Design and Development of a Multi-Frequency System for Microwave Heating

Abstract

Microwave systems are widely used for heating applications, mainly domestic food heating. The microwave oven sales figures place it as the first domestic appliance, giving its core element, the magnetron, an unbeatable production cost margin. However, recent improvements in RF highpower generator manufacturing have pointed out not only the limitations of these systems based on the magnetron but also the main benefits of the transistors technology.Nowadays, solid-state power amplifiers are mature enough to compete in efficiency, cost and quality with the magnetron. Transistors' main benefits are their reduced size, low operation voltages, pure frequency spectrum, lifetime, and straightforward digital control. Microwave systems based on solid-state power amplifiers have been recently introduced, although the real applications making use of them are rare. The main issue is the lack of applicator designs for specific solid-state sources that fully exploit the mentioned advantages; therefore, this is the main objective of the present PhD thesis.Solid-State Microwave Heating (S2MH) systems are presented in this PhD dissertation as an alternative that offers enhanced heating. Fine frequency selection, adjustable output power and coherent phase sweep in multiple outputs provide the system with accurate control over the heating process. The direct outcome of this control is the production of homogeneous heating and the application of microwave technology into high-added-value temperature-sensitive processes.The complete design and manufacture of two S2MH systems have been carried out and presented in this PhD thesis. The two designed systems are a multi-process chemical lab batch oven and an almond drying conveyorized oven. These two systems are composed of the Solid-State Microwave Generator System (SSMGS), consisting of four Solid-State Power Amplifiers (SSPA) with coherent wave generation, and the applicator.The design of the SSMGS has been carried out according to the power and frequency requirements of the application. A 4 x 250 W SSPA at 2,450 MHz SSMGS has been used for the chemical processes oven, while the almond drying application needs 4 x 500 W SSPA at 915 MHz. Both SSMGS allow the individual or combined digital control of the parameters of the four amplifying modules, i.e., power, frequency and phase.Multiphysics modelling has been thoroughly studied with special attention to the temperaturedependent thermophysical and dielectric properties of food and liquid solutions. The overall applicators' behaviour has been analysed with this tool. After completing the two PoC (Proof of Concept), the results show good agreement with the models. Both PoCs have shown promising improvements to the current state-of-the-art systems. The chemical applications PoC shows Abstract viii electromagnetic field distribution improvements, independent of the application or load. On the other hand, the almonds drying system provides increased control over the process avoiding material losses through overheating. Resumen xTodo el proces...