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DIY Powerful Induction Heater instructables DIY Powerful Induction Heater by DIY KING 00 Induction heaters are definitely one of the most heater works and where you can source your material efficient way of heating metal objects specially to built one for yourself that looks like a professional ferrous metals. The best part about this induction one. heater is that you dont need to have a physical contact with the object to be heated. //www.youtube.com/embed/nlZl8YcKnLY There are a lot of induction heater kits available online but if you want to learn the basics of induction heating and want to built one that looks and performs Lets get started... exactly like a high end one then keep going through this instructable as I will show you how an induction https://youtu.be/nlZl8YcKnLY DIY Powerful Induction Heater: Page 1 Step 1: Concept Behind Induction Heating There are multiple methods of heating metals, one of instant heating and the effect is most prominent in which is induction heating. As the name of the ferrous metals due to its higher response to magnetic method refers the heat is generated within the forces. material by using electrical induction. You can get more in-depth overview on wikipedia : Electrical induction takes place within the material as the magnetic field around it changes continuously that https://en.wikipedia.org/wiki/Induction_heating results in the induction of eddy currents within the material that is placed inside the coil. Thus causing DIY Powerful Induction Heater: Page 2 Step 2: Printed Circuit Board and Components Since I am going to use a battery/ power supply that So I have designed an Oscillator circuit which gives us an output of 12v DC that is not sufficient produces AC output having square wave of nearly 20 enough to produce induction as the magnetic field KHz frequency. The circuit uses four IRF540 N- produced in the induction coil due to Direct Current is Channel mosfets to frequently switch the current in a Constant Magnetic Field. So the task here is to alternating direction. To safely handle larger amount convert this DC voltage into Alternating Current which of currents I have used a pair of mosfets in each will thus produce induction. channel. Since we are going to deal with higher amount of outstanding prices. I have ordered 10 PCBs for the currents thus a perfboard is definitely not a reliable induction heater and as the first order these guys are and of course not a neat option. So I decided to go offering all that in just 2$ including the shipment cost with a much reliable option that is a printed circuit at door step. board. That might sound like an expensive option but with that thought in mind I came across JLCPCB.com The quality is premium as you can see in the pictures. So be sure to check out their website. These guys are offering high quality PCB at DIY Powerful Induction Heater: Page 3 Step 3: Ordering PCB The process to order PCB is quiet simple. First you have to visit jlcpcb.com. To get an instant quote all you need to do is to upload your Gerber file for the PCBs and one they are done uploading you can go through the option given below. I have also added thee Gerber file for the PCB in this step so be sure to check it out. DIY Powerful Induction Heater: Page 4 Download http://www.instructables….com/ORIG/FH5/UMBH/JDYUVFJM/FH5UMBHJDYUVFJM.zip Step 4: Complementary Parts I have started to assemble PCB with small Fast), don't replace them with 1N4007 diodes as they complementary parts which includes resistors and a will blow up. D3 and D4 are zener diodes 1N821. couple of diodes. Make sure you place the right component at right R1,R2 are 10k resistors. R3 and R4 are 220Ohm place and also place the diodes in the right direction resistors. as shown on the PCB. D1 and D2 are UF4007 diodes (UF stands for Ultra DIY Powerful Induction Heater: Page 5 DIY Powerful Induction Heater: Page 6 Step 5: MOSFETs In order to handle large amount of current drains I spikes generated during high speed switching can decided to go with N-Channel MOSFETs. I have used easily jump upto those limits. So better to go with a pair of IRF540N MOSFET on each side. Each of even higher Vds ratting. them is ratted at 100 Vds and upto 33Amperes of continuous current drain. Since we are going to To dissipate excess heat I have attached aluminium power this induction heater with 15VDC, 100 Vds heat sinks to each one of them. might sounds an over kill, but actually its not as the DIY Powerful Induction Heater: Page 7 DIY Powerful Induction Heater: Page 8 Step 6: Capacitors The capacitors plays an important role to maintain a somewhere near 20KHz. desirable output frequency , which in case of induction heating is suggested at nearly 20KHz. This So I decided to go with WIMA MKS 400VAC 0.33uf output frequency is a result of the combination of non-polar capacitors. Actually I was unable to find induction and capacitance. So you can use an LC higher voltage ratting for these capacitors so latter frequency calculator to calculate your desirable they swelled up and I had to replace them with some combination. other non polar capacitors that are ratted at 800VAC. Its good to have more capacitance but always keep in There are two of them connected in parallel. mind that we have to get the output frequency Step 7: Inductors Since its hard to find high current inductors so I Its not necessary to get an exact size ferrite core but decided to built it by myy self. I have got some old the goal here is to get a pair of inductors that can ferrite core from old computer scrap with the following provide an inductance of nearly 100 Micro Henry. For dimensions: that I have used 1.2mm insulated copper wire to wind the coils such that each of them has 30 turns. This Outer dia: 30mm configuration is subjected to produce the required inductance. Make sure you do the windings as tight Inner dia: 18mm as possible since its not recomended to have more gap between the core and the wire. Width: 13mm After winding the inductors, I have removed the insulated coatings from both ends of wire so that they are ready to get soldered on to the PCB. DIY Powerful Induction Heater: Page 9 DIY Powerful Induction Heater: Page 10 Step 8: Cooling Fan In order to decipate the heat from the MOSFETs, I Since I am going to power this induction heater using have mounted a 12v PC fan just above the aluminium a 15VDC supply so I have added a 10 OHM 2watts heat sinks using some hot glue. The fan is then resistor to drop the voltage down to the safe limit. connected to the input terminals so that whenever you power the induction heater the fans will automatically power up to cool down the MOSFETs. DIY Powerful Induction Heater: Page 11 Step 9: Connectors for Output Coil To connect the output coil to the induction heating circuit I have made a pair of hatches onto the PCB using an angle grinder. Latter I have broken down an XT60 Connector to use its pins for the output terminals. Each of these pins push fit inside the output copper coil. DIY Powerful Induction Heater: Page 12 Step 10: Induction Coil The Induction coil is made using a 5mm diameter Make sure to wind the coil patiently as you might end copper pipe that is commonly used in air conditioners up bending the pipe causing a dent in it. Moreover and refrigerators. To wind the output coil perfectly I after you are done winding the coil make sure that have used a cardboard roll measuring nearly an inch there is no contact between the walls of two in diameter. I have given 8 turns to the coil which consecutive turns. created a width of coil to fit exactly onto the output bullet connectors. For this coil you need 3 foots of copper pipe. DIY Powerful Induction Heater: Page 13 Step 11: Power Supply To power this induction heater I am going to use a server power supply that is ratted for 15v and can deliver upto 130 Amps of current. But you can use any 12v source such as a car battery or a PC power supply. Make sure to connect the input with right polarity. DIY Powerful Induction Heater: Page 14 Step 12: Final Results As I powered this induction heater at 15v, it beings to dangerous as compared to other methods. draw nearly 0.5 Amp current without anything placed inside the coil. For the test run I have inserted a There are alot of useful things that can be done using wooden screw and suddenly it starts to smell like its this method of heating. getting heated. The current draw also starts to increase and with the screw fully inserted the coil it If you like this project then don't forget to visit and seems to draw nearly 3 amps of current. Within just a subscribe to my youtube channel for more upcoming minute it gets red hot. projects. Later I have inserted a screw driver inside the coil https://www.youtube.com/channel/UCC4584D31N9R and the induction heater heated it to red hot with uQ-aE... nearly 5 amperes of current draw at 15v which sums up to 75 watts of induction heating.
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