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10/19/2019 Induction Heater - Series Resonant - uC/PLL Tuning [ReactorForge] / Projects / Forums - 4hv.
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omjtest ************************************************** **********
Most ever online: 76
Guests: 76, Members: 0 Github Repository: https://github.com/ThingEngineer/ReactorForge
on Monday 24 December
2018 - 05:02:03 ************************************************** **********
Members Birthdays: Photos: Flickr - Induction Heater (updated as I progress)
No birthdays today Goal: Replace dirty coal forge and heat producing propane forge in my brothers blacksmith shop for work on smaller items.
Next birthdays
10/21 ben106 (34) Primary Requirements:
10/22 803 (2019) Heat .5 inch square carbon steel to 2200-2400 °F DONE
10/23 Iniaes (11) Easy and safe to use by non technical users Easy DONE, working on safe
Draw under 30 Amps at 120V Update: 60A at 240V DONE
Water cooled work coil DONE
Contact Water or air cooled electronics DONE
Thermal readout of water temperature, power supply, and inverter DONE
If you need assistance,
Mains current usage readout DONE
please send an email to
Auto shutdown and warning for an over temperature condition DONE
forum at 4hv dot org. To
Operate in the 30-100KHz range DONE
ensure your email is not
Fully automatic - No user tuning required DONE
marked as spam, please
Working coil changeable by user without opening case DONE
include the phrase "4hv
Foot switch operation DONE
help" in the subject line. You
can also find assistance via
IRC, at irc.shadowworld.net,
Secondary Requirements:
room #hvcomm.
Heat .5 inch square carbon steel to 2600–2800 °F DONE
Thermal display (LED or LCD) DONE
Built in power control for operating at less than 100% powerDONE
Support 4hv.org!
Multiple resonant tank frequencies via capacitor or working coil inductor changes without system recalibration DONE
Donate: EMI filtering DONE
4hv.org is hosted on a Unity power factor DONE (.97 to .99)
dedicated server.
Unfortunately, this server
costs and we rely on the Type: uP/PLL tuned inverter coupled to a series resonant tank via a toroidal coupling transformer, .5-1.5 uH work coil
help of site members to
keep 4hv.org running. Resources:
Please consider donating. Design And Application Guide For High Speed MOSFET Gate Drive Circuits
We will place your name on Eliminating Parasitic Oscillation between Parallel MOSFETs
the thanks list and you'll be Phase-Locked-Loop Applications
helping to keep 4hv.org A decent Current Transformers application note
alive and free for everyone. Latch-Up Protection For MOSFET Drivers
Members whose names Hall-based sensing devices (current sensing is what we are looking for here)
appear in red bold have IGBT Drive using MOSFET gate drivers
donated recently. Green Soft-Switching principles and design techniques
bold denotes those who Power Factor Boost Preregulator Core Loss Calculations
have recently donated to All the other great IHs on this site of course!
keep the server carbon Johnathan's IH Tutorial
neutral. Tim Williams induction heating saga
Neon John's IH examples
Richie Burnett's IH theory
************************************************** **********
Special Thanks To: ************************************************** **********
https://4hv.org/e107_plugins/forum/forum_viewtopic.php?id=140297 1/23
10/19/2019 Induction Heater - Series Resonant - uC/PLL Tuning [ReactorForge] / Projects / Forums - 4hv.org
Aaron Holmes
Aaron Wheeler Progress: (See Flickr gallery for full-size photos, and more photos not shown here.)
Adam Horden
Alan Scrimgeour 12/29/2017
Andre Another video, this one goes over the basic functionality of the machine. Not how to use it but more how it works on a high-
Andrew Haynes level. I'll be making videos of each component/system and how they specifically work individually, this is more a walkthrough
Anonymous000 of how they all work together. (And don't worry, I'll get a microphone before making those videos.)
asabase
Austin Weil Have a great weekend everyone!
barney
Barry Here is the link if the embeded video doesn't work.
Bert Hickman https://youtu.be/q-JiucZY7mM
Bill Kukowski
Blitzorn
Brandon Paradelas
Bruce Bowling
BubeeMike
Byong Park
Cesiumsponge
Chris F.
Chris Hooper
Corey Worthington
Derek Woodroffe
Dalus
Dan Strother
Daniel Davis
Daniel Uhrenholt
datasheetarchive
Dave Billington
Dave Marshall
David F.
Dennis Rogers
drelectrix
Dr. John Gudenas
Dr. Spark
E.TexasTesla
eastvoltresearch
Eirik Taylor
Erik Dyakov
Erlend^SE
Finn Hammer
Firebug24k
GalliumMan
Gary Peterson
George Slade
GhostNull
Gordon Mcknight
Graham Armitage 12/29/2017 Here is a video update from today.
Grant
GreySoul
Henry H
IamSmooth
In memory of Leo
Powning
Jacob Cash
James Howells
James Pawson
Jeff Greenfield
Jeff Thomas
Jesse Frost
Jim Mitchell
jlr134
Joe Mastroianni
John Forcina
John Oberg
John Willcutt
Jon Newcomb
klugesmith
Leslie Wright I ran into an issue with the IGBT drivers. And rather than trying to patch the prototype boards up AGAIN I think it's time to
Lutz Hoffman get some real boards made for the ReactorForge.
Mads Barnkob
Martin King
Mats Karlsson 12/16/2017
Matt Gibson Wow, jump forward in time again and here we are. I have been busy over the years but I have never given up or complete
Matthew Guidry stopped work on the ReactorForge. I am making an active effort to continue this project now.
mbd
Michael D'Angelo
Mikkel
mileswaldron
mister_rf
Neil Foster
Nick de Smith
Nick Soroka
nicklenorp
Nik
Norman Stanley
Patrick Coleman
Paul Brodie
Paul Jordan
Paul Montgomery
Ped
Peter Krogen
Peter Terren
PhilGood
Richard Feldman
Robert Bush
Royce Bailey
Scott Fusare
Scott Newman
smiffy
Stella
Steven Busic
Steve Conner
Steve Jones
Steve Ward
Sulaiman
Thomas Coyle
Thomas A. Wallace
Thomas W
Timo
Torch
Ulf Jonsson
vasil
Vaxian
vladi mazzilli
wastehl
Weston
William Kim
William N.
William Stehl
Wesley Venis
The aforementioned have
contributed financially to the
continuing triumph of
4hv.org. They are deserving
of my most heartfelt thanks.
I've got it hooked up to a decent chiller now. No more pond pump and the 5-gallon bucket with a small computer fan radiator.
Although that worked quite well.
I also set the whole thing up on a rolling metal cart from Sam's Club. This was perfect, lots of room on the bottom for the
chiller, a small area for spare coils and a shallow top for the induction heater to sit.
I'm now working on the new firmware. If you follow the GitHub (click watch) you'll see the progress.
Since the scope of this project has gotten quite large I needed a bit more room than one forum thread so I have also been
posting updates on the blog and on Patreon. But I will continue to update this thread and be active on here as well. Thank you
all for your input and help over the years!
6/13/2014
It's been a while since my last update here but I've been busy with this project and my day job. Since the last update, my
brother has quit his day job, built a big new shop and is now full time making tools using an updated induction heater model
as his sole heat source (no coal or gas forge).
In an effort to give back to the open source community I have organized the older project files into a repository on GitHub
that I am making publicly available under the project name ReactorForge. This repository includes all schematics and code for
my first 2 induction heaters (the second of which has been in operation full time for over a year). Over the coming weeks I
will be organizing and releasing the information for the new version seen in the video below. This will be the last update to
this thread as it has been focused on the older model. The newest prototype is much different and I will be starting a new
thread to cover it.
The video below is of the mark III beta prototype (code name: CriticalMass) in operation.
Reactor Forge Induction Heater - 1/2" bar in 6" long coil
2/15/2012
My brothers company he started, Argyll Hammer is doing well on eBay and he's starting to get customer orders now. He just
posted this one today on his Facebook page:
"Big order, 40 pairs of tongs going to the guys at Trackers Earth, a wilderness survival/outdoor skills school in Oregon. They
will be doing some blacksmithing classes soon now too and needed tools."
The pressure is on to get the next version up and running. Just working on the case and refining the coupling transformer.
01/2013:
I updated this thread so that the newest updates are on top and the old ones are on bottom since it was getting so long. I'll
remember to do that in the future since it was a pain inverting the list items.
I've added a cooling solution to the IH to eliminate the need for running hoses to and from it before use.
I also added a small high CFM fan with a push button switch powered from the 12V cooling fan supply to pull away fumes
when heating a work piece. This came as a request from my brother who was surprised this was not an add on feature for
commercial units.
Pump 1/2HP 650GPH
Radiator for 4 x 120mm
High RPM 12V Fan 120mm x 4
12V Power Supply
What's next? Well not much for this unit. I've been working on the next one which is an LCLR tank topology vs this series
resonant version. The entire unit is more robust and much simpler. I've eliminated the PLL drive and am driving each of 4
individual gate drivers with a high frequency PWM (64MHz base F) power stage controller. This has eliminated the touch
analog circuitry, and most important allowed me to phase shift the full-bridge for perfectly smooth power control from 0 to
100%.
I'll be compiling that project in it's own topic most likely since it is vastly different from this one. I'll also circle back and
update the schematics and code for this one. The field testing and heavy use my brother has put on the unit has reviled much
and yielded beneficial changes.
On another note, my brother sold his Habañero Chile Grande -

Not because it didn't work as intended but because it was more expensive and vastly less convenient to use than the IH. He
also went part time on his day job and is now making more selling custom tools than he is in his career position. So the
pressure is on to get a more reliable, higher power unit going! Not to mention a backup.
8/18/2012:
My brother made a video of his shop progress and did a big portion of it on the IH, it was cool seeing it used by someone
besides myself when I was not there to baby it which was really the biggest goal.
When he is talking he is addressing some online blacksmith community. A quick warning, he is a big dork which is not the
same as us nerds and geeks. :)
update: I think he deleted the video.
Work in progress UPDATE: COMPLETE:

A few of the items I'm working on right now:
The next tank setup which will eliminate case heating by reducing inductance and raise tank efficiency.
A new control board with lots of upgrades including a micro-controller that will do the phase locking (on its own, no
FPGA, working on a breadboard now with a small LV test tank, just needs some more tweaking). This is big not
because there is an issue with the PLL, that thing works like a champ. But because it will allow me to have a tunable
range with no center frequency, basically a PLL that can set it's own tunable range each time it runs allowing the user
to switch coils out without retuning the PLL circuit. I know I could accomplish this to some degree using a varactor
(C1) and two digitally set potentiometers (R1,R2) on the PLL but that's adding more failure points to an already
touchy circuit in my opinion.
I'm also redesigning the IGBT driver to be more like a commercial driver with isolated DC/DC converters for each
transistor, fault sensing and protection to detect over-current and short-circuit conditions, adjustable blocking time,
desaturation protection and better common mode rejection... to name a few.
9/16/2012: So exciting day today, finally got the IH set up in my brother shop for some real life tests and heavy use. After
using it for only a few minutes I think he was ready to git rid of his $1500 propane forge he just bought.
There was a lot more I wanted to work on such as better current limiting, current readout on the LCD, program timed cycles,
temperature sensing and safety cutoffs, etc. Although the unit can run at a 20KW (.99PF) at 100% duty cycle indefinitely with
no over heating as long as the water is running even with no work piece in the coil. Much more over 20KW and the coupling
coil heats up above 130F so that will be the first thing that gets upgraded. I'm going to let him keep this one and build a new
one with a new board and better tank setup and see how far I can go. He would like to be able to melt about 5-10lbs of
material for making his own steel, seems easily do able.
Anyway here are a few pics and videos, nothing really technical just the results of a semi-permanent setup in the shop. I left
the case off to allow some tweaking if needed and because there is a bit of inductive heating in the case where the tank is
close to the metal, a cleaner tank setup will probably solve that. Copper stock on order!
Messing with a 1/2 bar at 10-20KW (10 cold, 18-20 hot)
Pulling apart a 1/2" bar with an induction heater at about 12 KW
More in the Flickr album of course...
9-12-2011: Here is the current schematic for the control board and a few photos of the first prototype board, good bye noisy
breadboard!
The small breadboard on the side was for testing an active filter/amplifier for mains current sensing (which is a pure sine
wave with Fo embedded in it) that is currently using a ratiometric hall effect sensor: ACS756SCA-100B. There were a few
other tweaks and additions I made after the board was fabricated as with most prototypes, but the schematic is updated.
Also it now supports small controlled fusion reactions. ;)
8/24/2012: Ok it's been a while since my last update, these things take time to create and well time is money. I received
the hall effect sensors (Allegro's ACS758ECB-200B-PSS-T) and have those hooked up to monitor mains current so I can
implement current limiting and power factor correction. These are very easy to use, the output is ratiometric to Vcc so it
remains accurate in a noisy environment and with temperature fluctuations.
The main reason for current monitoring was to be able to implement some form of current limiting. At the moment I am using
a simple zero point detector circuit to signal to the uController the beginning of an AC cycle. A time delay is then imposed
before reading the current with an ADC channel to ensure that the reading is taken at the peak of each cycle.
2mS Scale
Top trace: Top half of the 20V-peak AC on the low voltage power supply
Bottom trace: 5V squared representation of the mains AC inverted
So using falling edge detection to fire an interupt in the uController we can now measure the current at any phase angle on
the positive current slop.
1mS Scale
Top trace: Top half of the 20V-peak AC on the low voltage power supply
Bottom trace: 5V test pulse generated 4mS after the beginning of the positive going AC slope putting the test pulse roughly at
the peak of the half cycle
Shown below is the 240VAC waveform along with the mains current waveform. Since we are using a rectifier and a filter
capacitor we have this horrible non-linier current wave form. To measure the peak current we need to sample it at exactly
2mS into the positive half cycle. We can not simply cut off the bottom of the current waveform and smooth it with a low pass
filter since the waveform is non-linier. Doing so would give us an average current reading, but I am interested in the peak
current. This is where some reading up on Power Factor would be good if you do not already understand the benefits of
having a unity power factor.
Power factor on Wikipedia

Power Factor Basics <-- very good one
2mS Scale
There was a problem with measuring the current at a set phase angle, depending on the load the current waveform can shift
or change shape entirely as seen below.
2uS Scale
120VAC waveform along with the mains current waveform. This is a better power factor than running on 240V at higher
power levels but still below .80.
So I need to measure the current at any point from 0-90 or 0-4mS from the positive slop trigger point. I decided to run the
ADC continuously after triggered by the falling edge of the inverted square AC waveform, keeping track of two values. 1: the
highest current value read since the beginning of this phase and 2: the average current value since the beginning of this
phase. The ADC keeps running until the average level begins to drop, a 5 amp drop was a good point to avoid prematurely
stoping the ADC due to fluctuation. This means the zero point detector is no longer needed for current reading, but I still have
something else in mind that will require it later... active power factor correction.
Power factor is a big deal when you are drawing a lot of current. Say running at 240VAC your peak current is 100A but your
current wave form is non-linear, you have a lot of wasted power or KVAR. If your power factor is .75 then then your true
power or KW is only 18,000, the KVAR is 6,000, and the total KVA is 24,000. Your machine is making use of 18,000 watts of
power or 75A but your breaker, rectifier, and filter cap all need to be able to handle 24,000 watts or 100A. If you could bring
your power factor closer to unity or 1 then your reactive power (KVAR) to true power (KW) would be zero and the current
used in the system would equal the current supplied to the system. So no energy would be wasted as reactive power.
There are many ways to go about correcting power factor depending on if you have an inductive, capacitive, or non-linear
voltage to current phase relationship. The method I had chosen, although it would require a fairly large inductor was a buck-
boost type which to put it simply uses a switch to short the rectifier output across an inductor. The inductor holds a charge
that is then released back into the filter capacitor through a diode. The switching rate is varied to force the capacitor to draw
charging current in phase with the AC mains. Not a terribly complex idea and not complex to implement. But it does require
another switch either MOSFET or IGBT since the switching rate is still fairly low which means another driver. And it requires a
large inductor to store energy and a diode to direct the flow of that energy. It will also require uProcessor time to read the
current waveform and adjust the pulse rate to correct as needed, or a stand alone buck-boost power factor correction chip
which will require another handful of passive components. In short I'm trying to keep this project simple and cost effective but
still with incorporate some valuable features like power factor correction.
This lead me to start at the root of the problem (which is why it has been a while since my last update). What causes bad
power factors. A lightbulb which presents a purely resistive load on the AC mains has a perfect power factor of .98 to 1.
(Some stray inductance here and there, and probably a very small amount in the filament coil.) But nearly perfect by any
measure. So what is causing my big amp sucking DC power supply to have such a crap current waveform. The rectifier itself
doesn't draw any current or affect current draw of the load, hook one up to AC and you get 120Hz out. Hook a light bulb up to
that and you still get a power factor of 1.
AC Mains
Rectifier output (Inverter input) No Load / Load
Hook a filter capacitor up to that same circuit and bam, the power factor drops to about .70. This is because the capacitor
does not re-charge in phase with the voltage. Rather the current begins to rise early in the phase and peaks just before the
peak of the voltage so the current leads the voltage. Any capacitive reactance causes current to lead voltage. We could
counter act that capacitive reactance with inductive reactance, similar to what is happening in the tank circuit at resonance.
But we have the same problem here as we did trying to read the current at the peak of the waveform, depending on the load
that the IH is drawing the effect of capacitive reactance varies because there are other factors involved besides a simple
XL/XC circuit, so we would need to vary the inductance. Again requiring the need to read the complex waveform and adjust.
Let's go back to the light bulb hooked up to the AC mains through a rectifier with no filter capacitor. Why can't I do that with
the induction heater? Rather than a feeding a fixed DC voltage of 340V (240 x √2) to the IGBTs and getting a consistent
square wave output of pulsed 340V we feed 120Hz 340V peak into the IGBT inverter and the output is a 120Hz envelope
containing the resonant high frequency component. Well I say I can do that. There can be issues with under voltage IGBT's
turning on from an off state but since we are pulsing them at a frequency much higher than the frequency of the input voltage
this effect is non-existant or does not affect IH operation at least.
Power Factor reading on a Kill-a-Watt meter (While running on 120V about 10A)
240VAC mains input and current waveforms
Same as above but zoomed in on the high frequency resonant component of the current waveform
Inverter drive Fo and mains current waveform
Inverter output showing the resonant component Fo inside of the 120Hz envelope
Another feature I added was soft starting and stopping of the inverter Fo by ramping the PWM output feeding the VCO from
15V (Max VCO Fo) down until a resonant lock is achieved, and when the stoping the IH the VCO is ramped up from it's current
setting back to VCO max be for disabling the PLL VCO using pin 5 of the PLL. This gives a nice smooth start and stop of the
inverter with no bucking or large in-rush current.
So far I have not been able to find any negative side effects in running the inverter like this, only one big positive. Which is
25% less current draw while still maintaining the same output power both by measurement and by results.
1/2 Bar white hot and sparking in 10 seconds from cold. Melted in half at about 12 seconds.
In this video I pulse the IH on and off to keep the metal from just melting and falling off but keep it hot enough to burn it
away. I am going to add a code to allow the user to change the maximum current so pulsing to do this type of heating will not
be necessary.
Melting 1/2 carbon steel
Time for some fun:
Penny Fire:
Zinc has a fairly low ignition temperature, seen here is the zinc oxide left behind from a penny fire! I had a vacuum ventilating
to outdoors for this. I would have taken a picture of the fire but I was to busy making sure it was contained. It was a brilliant
white (similar to burning magnesium) with a ting of green. Out of the fire spewed long strands of smokey blue zinc oxide.
Another way to use the work coil
Quickie furnace cement crucible
Molten zinc in a crucible and the effect of the magnetic field on the zinc.
Molten Al, Cu, Zn alloy
Cooled Al,Cu,Zn alloy
Alloy: 75% Al - 20% Cu - 5% Zn : This ended up being a very interesting alloy, with a dark sheen and heavy feel, very brital
even though it was cooled slowly and has a beautiful crystalline structure.
Alloys of Al Cu and Zn are very common and among some of the hardest and lightest known to man. With a little precipitation
hardening this one would be much less brittle but it has much more copper than most alloys of this type to be useful for
much.
8/9/2012: I've migrated away from the MOSFETs to IGBT's using a simple driver setup, TC4421A/22A's driving a P0585NL
gate transformer which is controlling the gates of 4 x 30W discreet MOSFETs which are in turn driving a custom wound
1:1:1:1:1 gate transformer that can handle about 30 watts to drive the IGBTs directly. I chose to go ahead and do this before
working on the current limiting for two reasons. One because IGBT's will be used in the final design so it has to happen
anyway and two because I'm waiting on some single IGBT blocks for the current limiting circuit. I'm not going to use SCR's
like originally planned. I'm either going to detune the tank or use an IGBT to PWM the the DC bus output between the rectifier
and filter cap.
Water block construction:
IGBT setup on water block with the 3 Phase rectifier, filter cap, snubber cap, and bus connections:
New IGBT inverter mounted:
IGBT driver test setup
Currently I'm running two 580V 3.75uF Eurofarad tank capacitors with a .864uH work coil for an uploaded Fo of 62.5Khz.
Unloaded this setup pulls 50A when feed with 120VAC single phase and 125A when feed with 240VAC single phase. With 200A
IGBT's I won't be trying it on 3 phase.
Videos:
Testing 1/4" square on 120V peaking at about 35A Sparkling white hot in about 25 sec
First Shop Test of the Microcontroller/PLL Controlled Induction Heater
1/4" square bar @ 25KVA

1/2" round bar @ 25KVA
7/30/2012: Over the weekend I got the resonant control working with the micro controller and PLL and changed to a larger
coil (4 uH) which lowered the resonant frequency to around 41KHz. I still need to do some work on the coupling transformer,
I don't have an issue with the wires heating just the toroid cores.
7-30-2012: I had a noisy ground issues that was causing the uProcessor to reset when the unit hit about 12 amps of current
draw from the mains but solved it last night when I rearranged the test setup so that the control lines were all leading away
from the tank. I also removed the variac and hooked directly to a 30A circuit breaker through 6AWG wire. With this setup the
unit draws about 20A with a cold work piece and 30 to 32 past curie.
Something else interesting is that I no longer seem to have a problem with the toroids in the coupling transformer heating up.
This was after a 5 minute run at 3000VA. Will take a closer look at this later.
The next addition to the unit (after I complete the current sensing circuit and code) will be to replace the MOSFETs with IGBT
bricks (200 or 400A). My brothers original power requirements were a bit limiting but he now has available a 240V 60A circuit
so I can up this to a 15KW unit.
7/25/12: So it's been a while since my last update, I tend get caught up in the process and don't make time to document
my progress. Once it's complete I'll have a nice summary of the whole project. Since the last update I made and stuffed an
inverter board. This board was initially just for testing so I could complete the control logic and work with the basic signals
that are present in this type of IH. Well I wasn't happy with it. I had trace heating at higher power levels and and melted
solder resulted in a flash over from tank output to ground taking out a few components near it's path. I redesigned the
inverter board routing the HV manually on larger bus lines, seperated the HV from LV control, and added some latch up
protection on the now larger TO-220 drivers (from SOIC-8). I also made the inverter ground and LV ground connection
optional and clearly defined. All signals look beautiful and I can safely run at 15Amps (off of 120V mains using the voltage
doubler power supply) for long periods using the now water cooled MOSFETs. Even with the cooling water around 90-95
degrees F the FETs hover around 115-130 degrees when pulling 15A at resonance.
Flash over:
New inverter board, water block for bridge and MOSFETs, coupling tx (trying different toroids and wire), tank setup (removed
loop intended for current balancing an MMC), terminal strip for connections.
Test setup with Inverter logic drive in, Inverter current out, and tank voltage out. Will get some cleaner pics up as well as all
the scope tracings.
New Inverter (V2.1):
Updated eagle project files for the inverter: ]ih-inverter.zip[/file]
As always there are more pics in the Flicker album not shown here. Since these pictures I have removed one of the tank
capacitors and raised the work coil inductance slightly, the resonance frequency is still around 65KHz. More to come soon on
the PLL/uController resonance lock.
7/2/12: Completed initial schematic and board design for the Inverter Power Supply, Low Voltage Power Supply, & Inverter.
All control logic will remain on a breadboard until I work out how I want to control resonance, manage power, and what needs
monitoring. I'll make the boards on the 5th and stuff them on on the 6th when the last of the components arrive. That leaves
the weekend for the fun part, putting it all together and making it work!
Images and Eagle project files:]ih-power-inverter.zip[/file]
6/28/12: Bonded tank cap mounts to the tank cooling pipes and mounted the caps. A little No-Ox on the copper plates
between the caps to keep the connection clean. The brackets are made from 1/16" rigid coper and are short to allow the
capacitors to dissipate heat via the cooling water running through the pipes just below them.
6/27/12: Assembled the first coupling transformer (will use litz wire when it arrives), and capacitor mounting brackets for
the Eurofarad tank caps. Working on a phase monitoring set up to possibly eliminate the PLL. Basically I'm using a comparator
to turn the wave form of a current transformer (at the output of the inverter going to the coupling transformer) into a square
wave, changing states at the zero cross points. This is fed into one port of the uP. Another comparator set up connected
across the tank capacitor sends a similar square wave to the uP, this one shows the phase of the voltage across the capacitor.
Since we know that the current and voltage are in phase in the tank at resonance we can use these inputs to determine if we
are at resonance and if not which way to tune. The comparators outputs are shown in the photo below, I on top and E on
bottom. I'm not sure yet if I want to generate the inverter driver frequency with a uP interrupt or a VCO of some type, we'll
see. I'll have schematics and results up here as soon as I complete them.
6/23/12 - 6/25/12: Built the PLL/uProcessor circuit on a bread board to test and work out a final schematic design for the
resonant frequency range needed. (Currently 45-100KHz) - Received lots of toroids, caps, and other fun stuff, most of the
parts that I don't have in stock are here now.
6/20/12: Received rectifiers (1000V 50A) and caps for HV supply. Wired up the HV multiplier power supply for testing. AC
IN:DC OUT = about 1:2.85 so 120VAC in yields about 340VDC out.
6/16/12 - 6/18/12: Obtained the remaining copper parts needed to assemble the tank. Cleaned out an old ATX computer
case and modified to work as a case for the Induction heater. Fabricated and mounted working coil and internal plumbing for
tank capacitor mounting, coupling transformer mounting, and water cooling. Most of the parts will be arriving this week form
Digikey, Mouser, Newark, OnlineComponents, AliExpress, and of course eBay
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Dr. ISOTOP Tue Jun 19 2012, 04:54AM
How are you planning to control power? Bus voltage control, phase shifting the legs, detuning, pulse-skipping?
Registered Member #2919

Joined: Fri Jun 11 2010,
06:30PM
Location: Cambridge, MA
Posts: 652
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Josh Campbell Tue Jun 19 2012, 05:30PM
I'll most likely adjust the phase angle before the HV bridge rectifier using large Eupec PowerBlock SCR's:

Joined: Sun Jun 10 2012,
10:15PM
Location: Missouri - USA
Posts: 119
Other options I will want to try are making a fully-controled SCR bridge rectifier in place of the standard one. Or making a
variable tap coupling transformer.
Did you ever incorporate any type of power control into yours, have any suggestions or pointers?
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Dr. ISOTOP Tue Jun 19 2012, 08:33PM
2bytes wrote ...
I'll most likely adjust the phase angle before the HV bridge rectifier using large Eupec PowerBlock SCR's:

Joined: Fri Jun 11 2010,
06:30PM
Location: Cambridge, MA
Posts: 652
Other options I will want to try are making a fully-controled SCR bridge rectifier in place of the standard one. Or making a variable tap
coupling transformer.
Did you ever incorporate any type of power control into yours, have any suggestions or pointers?
I had a 4-tap transformer to control power for different work piece materials, and I detuned the driver for finer control. Its
not good for the bridge, but I was using watercooled CM400's, which dealt with it fine.
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Dr. Dark Current Sat Jul 14 2012, 10:11AM
Remember to use an inductor if you are controlling a capacitive load with a SCR.

Joined: Sun Feb 12 2006,
03:36PM
Location: Czech Rep.
Posts: 3384
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Josh Campbell Wed Jul 25 2012, 07:32PM
Dr. Dark Current wrote ...
Remember to use an inductor if you are controlling a capacitive load with a SCR.
Definitely! But thank you for the reminder, sometimes I'm only reminded of subtle things like this AFTER catastrophic
component failure. I would like to actually cancel out any reactance using a boost type converter and correct the power
factor to 1 so the SCR's would only see a resistive load. But this is obviously not a major requirement in order for the IH to
work properly so it will probably be the very last thing I do, if I do it at al, for now denting above resonance works just fine.

10:15PM
Posts: 119
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Josh Campbell Thu Aug 09 2012, 11:30PM
I was really looking for a reason to use these SCRs in something but I don't think I want to use them just for the sake of
using them when driving an IGBT is so much easier and more flexible. I am going to test using an IGBT to PWM the DC bus
before the filter cap, will update with results soon. I do need to do some type of current limiting for sure since when
connected to 240V it pulls about 125 amps with no work piece to load it, which is about twice what my brother has available
where this is going.
Joined: Sun Jun 10 2012, Check out the new vids, nothing new really (glowing stuff) but it does show the working PLL/uP tuning in use. I'll get some
10:15PM videos of the scope and the IH together while in use to show that part a little better. One button operation is really nice,
Location: Missouri - USA rather not say how many MOSFETs I blew tuning it manually during testing. :)
Posts: 119
Videos:
Testing 1/4" square on 120V peaking at about 35A (Sparkling white hot in about 25 sec)
1/4" square bar @ 25KVA
1/2" round bar @ 25KVA
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Gabriel35 Fri Aug 10 2012, 12:21PM
Pretty Impressive!!!
I hope that someday I can reach something like that!!!

Joined: Wed Aug 19 2009,
08:04PM
Location: Santa Catarina -
Brazil
Posts: 169
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Josh Campbell Fri Aug 10 2012, 11:19PM
Gabriel35 wrote ...
Pretty Impressive!!!
I hope that someday I can reach something like that!!!
Appreciate it Gabriel, once I finish the closed loop hall effect current sensing/limiting portion I'll get the rest of the
10:15PM
schematics and pcb layouts up along with descriptions and walk throughs. And after I refine the Atmel code I'll post it up
here as well. So far I've made the prototype boards but once I get a revised "final" version I'll have some made and
Posts: 119
probably post the rest of them up here just to offset the cost of ordering multiples. As of now it will have a low voltage ps
board and then all the control and driver circuitry on another board. With a possibility of having the driver circuitry on it's
own board as well, we'll see, there's not much to that part now that I'm using IGBT's.
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Jrz126 Sat Aug 11 2012, 07:05PM
Looks great.
Where'd you get the ferrite cores for the coupling transformer? What material is it?

Joined: Thu Feb 23 2006,
11:37PM
Location: Erie PA
Posts: 210
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Saturday, 19 October 2019 22:12

Main Menu Forums

Members Birthdays: Photos: Flickr - Induction Heater (updated as I progress)

Reactor Forge Induction Heater - 1/2" bar in 6" long coil

Radiator for 4 x 120mm

High RPM 12V Fan 120mm x 4

12V Power Supply

On another note, my brother sold his Habañero Chile Grande -

update: I think he deleted the video.

Work in progress UPDATE: COMPLETE:

Messing with a 1/2 bar at 10-20KW (10 cold, 18-20 hot)

Pulling apart a 1/2" bar with an induction heater at about 12 KW

More in the Flickr album of course...

Also it now supports small controlled fusion reactions. ;)

Power factor on Wikipedia

Rectifier output (Inverter input) No Load / Load

240VAC mains input and current waveforms

Inverter drive Fo and mains current waveform

Time for some fun:

Another way to use the work coil

Quickie furnace cement crucible

Molten Al, Cu, Zn alloy

Cooled Al,Cu,Zn alloy

Water block construction:

New IGBT inverter mounted:

IGBT driver test setup

First Shop Test of the Microcontroller/PLL Controlled Induction Heater

1/4" square bar @ 25KVA

New Inverter (V2.1):

Updated eagle project files for the inverter: ]ih-inverter.zip[/file]

Dr. ISOTOP Tue Jun 19 2012, 04:54AM

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Josh Campbell Tue Jun 19 2012, 05:30PM

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Dr. ISOTOP Tue Jun 19 2012, 08:33PM

2bytes wrote ...

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Dr. Dark Current Sat Jul 14 2012, 10:11AM

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Josh Campbell Wed Jul 25 2012, 07:32PM

Dr. Dark Current wrote ...

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Josh Campbell Thu Aug 09 2012, 11:30PM

Gabriel35 Fri Aug 10 2012, 12:21PM

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Josh Campbell Fri Aug 10 2012, 11:19PM

Gabriel35 wrote ...

Jrz126 Sat Aug 11 2012, 07:05PM

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