
Figure 6 which represents one full rotation of the motor. In the first segment connection is in
between SS2 and S1 while the rotor starts moving. It draws power from the main and simultaneously
produces back emf shown as BEMF in the figure 6 which is used in rotating the rotor in the second
segment and as such no power is consumed from the main during the rotation in the second
segment. Similarly, while the rotor moves in the third segment, the connection is made between J1
and JJ2. Here it draws current from the main line and at the same time produces back emf shown as
BEMF in the figure 6, which is used to move the rotor in the fourth segment. Hence here also power
is not required for the movement of the rotor in the fourth segment and similar cycle is repeated
throughout the running of the motor. Due to this phenomenon of back emf there is lot of saving in
the power consumption.
As mentioned earlier the electronic module helps in selecting the capacitor while running the motor
based on load.
To start with, based on the current consumption measured by the CT Coil provided in the electronic
module, is passed on to microcontroller (6) which is programed so as to activate the relay based on
the load, which in turn actuates the relay so as to select and connect the specific capacitor to suit
the torque requirement from a plurality of capacitors having different rating provided therein. For
Example, for 1 hp motor the capacitor chosen is 5 to 20 µf.
The electronic module displays, current and voltage. It is provided with over load protection, short
circuit protection as well as over heat tripping arrangement.
Example
The following example shows how the induction motor according to the present invention is
superior to that of the conventional induction motor. For the purpose of comparison, we have given
different loads to the motor viz. 1kg, 5kg, 8kg.
Example-1 (on No load)
Test was carried out to find the power consumption of the ordinary Induction motor as well as that
of high efficiency induction motor according to the instant invention. The comparative test results
are given in the following Table-1.
Table-1
Volts Amps Watts Speed in RPM
Motor according to the invention 220V 0.785amps 120.32W 2980
Conventional Motor 220V 5.8amps 888.99W 2900
From the above example it can be seen that at no load the amount of power saved is 768.67 wats,
which shows how efficient is the induction motor according to the instant invention.
Example 2 (with a load of 1 kg)
Test was carried out by giving a load by fixing a flywheel having the weight of 1 kg on the shaft motor
to find the power consumption of the ordinary Induction motor as well as the induction motor
according to the invention.
The comparative test results are given in the following Table-2.
Table-2
Motor according to the invention 220V 0.838 A 128. 44W 2974 RPM
Conventional Motor 220V 6A 919.65 W 2800 RPM
From the above example it can be seen that on load the amount of power saved is 791.21wats,
Example 3 ( with a load of 5 kg)
Table-3
Motor according to the invention 220V 0.900 A 137.94 W 2970 RPM
Conventional Motor 220V 6.8 A 1042.27 W 2570 RPM
From the above example it can be seen that on load the amount of power saved is 904.33 wats,
Example 4 (with a load of 8 kg)

Table-4
Motor according to the invention 220V 1.2 A 183. 93 W 2950 RPM
Conventional Motor 220V 7.2 A 1103.58 W 2530 RPM
From the above example it can be seen that on load the amount of power saved is 919.65 wats,
The novel features of the invention have been brought out by explaining some of the preferred
embodiments under the invention, enabling those in the art to understand and visualize the present
invention. It is also to be understood that the invention is not limited in its application to the details
set forth in the above description or as illustrated in the drawings. Although the invention has been
described in considerable detail with reference to certain preferred embodiments thereof, various
modifications can be made without departing from the spirit and scope of the invention as described
herein above and the appended claims.
,CLAIMS:1. An electronically controlled high efficiency induction motor comprising a stator for
generating a rotating magnetic field; and a rotor disposed to rotate relative to the stator and the
winding of the stator coupled with an electronic module characterized in that,
a) the stator (1) is provided with conventional main winding producing rotating magnetic Field
and another additional winding for producing the back EMF which in turn is fed back to the main
winding through the electronic module; and
b) the electronic module is provided with i) a micro controller (6) that controls the voltage
frequency and selects the capacitance of the motor from lower to higher limit, ii) a variable
frequency drive (7) that stabilize the frequency at a constant limit; iii) relay switch (8) that helps for
switching (on/off) the motor and also controls the capacitor; iv) display (9) that displays the voltage,
current and power consumption of the motor; v) current transformer coil (CT-coil) (10) that sense
the output current and transmit to the microcontroller; vi) step down transformer (11) that provides
low voltage for the working of the electronic module; vii) Integrated Circuit (12) that receives the
output of the micro controller and converts the output signal into analog signal and give to the input
of the relay switch (8) and capacitor bank (13) that stabilize the motor input and the power factor
(pf) while the motor is running on load.
2. The electronically controlled high efficiency induction motor as claimed in claim 1, wherein
the additional overlapping parallel winding over the normal winding provided in the stator develops
what is known as back emf (BEMF).
a) in the main winding one end of the each coil (J1, H1, and S1) is connected to Motor through the
electronic module and the other end (J2,H2 and S2) is short circuited and
b) in the additional one end of each of the coil (JJ2, HH2, and SS2) is connected to Motor through the
electronic module and the other end (JJ1, HH1 and SS1) is short circuited.
4. The electronically controlled high efficiency induction motor as claimed in claim 1, wherein in the
stator winding connection with the electronic module : a) power input is first given to the Electronic
module through the capacitor bank; b) from capacitor bank the connection goes to one end of the
coil (S1) of the main winding and one end of the coil (SS2) of the additional winding; c) the entry of
the Electricity input (Neutral) goes to the electronic module as well as to one end of the coil (H1) of
the main winding and one end of the coil (HH2) of the additional winding; and d) the Control relay (8
) of the board is connected to one end of the coil (J1) of the main winding and one end of the coil
(JJ2) of the additional winding.
variable frequency drive (7) controls the out put of the motor and this voltage is given back to the
stator winding of the motor and the winding is wound for a definite number of poles and the exact
number of pole being determined by the requirement of speed.
the electronic module attached to the induction motor enable the selection of the capacitor, by
means of relay switch (8), connected to the motor at a given point of time while running the motor
based on the torque/load taken by the motor which is measured by the CT coil provided in the
electronic module in terms of amperage of the motor and thus stabilize the running of the motor.
7. The electronically controlled high efficiency induction motor as claimed in claim 1, wherein,
once the motor is switched on, in the electronic module, the connection is made to capacitor C3 by
means of relay1 (RL1), the motor starts rotating, as the load increases, relay 2 (RL2) activates
capacitor C4, as the load still increases, Relay 3 (RL3) activates the capacitor C5 and later Relay 4
(RL4) activates capacitor C6.
during the rotation in every segment, back emf is produced and simultaneously said back emf
produced during the rotation of the specific segment is used in rotating the rotor in the succeeding
segment and this cycle is repeated in all the segment and as such alternate segment produces the
back emf which in turn is used in the rotation during the next segment.
the CT Coil provided in the electronic module measures the current consumption and passes to pre
programed microcontroller (6), which in turn actuates the relay switch (8) , so as to select and
connect the specific capacitor from the capacitor bank (13) having different rating to suit the torque
requirement.
over load protection, short circuit protection as well as over heat tripping arrangement is provided in
the electronic module.
HIGH EFFICIENCY INDUCTION COOKING SYSTEM
Invention Title WITH ZERO POWER CONSUMPTION
Publication Number 48/2013
Publication Date 29/11/2013
Publication Type INA
Application Number 5273/CHE/2013
Application Filing Date 18/11/2013
Priority Number
Priority Country
Priority Date
Field Of Invention NO SUBJECT
Classification (IPC) H05B6/00
Inventor
Name Address Country Nationality
THEKKE THEKKEPEEDIKAYIL HOUSE,

PEEDIKAYIL CHALISSERY, PO, PALAKKAD DIST -
KUNJIMON 679 536 India India
Applicant
Name Address Country Nationality
THEKKE THEKKEPEEDIKAYIL HOUSE,

PEEDIKAYIL CHALISSERY, PO, PALAKKAD DIST -
KUNJIMON 679 536 India India
Abstract:
The invention discloses a high efficiency induction cooking system with zero power consumption
powered by rechargeable batteries which automatically gets recharged as the induction cooking
progress. It comprise of an induction coil assembly (11) having primary and secondary windings;
source unit (6) charging unit (7) having rechargeable battery pack (24V, 2.5A) and electronic circuitry
having signal processor (8) for generating 20 kHz signal from the source voltage ; a drive circuit (9)
provided with power MOSFET adapted to convert the low range volt and ampere of the 20kHz signal
into the range of 24v and 2.5amps for giving to the primary side of the coil; power and heat control
unit (10) including a battery and coil control unit to upgrade said 20kHz signal to 150kHz and to
facilitate to get 82V output in the secondary coil and for recharging the batteries. Fig-4
FIELD OF INVENTION
The present invention relates to a high efficiency induction cooking system with zero power
consumption, more specifically an induction cooking system which can be operated by a captive self
sustaining rechargeable battery system. The power required for induction heating is initially
provided by the battery pack provided therein and recharging of the expended battery pack takes
place simultaneously during the
induction heating system itself.
BACKGROUND OF THE INVENTION
The world is moving towards a sustainable energy, with an emphasis on energy efficiency and energy
conservation. Energy has always been a vital resource in the development of any nation. We can no
longer support infinitely, increasing consumption of energy whatever form it is. Hence here comes
the relevance of the high efficiency induction cooking system with zero power consumption being
disclosed here.
Mankind has evolved many ways to generate heat, starting from the open fire by burning some
combustible substance-such as wood, coal, or gas and the other one runs an electrical current
through a resistance element, it may be coil elements, halogen heaters, and induction. Another
technology used for cooking is microwaving, an oven-only technology, wherein the heat is generated
directly in the food itself.
Induction heating is the heating of an electrically conducting material using the energy from
electromagnetic radiation. The process of electromagnetic induction creates Eddy currents (Foucault
current) in the conductor and the electric currents induced within these conductors by a changing
magnetic field in the conductor. These circulating eddies of current have inductance and thus induce
magnetic fields. When this Eddy current (not a shocking one) passes through the material of the pot,
friction develops in the molecules of the pot material and heat develops. The stronger the applied
magnetic field, the greater the electrical conductivity of the conductor, and the faster the field
changes, the greater the currents that are developed and the greater the fields produced.
Induction heating results from the direct application of two physical laws, the LENZ law and the
JOULE effect. According to Lenz law an electric current, induced by a source such as a changing
magnetic field, always creates a counterforce opposing the force inducing it. This law explains such
phenomena as diamagnetism and the electrical properties of inductors. Due to the Joule effect (P =R
x I2), these currents dissipate heat in the material in which they appeared.
In other words the magnetic field generates a loop current-a flow of electricity—within the metal of
which the cooking vessel or pot or pan is made, and that current flow through the resistance of the
metal generates heat, just as current flowing through the resistance element of a conventional
electric range's coil generates heat. The difference here is that the heat is generated directly in the
pot or pan itself and not in any part of the cooker his mode of heating when applied for cooking is
called Induction cooking, which is not only a flameless but also will not heat the cook top by
exploiting the ferromagnetic property of some metals and electromagnetic induction. The induction
cooker has a large circular coil made up of enamelled copper windings placed under the space for
the pot.
According to prior art induction cooking process domestic power supply, either 230 V 50 kHz or 110V
60 Hz. AC of a particular frequency passes through the coil, an oscillating magnetic field develops
which induces electric current into the pot material. When this Eddy current (Not a shocking one)
passes through the material of the pot, friction develops in the molecules and heat develops. This
heat is transferred to the water to boil the contents in the pot. But according to our invention a set
of Lithium Ion rechargeable battery having a voltage of about 24 volt, 40ah can supply the power
required for induction heating in addition to recharging the depleted battery by the same induction
heating system itself, there by almost consuming zero power.
On a perusal of the prior art patents application/ granted patents and literature, it can be seen that
the method adopted for induction cooking according this invention is unique and is different when
compared to hitherto followed process for induction cooking.
EP0888033 B1 discloses high-frequency inverter and induction cooking device having a simple circuit
that performs constant-frequency operation and zero-volt switching. An induction cooking device
using the inverter is also disclosed. The inverter is constituted of an inverter circuit which converts a
direct current from a DC power source into a high-frequency current and a control circuit which
controls the inverter circuit. The inverter circuit is constituted of a heating coil having one end
connected to one end of the DC power source, a one-chip inverter composed of a first switching
element which is connected in series between the other ends of the heating coil and DC power
source and a first resonance capacitor which is connected to the heating coil so as to form a
resonance circuit with the heating coil, and a series circuit which is connected in parallel with the
heating coil and composed of a second switching element and a second resonance capacitor.
D-2 EP1629698 B1 pertains to an induction cooking system including a power inverter, a

microprocessor, a protection circuit and a pan detection circuit is provided. The power control,
timing and a monitoring of the power inverter circuitry is managed primarily by a microprocessor.
Also an additional analog protection circuit is provided to protect the system against hazardous
conditions, such as over current and inappropriate gating signals that may be resulted by the
malfunction of the microprocessor. So that main disadvantage of a system controlled primarily by a
microprocessor is eliminated. Another circuit for detection the presence of the suitable cookware is
provided.
WO2009047768 A3 teaches an inductive power providing system to a workspace by induction

comprises at least one inductive power outlet incorporated into a bounding surface of the
workspace. The inductive power outlet comprises at least one primary inductor connectable to a
power supply via a driver. The driver provides an oscillating voltage supply to the primary inductor
and the primary inductor may inductively couple with a secondary inductor wired to an electric load.
WO2013098227 A1 relates to a kitchen appliance operated wirelessly on an induction heating

cooker, comprising a programmable microcontroller, one or more than one electronic circuit that
provides the microcontroller to control the communication means, user interface and sensors,
providing communication with the induction heating cooker whereon the kitchen appliance is
operated, a power control circuitry that supplies the microcontroller and the electronic circuits with
low level DC voltage, a receiver coil that partially collects and provides transfer of the power
generated by the induction coil in the induction heating cooker to the power control circuitry, a
rectifier that converts the AC voltage delivered from the receiver coil to DC voltage and a buffer
capacitor which filters the DC voltage at the rectifier outlet.
US4013859 A discloses an Induction cooking unit having cooking load sensing device and essentially
zero stand-by power loss. This induction heating unit comprised of a high power solid-state inverter
for supplying relatively high frequency excitation currents to an induction heating coil, and including
inhibit, delay, and starting and stopping gating circuits to control the operation of the high frequency
power inverter. An induction heating load sensing device senses the presence or a load sucn as a pan
or other metal base cookware located in induction heating relationship with respect to the induction
heating coil.
The pan presence sensing device comprises a very low power oscillator coupled to a load sensing coil
for exciting the load sensing coil with high frequency oscillatory signals which preferably are in the
range of two to three times the frequency at which the power inverter operates. The load sensing
coil is physically positioned adjacent the induction heating coil in a location to provide inductive
coupling of the high frequency sensing signal to a pan load suitably supported near the induction
heating coil. The pan load sensing coil is designed to minimize the effect of inductive coupling to the
induction heating coil, and for this purpose is provided with a multiple loop figure-eight or cloverleaf
shape so designed and positioned that currents induced in the loops of the sensing coil by the
magnetic field of the induction heating coil null one another at the terminals of the sensing coil. A
load sensing detector responds to the magnitude of the high frequency voltage across the pan load
sensing coil and controls the operation of the gating circuits of the power inverter in a load-selective
manner to cause turn-on of the power inverter only in the presence of a proper pan load.
US8169185 B2 relates a system and method for variable power transfer in an inductive charging or
power system. In accordance with an embodiment the system comprises a pad or similar base unit
that contains a primary, which creates an alternating magnetic field. A receiver comprises a means
for receiving the energy from the alternating magnetic field from the pad and transferring it to a
mobile device, battery, or other device. In accordance with various embodiments, additional
features can be incorporated into the system to provide greater power transfer efficiency, and to
allow the system to be easily modified for applications that have different power requirements.
These include variations in the material used to manufacture the primary and/or the receiver coils;
modified circuit designs to be used on the primary and/or receiver side; and additional circuits and
components that perform specialized tasks, such as mobile device or battery identification, and
automatic voltage or power-setting for different devices or batteries.
US8493755 B2 discloses power supply with zero power consumption capability. Power supply
devices are provided that can include power regulating circuitry for regulating (e.g., transforming or
converting) electric power to be passed to an electronic device. A power supply device can also
include control circuitry coupled with the regulating circuitry. The control circuitry can determine
when the power supply device is coupled with an electronic device. The control circuitry can control
the operation of the regulating circuitry based on whether or not the power supply device is coupled
with the electronic device.
US8519666 B2 relates to a charging system including a device housing a battery and charging pad. A
charging pad is provided with a power supply coil, and a device housing a battery containing an
induction coil. The device housing a battery is provided with a rectifying circuit that rectifies AC
power induced in the induction coil, a charging circuit that charges the internal battery with output
from the rectifying circuit, a shorting circuit that short circuits the terminals of the induction coil, and
a control circuit that controls the shorting circuit ON when a charging abnormality is detected. If the
control circuit detects a charging abnormality during power transmission from the charging pad
power supply coil to the device housing a battery induction coil, it controls the shorting circuit ON to
cut-off the supply of power from the induction coil to the rectifying circuit.
US20100288754 A1 discloses an electric power supply apparatus. A feeder capable of feeding power
to a load such as an electric appliance without remodelling an IH cooker already owned at home and
usually used for cooking by heat, and just by putting on a plate of the IH cooker with its power ON
without the need of an outlet. The feeder includes a power generating coil for interlinking an
alternating magnetic field generated by the IH cooker having a proper pan sensing function to
generate an induction current and supply to the load, a blocking part connected between the coil
and the load , a sensing part for detecting a physical quantity generated by the coil, the blocking part
and/or the load for converting it into a corresponding signal, and a control part for controlling to
shut the blocking part based on the signal output from the sensing part. The power generating coil
and the load are blocked by the blocking part, and power consumption on the load is put out of a
specified range set with the power consumption by a magnetic cooker mounted on the IH cooker as
reference, thereby causing the IH cooker to determine that the magnetic cooker is not mounted to
interrupt the generation of the alternating magnetic field from the IH cooker.
Hence, in spite of the availability of a variety of induction cooker available according to prior art, it
can be seen that the novel features of our invention which makes our method and system unique
and stands apart from the prior art system, since a set of rechargeable storage battery having a
voltage of about 24 volt can not only supply the power required for induction heating but also the
used up battery gets recharged by the induction heating system itself and the charging and
discharging cycle continues during the induction cooking process, there by almost consuming zero
power.
SUMMARY
The present invention provides high efficiency induction cooking system with zero power
consumption powered by a set of rechargeable battery pack which automatically gets recharged
from the system itself and self sustaining as the induction cooking progresses. It comprise of a body
forming an outer shell; a top plate made of a thermally or chemically strengthened material capable
of passing high frequency magnetic field there through adapted to place a cooking vessel made of
ferromagnetic material mounted on a top area of the body ; an induction coil assembly consisting of
primary winding and secondary winding arranged beneath the top plate in face to face relation with
the top plate for generating high frequency magnetic fields necessary to heat bottom of a cooking
vessel placed on the top plate by induction, a captive battery pack having rechargeable batteries and
associated electronic circuitry.
The required power is provided by a source unit consisting of battery pack having plurality of
rechargeable batteries connected in series so as to obtain a voltage around 24V, 2.5A and another
charging unit consisting of battery pack having plurality of rechargeable batteries connected in series
adapted to replenish to the voltage around 24V, 2.5A when discharged, from the said induction
cooking system itself.
The electronic circuitry comprise of a) a microcontroller based signal processor for generating 20 kHz
signal from the source voltage (24V) provided therein; b) a drive circuit consists of power MOSFET,
transistors and resistors adapted to convert the low range volt and ampere of the 20kHz signal
received from the signal processor into the range of 24v and 2.5amps for giving to the primary side
of the coil; c) power and heat control unit having microcontroller-2, op-amp (IC), resistors,
transistors, relays, sensors including a battery and charge control to upgrade said 20kHz signal to
150kHz and to facilitate to get 82V output in the secondary side of the coil and for recharging the
charging unit.
Said source unit initially provide the required power for generating high frequency magnetic fields to
facilitate induction heating and said charging unit gets charged when the induction heating system is
in progress and later on become source unit by means of the built in relay causing to interchange it.
During this induction cooking process, no energy gets lost as the power consumed during the
induction heating is replenished as the system regenerates power and the power source get
charged. This is one of the main features of this state of the art invention that makes it unique and
sets apart from its class of Induction cooker ever known. Energy savings aspects of this invention will
go a long way towards energy conservation when world is likely to face energy crisis in the near
years to come.
BRIEF DESCRIPTION OF THE DRAWING
These and other features, aspects and advantages of the present invention will become better
understood when the detailed description is read with reference to the accompanying drawings. This
invention is well illustrated in the drawings, with reference to numerals indicating various parts in
the figures.
Fig.1 View of the induction cooker according to one of the embodiment under the invention. Fig.2
Blown out view of the one unit of induction coil assembly with top plate shown in Fig.-1 Fig.3
Induction coil showing terminals of primary and secondary winding. Fig.4 Functional block diagram
depicting the induction heating cooker according to invention. Fig.5 Circuit diagram of the induction
heating cooker showing source unit, signal processor and drive unit according to invention. Fig.6
Circuit diagram of the induction heating cooker showing power and heat control unit, charging unit
and induction coil assembly.
Wherein, 1- Top plate of the cooker body made of thermally or chemically strengthened material
like ceramic glass; 2- Holding frame for the ferrite core; 3- Ferrite cores; 4-lnduction coil; 5-Cook top
(top plate) over which cooking vessel is supposed to keep for cooking vessel made of thermally or
chemically strengthened material like ceramic glass ; 6- Source unit; 7- Charging unit; 8-Signal
processor; 9-Driving circuit; 10-Power and heat control unit; 11- Induction coil assembly; 12- Battery
and charge control of the Power and heat control unit; 'A'- Primary winding; 'B'- Secondary winding;
P1- Microcontroller; P2 - Microcontroller; T1 - TransistoM; T2 - Transistor2; T3 - Transistor3;T4 -
Transistor4; R1 - Resistoh; R2 -Resistor2; R3 - Resistor3; R4 - Resistor4; MOSFET-1( Metal Oxide
Semiconductor Field Effect TransistoM) ; Metal Oxide ; MOSFET-2 (Metal Oxide Semiconductor Field
Effect Transistor.2); IC1 - Op-amp ; VSE - Voltage sensor; TSE - Temperature sensor
DETAILED DESCRIPTION OF THE INVENTION
A high efficiency induction cooking system with zero power consumption according to the invention
is a self contained system wherein the electric power required for generating high frequency
magnetic fields to facilitate induction heating is generated by itself, making it unique in its class of
induction cookers. The power source of the induction cooker is a battery pack of rechargeable
batteries 24V, 2.5A.
Fig.1 shows the perspective view of the induction cooker according to one of the preferred
embodiment under the invention with two cook top. One can have any number of such cook tops
according to the need. Fig. 2 shows a blown out view of one of such cook top shown in Fig.1 showing
the parts of induction coil assembly (11) according one of the embodiment under the invention. The
induction coil assembly is arranged beneath the cook top / top plate (5) in face to face relation with
the top plate for generating high frequency magnetic fields necessary to heat by induction. On the
other hand, a plurality of longitudinal ferrite cores in a radial pattern (3) which functions as
ferromagnet for concentrating magnetic fluxes, emanating from the induction coil (4) to the rear
surface thereof, in an area adjacent the induction coil is fitted to an under surface of the coil over a
holding frame (2).
Referring to fig.3 the induction coil (4) consisting of a large circular coil made up of enamelled
copper windings. In a preferred embodiment under the invention the windings are of 20SWG copper
bi-filler coil. The induction coil is horizontally and spirally disposed from the inside toward the
outside to the rear surface thereof. It has primary winding 'A' and secondary windings 'B' and
provided with 4 terminal each numbered as 1, 2, 3 and 4. The induction coil is arranged beneath the
top plate (5) in face to face relation with the top plate for generating high frequency magnetic fields
necessary to heat by induction bottom of a cooking vessel placed on the cook top / top plate.
Fig. 4 is a functional block diagram depicting the induction heating cooker according to the
invention. It comprising mainly of source unit (6), charging unit (7) signal processor (8) drive circuit
(9) power and heat control unit [10) magnetic induction unit or induction coil assembly (11) and
Battery and charge control of power and heat control unit.
Referring to Fig-5 and Fig.6 which are circuit diagram depicting an Bxemplary embodiment under the
invention, the initial power required is provided by the source unit (6) consisting of a battery pack
having plurality Df rechargeable batteries connected in series so as to obtain a voltage around 24V,
2.5A which gives the charge to the input side of the niicrocontroller-1 (P1) provided in the signal
processor (8). The processor generates a 20 kHz signal and from the drain terminal of the MOSFET
present in the drive circuit (9) it is given to the primary side of the coil (coil M and A4). An increased
voltage is now obtained from the secondary side of the coil (coil B1 and B4), which is then connected
to the power and heat control unit (10), where it is rectified with the help of bridge rectifier present
in the battery and charge control part (12) of the power and heat control unit and it is driven to the
charging unit (7) for the recharging of the batteries with the help of power MOSFET present in the
battery and charge control part of the power and heat control unit using the upgraded 150kHz signal
by the microcontroller- 2 (P2) provided therein.
When the high frequency pulse is given to the coil, an increased voltage (82v,1.25A) is generated
across the secondary of the coil and at the same time a temperature of around 150 ° C is produced
within the bottom of the cooking vessel or pan positioned above the coil within few seconds The
surface of top plate (5) which is made of thermally or chemically strengthened material like ceramic
glass does not heat and will not glow red because the electromagnetic energy passes through the
cook top into the cooking vessel made of any magnetic material. This causes iron molecules of the
material used for making the cooking vessel to vibrate 20,000 - 50,000 times per second and the
friction between those molecules creates heat. All of the heat is produced within the bottom of the
cooking vessel made of ferromagnetic material is transferred to the content of the cooking vessel.
The charging unit (7) consisting of plurality of rechargeable batteries connected in series is recharged
and replenished to a voltage around 24v, 2.5A, during the induction cooking. The interchanging of
the source unit and charging unit is made possible with the help of the relays provided in the power
and heat control unit (10).
The induction heater consume power from source unit (6) and at the same time power is given to
the charging unit (7) which is controlled by the power and heat control unit (10) with the help of
relays and sensors as per the control signals from micro controller based signal processing unit (8). If
the charging unit attains the desired energy level, the sensors detects that and convert the charging
unit to source unit. During this time charging unit acts as source unit and the source unit acts as
charging unit. The interchanging of source and charging unit is done with the help of relays as per
the control signals from control unit. Hence once the charging unit attains desired energy level, the
above operation gets repeated.
Source unit (6), as well as the charging unit (7) are a set of battery pack having plurality of
rechargeable batteries connected in series and consist of a set of lithium-ion batteries according to a
preferred embodiment under this invention. It can be preferably even made of single lithium-ion
battery which comes in the range of 3.7v 40ah. Since we need 24v 40ah for the working of our
system, we have to connect sufficient number of batteries in series to get the required voltage. The
life span of the battery pack may be around 10 years.
Referring to Fig.5, signal processor (8) is one of the main parts of the induction heating system. The
processor generates 20 kHz signal. The source voltage (24v) is given to the microcontroller based
signal processor where microcontroller-1 helps to generate 20 kHz signal. In addition, the
microcontroller-1 will detect the deep discharging of the batteries of source unit (6) and gives the
signal to the microcontroller-2 used in the heat and power control unit (10) shown in Fig.6. Said
microcontroller- 2 with the help of relay will interchange the source unit to charge unit and vice
versa. The heat control of the power MOSFET provided in the drive unit (9) is also controlled by this
microcontroller-1. The fan provided for the cooling of the heat protection of the MOSFET is also
controlled by the same microcontroller-1 of the signal processor. The generated pulse in the signal
processor unit is now given to the drive unit (9).
The microcontroller-1 provided in the signal processor (8) is programmed to execute the following
functions:-
• Give instructions for the generation of 20 kHz signal.
• Detect the deep discharge of the source battery and give the signal to the microcontroller-2
for interchanging the source unit and charging unit during the required time with the help of relays
provided in the power and heat control unit.
• Control the heat control of the power MOSFET provided in the drive unit.
• Control the fan provided for the cooling of the heat protection of the MOSFET
Referring to the Fig- 5 the drive circuit (9) consists of power MOSFET, transistors and resistors. The
generated 20 kHz signal in the signal processor (8) is in the range of milli volt and milli ampere. This
low range volt and ampere must be converted into the range of 24v and 2.5amps. Hence we use
power MOSFET for this conversion, which is known as switching process. Now the drain terminal of
the MOSFETs is connected to the primary side of the coil (coil A1 and A4). A further connection goes
to the power and heat control unit (10) also.
Referring to the Fig- 6 the power and heat control unit (10) plays an important role of controlling
and managing the induction cooking system. Power and heat control unit consists of
microcontroller-2, op-amp (IC), resistors, transistors, relays, sensors and battery and charge control.
The main function of the microcontroller-2 is to upgrade the 20kHz signal to 150kHz signal. Another
function of the microcontroller-2 is to detect whether a cooking vessel is introduced on the cook top
and also control the heat or temperature of the cooking vessel with the help of sensors provided in
this unit. Microcontroller-2 also detects the overcharging of batteries provided on the charging unit
and with the help of op-amp ,the control signals are given to the relay and with the help of relay the
charge cut-off and interchanging of the source unit and charging unit takes place.
Another function of the power and heat control unit (10) is that the voltage (increased voltage)
coming from the secondary side of the coil (coil B1 and B4) is rectified with the help of bridge
rectifier (present in the battery and charge control part of the power and heat control unit) and it is
driven to the charging unit for the recharging of the batteries with the help of power MOSFET
( present in the battery and charge control part of the power and heat control unit) using the
upgraded 150kHz signal.
The 20 kHz signal coming from the drain terminal of the MOSFETs present in the drive unit is
connected to the primary side of the coil (coil A1 and A4). An increased voltage is now obtained from
the secondary side of the coil (coil B1 and B4), which is then connected to the power and heat
control unit, where it is rectified and given to the charging unit for charging.
The charging unit will consists of 24v battery pack. The rectified output from the bridge rectifier
(present in the battery and charge control part of the power and heat control unit) is given to the
charging unit for recharging of the battery.
While the deep discharge of the source battery pack is detected by the microcontroller-1 provided in
the signal processor unit, the overcharging of the batteries used in charging unit is detected by the
microcontroller-2 of the power and heat control unit. When our system is working, according to
which of the conditions slated above is first occurred, the respective microcontroller will give the
signal to the op-amp. With the help of the op-amp, the relay will cutoff and interchange the source
unit and charging unit.
The microcontroller-2 provided in the power and heat control unit (10) is programmed to execute
the following functions:-
• Upgrade the 20 kHz signal to 150 kHz signal.
• Detect whether a cooking vessel is introduced on the cook top and also control the heat or
temperature of the cooking vessel with the help of sensors provided in the unit.
• Detect the overcharging of batteries provided in the charging unit and with the help of op-
amp, the control signals are given to the relay.
• Interchange the source unit to charge unit and vice versa with the help of relay.
Controlled automation requires device to sense system output. Sensors can be used so that a
controller can detect and respond to the changing conditions in its environment. In the induction
cooker according to the invention, sensors are used to check and measure the voltage level of
charge and source battery unit, presence or nearness of the cooking vessel, force or pressure acting
on the coil, temperature of the cooking vessel, power and frequency level of different stages in the
cooking system. In other way the sensors detects the different parameters of the system and gives
corresponding signals to the control unit. As per the signal received, the respective control unit gives
the different control signals to corresponding relays and other units in the system and maintain the
overall performance of the cooking system is ensured.
Induction cooking system according to a preferred embodiment under the invention comprise of the
following main functional steps
a) The signal processor will take charge from the source battery, once the induction cooking
system is put 'ON'.
b) The signal processor will produce 20 kHz signal and also detect the discharging of the source
battery.
c) The generated pulse is given to the drive unit for switching process.
d) After switching process, 20 kHz signal is given to the primary side of the coil.
e) The electromagnetic induction takes place in the coil. At this time the cooking vessel
provided on the cook top gets heated up and at the same time it gives charge to the charging battery
(i.e. recharging takes place).
f) The secondary side of the coil will produce an increased voltage.
g) The increased voltage is given to the power and heat control unit.
h) In the power and heat control unit, the up gradation of 20 kHz signal to 150 kHz signal takes place,
i) Bridge rectifier in the power and heat control unit rectifies the secondary coil output and with the
help of MOSFET, the recharging of the charging unit takes place, j) Microcontroller-1 present in the
signal processor gives signal about the discharging of the source battery to the microcontroller-2 in
the
power and heat control unit, and with the help of relays , the inter changing of the source unit and
charging unit takes place, k) With the help of sensors provided in the power and heat control unit,
the heat and temperature of the cooking vessel is controlled and maintained. In a preferred
embodiment under the invention the control and display panel of the induction cooking system can
be provided a number of features. To name a few important functional parameters among them are
a) Power On/ off switch b). Battery status display both of source unit and charge unit c) temperature
(heat) control, d) Holding Temperature Display LED Lights e)"Heating" Indicator Light f) "Heat"
Function Indicator Light, g) "Warm"(Hold Temperature) Function Indicator Light, h) Warm"(Hold
Temperature) Function Key i) "Heat" Function Key. Said control and display panel can have the touch
screen panel facility as well.
Some of the built in safety features provided in the induction cooking system are as under: -
a) Over heat control - If the cooking vessel's or pan's temperature becomes too high than set and the
temperature remains for 60 seconds, the unit will shut off automatically.
b) Over charging and deep discharging control - Separate battery packs (24 V) are used for both
source and charging unit. When the charging unit gets over charged to a value of 27v to 29 v or the
source unit gets discharged to a value of 20v (which ever condition first occurred) the interchange of
the source unit and charging unit takes place. And again when the condition arises that the charge
unit gets fully charged and the source unit didn't get discharged, then automatic charge cut-off will
takes place.
c) Automatic safety shut-off - If the induction cooker is left ON for more than 60 seconds
without a cooking vessel.
The term 'deep discharge' is used to indicate that the source battery pack (24v) gets discharged to a
value of 20v. When this condition arises the interchanging of the source unit and charging unit takes
place. If the 24v battery pack gets discharged to a value below 20v then the battery life gets affected.
Main advantages of the energy efficient induction according to our invention over the conventional
traditional induction cooker, no doubt, is that the system doesn't requires any external power
sources, as it is provided by the battery therein. This energy efficient induction heating cooking
system with zero power consumption uses almost nil energy whatsoever and heat generation is
uniform and constant throughout the period.
Since the induction heating cooking system of the present invention runs on rechargeable battery
and more over getting charged while the induction heating is on, whatever energy consumed during
the induction cooking is replenished by the system itself, thereby in effect there is zero power
consumption. Hence present induction heating cooking system is independent of electricity supply
to the home and any interruption in power supply will not hamper cooking. Since the energy
required for induction cooking is being provided by the battery, the life of the induction cooker
manly depend on the life of the battery used which can last many years. As of now lithium ion
battery is the best option for the induction cooker according to the present invention.
Additional advantages of the state of the art induction cooker under the present invention are : a)
No losses occurs during the operation since almost no ambient heat is produced and all the heat is
being generated in the cooking vessel itself; b) The system attains the required temperature level
with in short period of time; c) The system is highly energy efficient when traditional gas or electric
ranges waste up to (and usually more) than half the heat they generated; d) The system is free from
pollution; e) It is much safer than gas or other electric surfaces, since there is no open flame, red-hot
coil or other radiant heat source to ignite fumes or flammable materials; f) Cooking vessel can be
easily cleaned since there is no smoke accumulation and the pot surface is flat with no grates or
grease catch to worry about; g) There is total isolation of heating surface and the internal electric
circuit; h)There is air gap between the underneath coil and the cooking surface. All this advantages
are gainfully made use of at almost zero recurring expenditure.
The novel features of the invention have been brought out by explaining some of the preferred
embodiments under the invention, enabling those in the art to understand and visualize the present
invention. It is also to be understood that the invention is not limited in its application to the details
set forth in the above description or as illustrated in the drawings. Although the invention has been
described in considerable detail with reference to certain preferred embodiments thereof, various
modifications can be made without departing from the spirit and scope of the invention as described
herein above and the appended claims.
I claim,
1. A high efficiency induction cooking system with zero power consumption which comprises of a
body forming an outer shell; a cook top (5) made of a thermally or chemically strengthened material
capable of passing high frequency magnetic field there through adapted to place a cooking vessel
made of ferromagnetic material placed on said cook top mounted on the top portion of the body (1)
characterised in
a) an induction coil assembly or magnetic induction unit (11) consisting of primary winding and
secondary winding (4) along with ferrite core (3) arranged beneath the cook top (5) in face to face
relation with the cook top for generating high frequency magnetic fields necessary to heat by
induction bottom of a cooking vessel placed on cook top (5);
b) a source unit (6) consisting of battery pack having plurality of rechargeable batteries
connected in series so as to obtain a voltage around 24v, 2.5A;
c) a charging unit (7) consisting of battery pack having plurality of rechargeable batteries
connected in series adapted to replenish to the voltage around 24v, 2.5A when discharged, from the
said induction cooking system itself;
d) a microcontroller based signal processor (8) for generating 20 kHz signal from the source
voltage (24v) provided therein;
e) a drive circuit (9) consists of power MOSFET, transistors and resistors adapted to convert the
low range volt and ampere of the 20kHz signal received from the signal processor (8) into the range
of 24v and 2.5amps and given to the primary side of the coil as well as to the power and heat control
unit (10);
f) power and heat control unit (10) having microcontroller-2, op-amp (IC), resistors, transistors,
relays, sensors including a battery and charge control to upgrade said 20kHz signal to 150kHz and to
facilitate to get 82v output in the secondary side of the coil and for recharging the charging unit (7)
and interchange source unit (6) for charging and vica versa, effected by means of relays provided
therein.
2. A high efficiency induction cooking system as claimed in claim-1, wherein magnetic induction
unit or induction coil assembly (6) includes induction coil (4) horizontally and spirally disposed from
the inside toward the outside and plurality of longitudinal ferrite core (3) arranged in a radial pattern
for concentrating magnetic fluxes, positioned under surface of the coil base over a holding frame (2).
3. A high efficiency induction cooking system as claimed in claim-1, wherein voltage and
current given to the primary of the coil is 24V 2.5amps and the terminal of the primary coil A1 and
A4 are connected to the drain terminal of the MODFET used in the drive circuit (9) and the terminal
of the primary coil A2 and A3 are jointly connected to the 24v+ terminal.
4. A high efficiency induction cooking system as claimed in claim-1, wherein the terminal of the
secondary coil B1 and B4 are again given to the bridge rectifier and which is rectified and given to
the charging unit (7) with the help of MOSFET and upgraded to 150kHz signal and the terminal of the
secondary coil B2 and B3 are jointly connected to the 24v+ terminal.
5. A high efficiency induction cooking system as claimed in claim-1, wherein both the source
unit (6) and charging unit (7) consist of a battery pack having plurality of lithium-ion batteries
connected in series to get 24v 40ah required for the working of said system.
6. A high efficiency induction cooking system as claimed in claim-1, wherein the signal
processor (8) having microntroller-1 is adapted
a) to provide instructions for the generation of 20kHz signal;
b) to detect the deep discharge of the batteries provided in the source unit (6) and give the
signal to the microcontroller-2 for interchanging the source unit(6) and charging unit (7) with the
help of relays provided in the power and heat control unit;
c) to control the heat control of the power MOSFET provided in the drive unit;
d) to control the fan provided for the cooling of the heat protection of the MOSFET
7. A high efficiency induction cooking system as claimed in claim-1,
wherein the power and heat control unit (10) having the microcontroller-2 is adapted :
a) to upgrade the 20kHz signal to 150kHz signal;
b) to detect whether a cooking vessel is introduced on the cook top and also to control the
heat or temperature of the cooking vessel with the help of sensors provided in the unit.
c) to detect the overcharging of batteries provided in the charging unit and give control signal
to the relay with the help of op-amp;
d) to interchange the source unit to charge unit and vice versa with the help of relay.
8. A high efficiency induction cooking system as claimed in claim-1, wherein the power and
heat control unit (10) with the help of bridge rectifier provided therein adapted to rectify the
increased voltage coming from the said secondary of the coil and drive to the charging unit (7) for
the recharging of the batteries with the help of powerMOSFET using the upgraded 150kHz signal.
9. A high efficiency induction cooking system as claimed in claim-1, wherein the respective
microcontroller adapted to give the signal to the op-amp and the relay to cutoff and interchange the
source and charging unit according to which of the conditions have occurred first, while the
induction heating is in progress.
10. A high efficiency induction cooking system as claimed in claim-1, wherein cook top (5) is
made of ceramic glass.
11. A high efficiency induction cooking system as claimed in claim-1, wherein said induction
heating coil (4) is preferably made of 20 SWG copper bifiller coil with 6 turns.
12. A high efficiency induction cooking system as claimed in claim-1, wherein over heat control
is provided which is adapted to function, if the cooking vessel temperature goes on higher side than
the set temperature limit and remains there for 60 seconds , the system gets shut off automatically.
13. A high efficiency induction cooking system as claimed in claim-1, wherein over charging and
deep discharging control is provided which is adapted to function in the event of overcharging said
charging unit to a value of 27v to 29v or said source unit gets discharged to a value of 20v, which
ever condition first occur, the interchange of the source unit and charging unit takes place and again
in the event of said charge unit gets fully charged and the source unit didn't get discharged, then
automatic charge cut-off takes place.
14. A high efficiency induction cooking system as claimed in claim-1, wherein automatic safety
shut-off facility is provided which is adapted to actuates, if the induction cooker is left ON for more
than 60 seconds without cooking vessel.
15. A high efficiency induction cooking system as claimed in claim-1, wherein sensors are
adapted to
a) check and measure the voltage level of charge and source battery unit;
b) detect the presence or nearness of the cooking vessel;
c) detect force or pressure acting on the top plate ;
d) measure the temperature of the cooking vessel;
e) measure the power and frequency level of different stages in the cooking system and
f) provide corresponding signals to the control unit, so that the control unit in turn gives the
different control signals to corresponding relays and other units in the system to maintain the overall
performance of the induction cooking system.
16. A method of functioning the high efficiency induction cooking system as defined in claim-1,
comprising the steps of:
a) taking charge of the operation from the batteries of source unit (6) by the signal processor
(8), once the induction cooking system is put 'ON';
b) producing 20 kHz signal and detecting the discharging of the battery in the source unit by
the said signal processor;
c) giving generated pulse to the drive circuit (9) for switching process;
d) giving 20 kHz signal to the primary side of the coil subsequent to switching process,
e) starting the process of electromagnetic induction in the coil causing heating up of the
cooking vessel placed on the cook top and simultaneously commencing the recharging operation
of battery in the charging unit (7);
f) producing an increased voltage by the secondary side of the coil;
g) giving the increased voltage to the power and heat control unit (10);
h) upgrading 20 kHz signal to 150 kHz in the power and heat control unit; i) rectifying the
secondary coil output by the bridge rectifier in the power and heat control unit and recharging of the
batteries in
the charging unit with the help of MOSFET; j) giving signal by the microcontroller-1 present in the
signal
processor about the discharging of the source battery to the microcontroller-2 in the power and heat
control unit; k) interchanging the source unit and charging unit with the help of relays and k)
controlling and maintaining the heat and temperature of the cooking vessel with the help of sensors
provided in the power and heat control unit.
17. A method of functioning the high efficiency induction cooking system as defined in claim-16,
wherein power is consumed from the source unit (6) initially and power is given later to the charging
unit (7) during induction heating controlled by the power and heat control unit (10) with the help of
relays , sensors as per the control signals from signal processing unit (8) and if the charging unit
attains the desired energy level, the sensors detects the same and converts the charging unit to
source unit and during this time charging unit acts as source unit and the source unit acts as charging
unit.
18. A method of functioning the high efficiency induction cooking system as claimed in claim-16,
wherein according to whether deep discharge of the source battery pack is detected by the
microcontroller-1 provided in the signal processor unit, or the overcharging of the batteries used in
charging unit is detected by the microcontroller-2 of the power and heat control unit, depending on
which occurres first, respective microcontroller will give the signal to the op-amp. and the relay will
cutoff and interchange the source unit and charging unit.
19. A method of functioning the high efficiency induction cooking system as claimed in claim-18,
wherein the interchanging of source and charging unit is done with the help of relays as per the
control signals from control unit and once the charging unit attains desired energy level, the above
operation gets repeated.

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Invention Title ELECTRONICALLY CONTROLLED HIGH EFFICIENCY INDUCTION MOTOR

Publication Number 49/2018

Publication Date 07/12/2018

Publication Type INA

Application Number 201741039429

Application Filing Date 06/12/2017

Field Of Invention ELECTRICAL

Classification (IPC) B60L 11/00

Thekke Peedikayil Kunjimon Thekkepeedikayil House Chalissery, PO Palakkad dist Kerala –

BACKGROUND OF THE INVENTION

US6700270B2 discloses a synchronous induction motor realizing a great reluctance torque by

US20120126741A1discloses a low-inductance, high-efficiency induction machine and method of

BRIEF DESCRIPTION OF THE DRAWING

Fig.1. View of the induction motors showing stator

Fig.2 Another view of the induction motor showing rotor

Fig.3 Induction coil showing the winding of the stator.

DETAILED DESCRIPTION OF THE INVENTION

Shorting is done between S2, H2 and J2 as shown in Fig.4

Shorting is done between SS1, HH1 and JJ1 as shown in Fig.5

Stator winding connection with the electronic module is as under:

Power input is first given to the Electronic module

4. The Control relay of the board is connected to J1- JJ2

Volts Amps Watts Speed in RPM

Motor according to the invention 220V 0.785amps 120.32W 2980

Conventional Motor 220V 5.8amps 888.99W 2900

Example 2 (with a load of 1 kg)

The comparative test results are given in the following Table-2.

Volts Amps Watts Speed in RPM

Conventional Motor 220V 6A 919.65 W 2800 RPM

Example 3 ( with a load of 5 kg)

The comparative test results are given in the following Table-3.

Volts Amps Watts Speed in RPM

Motor according to the invention 220V 0.900 A 137.94 W 2970 RPM

Conventional Motor 220V 6.8 A 1042.27 W 2570 RPM

Example 4 (with a load of 8 kg)

The comparative test results are given in the following Table-4.

Volts Amps Watts Speed in RPM

Motor according to the invention 220V 1.2 A 183. 93 W 2950 RPM

Conventional Motor 220V 7.2 A 1103.58 W 2530 RPM

Publication Number 48/2013

Publication Date 29/11/2013

Publication Type INA

Application Number 5273/CHE/2013

Application Filing Date 18/11/2013

Field Of Invention NO SUBJECT

Classification (IPC) H05B6/00

Name Address Country Nationality

THEKKE THEKKEPEEDIKAYIL HOUSE,

Name Address Country Nationality

THEKKE THEKKEPEEDIKAYIL HOUSE,

induction heating system itself.

BACKGROUND OF THE INVENTION

D-2 EP1629698 B1 pertains to an induction cooking system including a power inverter, a

WO2009047768 A3 teaches an inductive power providing system to a workspace by induction

WO2013098227 A1 relates to a kitchen appliance operated wirelessly on an induction heating

BRIEF DESCRIPTION OF THE DRAWING

DETAILED DESCRIPTION OF THE INVENTION

• Give instructions for the generation of 20 kHz signal.