Design of a Special Coil for Copper Tubes Induction Brazing System

In this study, modeling of the copper tubes brazing process is done to choose the best operating frequency using a complicated shape induction coil. To provide a thorough numerical simulation of this system, MATLAB computer package is intended to simulate the power supply composed of a resonant inverter loaded by a parallel tank circuit. Moreover, the Finite Element Method (FEM) is considered to tackle the induction coil simulation issue, by using the "ANSYS" computer package. There is a sequential coupling between the transient thermal analysis and the harmonic electromagnetic analysis is performed. The frequencies of 60, 75, and 90 kHz, are tested to choose the best operating frequency. This computer-aided algorithm used in the design of such systems as compared to the traditional trial-and-error, experience-dependent, design methods that result in an expensive and time-consuming design.