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Registered Member #190
Joined: Fri Feb 17 2006, 12:00AM
Location:
Posts: 1567
I think I am onto the right setup for the IGBTs to handle the large through-current. I have now repeatedly levitated solid copper and steel while melting them. I have a few more IGBTs to try and then I will feel confident enough to write this up for others.
Registered Member #190
Joined: Fri Feb 17 2006, 12:00AM
Location:
Posts: 1567
I have posted a video on Youtube showing 8kw levitating solid copper and steel. I measured an input power of 1-1.5kw to levitate aluminum. It took a lot more power to suspend the denser materials. I am still trying to improve some components, but the system handled the power. It took a lot of shorted and blown IGBTs and mosfets to figure out the right combination.
Registered Member #610
Joined: Wed Mar 28 2007, 09:44PM
Location: Middletown, RI
Posts: 110
I'm current;y trying to build an indiction heater with a microprocessor-controlled resonant tracker. I'm just using a PIC with a comparator and it periodically checks to see if the tank voltage is leading or lagging, then adjusts the system clock accordingly. I'd like to see what you've done because I have a hunch my idea won't work.
I will have some video of suspended molten copper and steel as soon as I fix one more component. I have solved the heating problem for all sections except the primary copper on my coupling transformer. It is not the core, but the wire itself that is getting too hot at the high power levels. I plan to build a water jacket to cool the coils. I am also considering running multiple strands of magnet wire.
Registered Member #190
Joined: Fri Feb 17 2006, 12:00AM
Location:
Posts: 1567
I was asked to show a video showing molten metal being suspended. It took about 10kw to do it, but I have posted a video showing the unit suspending molten copper and molten steel. Right now my limitation is my variac, which is only rated for 20A. I am putting 40A to 50A through it for short periods. The power requirements are huge. It takes way more power to levitation coper and steel than just aluminum or copper tubing. It takes even more power to keep the molten metal from slipping through the center, but this unit does it easily without any of the semiconductors getting warm.
Furthermore, the unit needed to be able to handle the magnetic radiation so it didn't create a self-destructing oscillation in the inverter. It took time, but all problems have been solved and now I will package the unit in a nice case. My next endevour, at a friend's request, is to fashion a larger coil to heat steel blocks for forging swords.
Registered Member #190
Joined: Fri Feb 17 2006, 12:00AM
Location:
Posts: 1567
I have just posted on my tutorial page the schematics for the 10kw unit. This can levitate solid copper and steel. It appears I can also use this to forge large bricks of iron now. The schematics to the uP control unit is at the end. The inverter so far has handled 40-50A for short periods of a few minutes. I am relying on air cooling and it is hot in the summer.
Registered Member #540
Joined: Mon Feb 19 2007, 07:49PM
Location: MIT
Posts: 969
Thank you for spending the time to upload the process. If/when I do get around to making an induction heater of my own, I'll use your page as one of my references. Good luck with heating large blocks of iron.
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Yeeeeha! Microprocessor controlled induction heater
