A Parametric Optimization Approach of an Induction Heating System for Energy Consumption Reduction

Nowadays, electromagnetic high-frequency induction is very used for different non-contact heating applications such as the molding process. Every molding process requires the preheating and the thermal maintenance of the molds, to enhance the filling phase and the quality of the final products. In this context, an induction heating system, mostly, is a customized equipment. The design and definition of an induction equipment depends on the target application. This technology is highly efficient and performant, however it provides a high-energy consumption. Therefore, optimization strategies are very suitable to reduce energy cost and consumption. The proposed paper aims to define a method to optimize the induction heating of a mold in terms of time, consumption, and achieved temperature. The proposed optimization method involves genetic algorithms to define the design parameters related to geometry and controller. A test case describes the design of an induction heating system for a polyurethane molding process, which is the soles foaming. This case study deals with the multi-objective optimization of parameters such as the geometrical dimensions, the inductor sizing, and the controller setting. The multi-objective optimization aims to reduce the energy consumption and to increase the wall temperature of the mold.