This paper presents iron loss reduction in the cores of induction heating (IH) coils for a small-foreign-metal particle (SFMP) detector with a 400-kHz SiC-MOSFETs high-frequency inverter. A new core shape for IH coils, which can reduce iron loss, is designed for the stable and continuous operation of the SFMP detector. Magnetic field analysis results using JSOL JMAG software, a 3D full-wave electromagnetic field simulation software, demonstrate that the iron loss caused by the new core shape for IH coils is decreased by 71.8%, compared with that of the previously proposed IH coils, which increase the magnetic flux density to heat SFMPs by 20%. Thus, the stable and continuous operation of the SFMP detector with the newly designed core shape of IH coils can be achieved. It is also shown that SFMP represented by 0.3-mm diameter stainless-steel balls (SUS304) can be detected on the high-performance chemical film (HPCF) with the newly designed core shape of IH coils using JSOL JMAG software. A prototype experimental setup of the SFMP detector with the new core shape of IH coils is constructed and tested. Experimental results demonstrate that a 400-kHz SiC-MOSFETs high-frequency-inverter-based SFMP detector with the newly designed core shape of IH coils can heat SFMPs, which can be observed by a thermographic camera. Therefore, the authors conclude that the 400-kHz SiC-MOSFETs high-frequency-inverter-based SFMPs detector with the newly designed core shape of IH coils is applicable for HPCF production lines.

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