Building a 3kW Induction Heater ll Complete Build Guide

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Complete build guide to construct your own induction heater at home!
JLCPCB: $2 for 2Layer, 5pcs & $5 for 4Layer, 5pcs: jlcpcb.com/DYE
For components, hardware & more info, visit my website using the link below:
www.schematix.co.nz/forum/how...
Circuit Schematic Download: bit.ly/3dZCDEy
PCB Gerber Files Download: bit.ly/3uM0xJp
0:00 Intro
1:50 JLCPCB Ad
2:35 Build info
2:57 Making 1st set of inductors
4:26 PCB assembly
6:25 Bolstering PCB Traces
10:25 Making the workcoil
14:35 First power up
18:39 Making 2nd set of inductors
21:11 Workcoil design
22:00 Final thoughts
Information provided in this video is for educational purposes only.
If you attempt to recreate/replicate anything you’ve seen in this Or any other video, you’re doing so at your own risk.
Schematix

Опубликовано:

28 июл 2024

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Комментарии : 463

@johnmcclain3887 3 года назад

Good job, I enjoyed the layout, the specs on components, and the very accurate description of the solitary drawback, and the immediate fix, using two cores, and 12 gauge wire. The "scope" shows the exact impact of fixing the core saturation issue. Quite a professional job, I have a 300 amp tig welder in my shop without running water, and found two water cooled motorcycle radiators, Honda, if I remember right, am running a "vibrator pump" circulating water when the welder is on, and it's worked a decade with no problems. I run ten or twenty percent radiator fluid, and have a glass "ball" quart canning jar, with a hole drilled in the bottom and near the top on the side for copper tube epoxied in, for a visual flow indicator and fluid quality view. I leave about half the jar air, for expansion, but haven't ever gotten the water more than warm. Thanks for a great video, good sound electronics, and sound engineering.

@maarkaus48 3 года назад

Loved this and am going to do it. On a side note, loved the fly checking out your work. It always adds to the video to have an assistant

@Schematix 3 года назад

Awesome! Thank you!

@peterkutas1176 3 года назад

Great to hear you say 'Soldering' as opposed to 'Soddering' ! Cheers mate; keep up the great work...

@richardmg9 3 года назад

Nothing wrong with regional dialects having different pronunciations.

@AZStarYT 3 года назад

You haven't seen hot until you've seen a 400 kW power supply on a 5' dia. chiller-cooled coil, heating a solid graphite billet surrounded by a few hundred pounds of powdered graphite. It was white hot for several hours and took all next day to cool. We were making the first woven carbon-carbon composite rocket nozzles and nose cones at SAI (before it was SAIC) for the Air Farce and NASA. Our technique was used to make the Galileo Jupiter probe's heat shield.

@EvenTheDogAgrees Год назад

Actually, I've seen hot. In fact, I see hot every day. So have you, and everyone else you or I know. It hangs in the sky. 😉

@MikeSims70 2 года назад

LOL - when you pulled out the 2.0 model I audibly cheered I was so happy to see that! This is great, thank you for this video.

@johnny4eel 3 года назад

A variety of coil sizes matched more closely to the size of the object being heated will greatly increase the temperature of the object Once worked for a company turning out induction heated rivets and such and our coils were not much more than .25" clearance or less around the part...also our coils had water circulating them for cooling

@sempertard 3 месяца назад

Johnny, if you are still there...? Could you please elaborate a bit more on what you mean by "coil sizes matched more closely to the size of the object" ? How much margin between the outer edge of an object (assuming it's closely centered in the coil) and the inner edge of the coil would you recommend? Thanks...

@johnny4eel 2 месяца назад

@@sempertard These devices operated at extremely high voltage and the coils were actually copper tubing, round or square, and shaped for the area of the product that needs hardening with water flowing through the tubes constantly. For instance, one item we did a lot of was a rivet slightly larger than a human thumb and the part would go from ice cold steel to bright red hot in a matter of seconds and then quickly removed and dropped into the quench tank edit: another critical component was the requirement to never ever let the part touch the coil and for that we had heat resistant cloth and a paper-like substance I would say maybe keep experimenting with coil sizes and if more or less turns in a coil makes a difference and if you want to have a smaller gap then make sure to have something non-conductive between the coil and the part being heated edit-edit: the gap shown at 21:40 is perfect and to make it even more perfect could be to make a dedicated crucible coil and turn the lower coils such that they maintain that same perfect gap all the way down, making your perfect crucible coil even more perfecter :-) Also if you can shed enough heat from the copper tube with water you might see higher temps on the crucible EDIT, EDIT, EDIT: just came back from your channel looking for a video about how the coil worked after hooking up to water and if you've melted anything in the crucible...so, did it work ??

@joshuastewart7309 3 года назад

around the 21 minute mark you state the internal resistance of the metal decreases with heat - it is actually increasing in resistance. This can be explained by faradays law of induction. because a constant Bflux is changing, a constant EMF is applied to the metal causing eddy currents. and P = V^2/R. which tells us as resistance increases, P decreases.

@ichbineltyb3814 3 года назад

AFAIK it has to do with curie temperature

@qwadratix 3 года назад

@@ichbineltyb3814 That's right. It's not the electrical resistance that's at issue here. He's heating a FERROUS metal. That means it's highly magnetic and the main heating effect is not from eddy currents but the continuous, rapid reversing of the magnetic field is 'jiggling' the magnetic domains of the metal, causing friction and hence heat. BUT as the metal heats up and passes the Curie point, the magnetic response suddenly drops and that strong heating effect ceases.

@HighVoltageMadness 3 года назад

Correct i think he just got mixxed up

@richardamullens 2 года назад

I'm sure it just a slip of the tongue.

@thomassutrina7469 2 года назад

Worked for Sundstrand Aerospace in packaging Wild frequency input from a generator mounted to a jet engine gearbox and rectifies it and converts it to 400Hz 3 phase. One in production is a 30KW unit. So I was responsible for coming up with cooling and packaging. One suggestion is to attach that copper tubing to the circuit board for the straight buses for the capacitor bank. Attaching the inductor and semiconductors to the back side with the tubing will make it easier to use the liquid to cool the circuit. Just a thought.

@PeterShipley1 3 года назад

for larger inductor rings check out ham radio supply sources, large rings are used with lower frequency "HF' antennas.

@carlopiaia2144 Год назад

I used to work for Vulcan Forge in San Jose we used to forge 2 1/2 inch wrenches for Stanley and Proto in closed die forgings they forged at temperatures 2,300° f , and the induction heaters we used to use were also tuned to the coil, by connections made on the capacitor Bank, and every coil had deionized water going through it, and the billets were fed through it also had two rails liquid-cooled rails going down through the center of the coil, they were all made a stainless steel tubing. The forge had coils that can handle anywhere from a half inch material all the way up to 3 in Plus

@jimthvac100 3 года назад

Much better with the music by not making it too loud. Great video by the way!

@mevk1 3 года назад

Great heater/melter. Can't wait to see where this one takes you.

@ReadyUpGo 10 месяцев назад

You do good work. People could learn a lot about doing things well regardless of the projects themselves. Thank you for the effort.

@DolezalPetr 3 года назад

I started my own induction heater project, so far you are way ahead of my progress but your project is looking exacly as I want my project to look, amazing, cant wait for the water cooling system, that is goint to be very interesting

@Schematix 3 года назад

You can do it!

@ihtsarl9115 3 года назад

I am Nasuh Jaber

@pwdrhrn 7 месяцев назад

funniest ad I've seen in a long while! You rock.

@Emulation_Inflation 3 года назад

Omg 😲this is amazing! 👏 I wish I had the tools and money to do the projects you do.

@davenewland4675 3 года назад

Thanks for the video. Nice work! Just a note on why the temperature of the iron stops climbing. Resistance actually increases with heat but that is not the reason. At these power levels and frequencies the heating depends mostly on the magnetic properties of the workpiece. That is why a non magnetic workpiece does not heat as well. The magnetic workpiece actually becomes non magnetic when it reaches the curie point or curie temperature and does not react with the coil as strongly. For steel this is almost 1400 deg. F. You can mess around with a propane torch, a nail, and a magnet for a demonstration. Nickel and its alloys can do this at lower temperatures. Some magnetic coins are fun to play with (Canadian one dollar loonie).

@mevk1 3 года назад

Can't believe he said resistance decreases with temperature (never heard of superconductors buddy ?). At melting temp of iron its resistance has increased by 100%.

@Yp-ku4sy 2 года назад

Eddy current losses versus hysteresis losses. Hysteresis losses are typically the bulk of your heating effectiveness with these frequencies and these metals. For metals that don't benefit from hysteresis losses (aka "nonmagnetic"), you generally need higher switching frequencies as well. Take all of this with a grain of salt and confirm yourself, but these are my experiences working in a place that designed these.

@michaelarcher4643 2 дня назад

Brilliant. I will be trying to make 3 heaters with elongated pancake coils to achieve 9 kw heating on top and sides. Leaving the bottom open to get a workpiece in the contraption freely and prevent contamination of the coils by falling debris. Thanks again.

@LitchKB 3 года назад

Interesting video. I was also thinking about a generator-based induction heater - getting into the 10-15kW range with a 20kVA second-hand genset. Potentially (in the future, after that) getting into higher power than that (Which is completely foreign to me, and will require a whole different set of considerations and learning curves) - but "medium DIY induction furnace" is definately one of the paths my creative endeavours seems to always realign to. I'd also be very interested in (and likely forced to) migrating to PF-corrected supply architectures as well. Subbed.

@borisj4054 3 года назад

Using coaxial cable braid is the best for reenforcing copper pcb tracks. Sweat it onto the tracks with a liberal amount of solder. Flexible and easy to work with.

@DaveGagliardi 3 года назад

I would really like to see a video of you using the crucible! What a fantastic idea!!!

@piousminion7822 3 года назад

Given the equilibrium you mention at #21:05, how do induction furnaces melt iron? Building an induction furnace is what I'd like to do.

@electronresonator8882 3 года назад

I see, thank you, I will use your inductor oversaturation tips also the frequency, as reference to make similar inductor

@landroveraddict2457 3 года назад

Hi thanks for the video, in the first version of the inductor you counter wound the rings. What was the reason for just one continuous winding in this version?

@personalcontent4484 3 года назад

Thank you, this is fantastic... I am assuming that it heats up to 600-700 deg celcius? If one was to make the bus bar, would you solder it to the traces or just have it attached at correct points?

@user-tz3fd8hm4q 5 месяцев назад

Really nice job! I love how you explained and showed all the steps. Please make a video where you use the crucible.

@unknown-ql1fk 3 года назад

I made a similar induction heater and if you have them, use copper nuts and bolts to cut down on resistance at the joints

@the13thparish 3 года назад

For induction heating of non-ferrous metals, can one use a longer coil to increase the magnetic field strength to compensate for the low permeability of the material? I don't anticipate using the same diameter coil as yours though as this would make it rather unwieldy.

@marbles430 3 года назад

Very interesting project and you are obviously very skilled in electronics. I was drawn to your video by the possibility of using an induction heater for heating some smaller projects in my black smithing work. Firing up my gas forge to do small work is not very efficient. While very informative I want to mention that the steel was no where near a forging temperature. The steel needs to be between 1200- 1300 degrees centigrade to be effectively forged. That is an incandescing yellow heat when viewed in shade. I am confident that you, given your expertise would be able to design an induction circuit to meet the temperature criteria. Again a great video and information thank you for sharing it.

@drewrinker2071 2 года назад

Very well documented and laid out video. Have you went ahead with this project anymore and tried melting metal with the crucible? I'm very interested in trying this project myself if it can do this.

@gregwmanning 3 года назад

Welldone cant wait for the foundry video

@michaelowen9997 2 года назад

What would a 10kw or 20kw look like? Would the scale of the project and power requirements be worth the effort for serious forging and heat treating and larger scale foundry work(3-6 kilo copper)? Is melting steel in a crucible realistic? I’ve seen it in other videos, but they didn’t seem to be taking considerations for several of the variables you’ve discussed. Great video, thanks.

@travism9376 3 года назад

You deserve more subscribers mate thanks for the content. 👍🏻

@DizzyRonson 3 года назад

if you use copper brake line to reinforce the traces. you could also use the reinforcemet for watercooling the PCB. possibly.

@pontiacg445 3 года назад

I was going to recommend just bending the whole work coil to match the trace shape and directly soldering components to it through the PCB, but your idea would be a lot easier...

@abdeljalilpr2033 3 года назад

Nice project!! I want to see you melting cast iron and bronze using this induction heater

@ClownWhisper 2 года назад

Alternatively you can fill the tube with water and freeze it I found it this works better than using sand. Have made heat exchanger coils for condensers for large distillation purposes

@h3mix 3 года назад

Can the power on this induction heater be adjusted (lowered down) in case it is too high for PCB desoldering? If it damages the copper on PCB

@ihtsarl9115 3 года назад

Excellent video rarely found on this subject

@tailehuynhphat9570 3 года назад

Really cool project. I cant help but see that it resembles the Neo Armstrong Cyclone Jet Armstrong Cannon

@RobbeDoes41 3 года назад

Can you maby try to make a 8.8Kw one beceause im from belgium and the power lines support 220V 40A i just reaaally wanna see it.

@borisj4054 3 года назад

The weak link with these circuits are the resonant capacitors. So many required to obtain the capacitive value and series current capability. Pity those old high power valve transmitter caps are not more common. Capacitors out of the high frequency TiG welders are made by Miller and can take a lot of current. What is really needed are water cooled capacitors. Must try making some.

@hernerweisenberg7052 2 года назад

If i understood the function of this device correctly, the resonance is used to create a high frequency AC to drive the work coil? One could use a microcontroller instead to run the semiconductors at the desired frequency like in an switchmode powersupply and get rid of the coils and capacitors alltogether right? Perhaps only one big cap to smoothen the draw on the supply.

@fnleong1 3 года назад

Can I used this inducting heater to heat up my dryer which need only abt 60 deg C heat circulation

@ghian696 3 года назад

Great project! Thank you - I will be following up.

@akindiranolanrewajujohnson1873 3 года назад

Love it. Works great

@oxfd611 3 года назад

I am a paramedic and have very little knowledge about scratch building any electronics. But I must give credit when due, you are very neat and tidy when you build sir. I wonder if the engineers who built the Apollo rocket systems had to be just as creative, neat, and tidy?

@wantafastz28 3 года назад

How can you set it up so that the frequency Is adjustable?

@maverick9708 4 месяца назад

That board layout is absolutely phallic

@FilipMunk 3 года назад

what solder tip type did you use there @20:05? I think i have the same handle but I only have solder tips for SMD work on that.

@GnuReligion 3 года назад

I like those clip-on TO-220 heat sinks.

@ladjkaoz 2 года назад

great vid. how hot the water pump into the coil would get. Im looking to build this to heat up water that would be spray on to dry ice to create a low laid fog. Can you spread the turns of the coil to cover a larger area and get a wider hot spot. ?

@0redthunder0 3 года назад

Would the 2x16AWG vs 12AWG be better for skin effect reasons? Given this operates at around 40kHz

@Arek_R. 3 года назад

I already have 34A 100uH inductors, will these work with your 3kW design?

@user-cv4zs8up4s 3 года назад

Good evening, sir! Please tell me if it is possible to power your 3000W induction heater from a welding inverter? Thanks for the answer!

@justanpayne8748 3 года назад

can you use a variable voltage to control the temperature?

@MuhammadHanif-bx4pb 3 года назад

what about designing soft start for that royer oscillator? that beast create massive inrush!

@eliotmansfield 3 года назад

another tip - if you own one, pre-heat the pcb and copper wire with a heatgun which helps out when soldering with a undersized iron

@fizzyplazmuh9024 2 года назад

You must have triggered some Kens on another of your videos or else 79 people accidentally pressed the thumbs down button. Seriously, very nice board and very thoughtful design and follow-up to clean your sine. And I am grateful for the doubled toroid trick. When I lived in Houston there was a serious electronics surplus and salvage shop with buckets of fist sized toroids on down with maybe the largest being $10 to $15. I always swore to come back and raid their stock when I started prototyping induction furnaces but sadly I have moved too far away now and they don't do online sales. This was the type of place that used to have salvaged ships radars and teletype machines and copper vapor lasers and on and on. I could spend half a day drooling in the aisles.

@anthonynoneofyourbeeswax6083 6 месяцев назад

I love EPO too moved to out of town but still get over their when I can

@anthonynoneofyourbeeswax6083 6 месяцев назад

And if you need anything just let me know I can just grab it for you when I go I only live out past Katy Mills so it's like a 45 min to 8 hours trip depending on how dumb i10 or West Park are being

@cbnto 3 года назад

Curious, what would happen if you put a workcoil inside another workcoil. Would it double the heat effect?

@thinkfirst6431 3 года назад

You could use a sanding disk in a Dremel type tool to keep from having to fight the non-ferrous type metal clogging your file

@johncoops6897 2 года назад

Just rub the file with CHALK. Completely prevents chips from sticking... try it.

@chrismckoy3533 2 года назад

Thanks for this video, very helpful.

@jajan625 3 года назад

Hi, I build similar heater, but during 30sec of working cables (5cm of 6mm2) between PCB and coil are so hot that tin alloy melt and open circuit. Is cables length between coil and capacitors important for oscillations?

@WolferAlpha Год назад

A question needs to be asked, in case the total capacitance of the capacitor bank is smaller like between 100nF and 600nF, would it affect negatively or positively? (in this case what I want to know is if the resonant current or voltage increases or decreases or if it remains the same and only changes the resonant frequency)

@Ilsonvp Год назад

Olá amigo, tudo bem? Parabéns pelo vídeo. Gostaria de saber se pode me ajudar? Tenho interesse em construir, mas gostaria realizar algumas alterações. Sabe se posso substituir o IRFP4668 pelo IGBT IXXK200N65B4? Outra dúvida é: tenho um gerador DC de 15kw e 100V, sabe se consigo alterar o projeto seu projeto para aumentar a potência e utilizar essa fonte? Grato desde já.

@engineer323 3 года назад

Can I pull a fiberglass tube onto the reel?

@power-max Год назад

@Mikron this video is perfect and you should aim to have a build just like this.

@Bob22.09 2 года назад

Thanks for the great video. It was amazing. well done.

@gabewhisen3446 3 года назад

Finally an Induction heater build in a language that I can understand

@Frank-bh3cm 3 года назад

Could you use HSK shrink fit tooling?

@spykerhond7008 3 года назад

if you hold somthing with a metal bezel that heats up , it seems like nice heat controll on object

@Mr_Wh1 3 года назад

PC water cooling parts would be perfect for this project. It's 1/4 inch standard, comes in many sizes and uses standard PC fan sizes.

@DAVIDGREGORYKERR 3 года назад

Can you get your hands on 1KW IOR MOSFET MODULES to replace the MOSFETS that seem to get very hot something like the IXFN360N10T

@Gacha.Cupcake Год назад

Ji Is there anyway you can modify the board to give a center tapped output please?

@TorneariadoSidney 3 года назад

Muito bom amigo, parabéns.

@Buzzhumma 3 года назад

Thanks buddy for the learnings 👍🏻 i have been using a cheap inverter arc welder for a power supply . It would be good to see your adaptation of using one to power your zvs .

@557itsec4 3 года назад

pls if someone knows the exact name or kind of that pliers used, 3:20.

@eyadeyad6040 3 года назад

Hi can I have a pdf file or a bord file for the PCB please, because in My country I cannot get the PCB online so I have to do it myself and thank you for everything.

@user-ux3xt4ix6z 2 года назад

I want to know what is the maximum temperature emitted by this device? Is it possible to melt metals such as gold, silver and iron to become liquid?

@henryquispe1701 Год назад

good circuit I would like to know if this circuit could be used as a magnetic induction cooker or not?

@mohamedsabbah9898 2 года назад

thank you sir . Can I use IRFP4227 instead of IRFP4668?

@khalidmequaoui5256 3 года назад

Good work ! 👍

@frenchcreekvalley 3 года назад

How much DC current does your system draw at 50 volts with that graphite crucible in the work coil? You have given me a great idea for transferring more power to the work. That is:- Using 3/8" diameter copper tubing instead of the 1/4" or 6mm tubing that usually comes with the Chinese pre assembled units.

@ghostnuke1797 2 года назад

What sort of temps are you getting out of it? doesn't look like it gets hot enough for forging

@shanebrennan4657 2 года назад

Can you share any sources for learning about who these are designed and built? I would like to know how I can design and build my own for a specific size and power use-case.

@dee5556 Год назад

Is the main copper pipe coil in a resonance tank circuit with the capacitor bank?

@samsue1224 Год назад

Does the cooling water going in/out of the coil have a voltage on it? I’d imagine it would be live?

@bluestonebest1893 3 года назад

with that you can also melt metal in a vacuumed controled area.

@ClericChris Год назад

What's roughly the efficiency? Would a SiC power transistor be better at maximizing what you get with 2000w so you don't have to drop new service lines? I know they are expensive but it seems like half of that 3000w is going off as heat. I don't know enough to make the best choice or even if a kiln wouldn't be better.

@schulzcbs 2 года назад

Is it worth clear coating the copper pipes for additional safety?

@eyadeyad6040 3 года назад

Hi Can I have a pdf file for the PCB please 🥺 ?

@rinokentie8653 3 года назад

Interesting project!

@allmytacks 5 месяцев назад

thank you for the video. Can you please answer: what does the frequency of the inductor depend on? how to increase it from 40-50khz to 90?

@stephanc7192 Месяц назад

Amazing build and video

@jeraldboy 4 месяца назад

I really love this video and want to try building this. I really want to build this in very small coil I want heat a very small pipe on my brass instrument can you advise how I can do this without overheating the pipe just keeping it warm ?

@carnright 3 года назад

Love this! Is it possible to describe it in terms of Teslas or fractions of Teslas?

@scottk7613 2 года назад

I want to know if its possible to make a solar powered, to charge a battery to heat up the induction forge?

@ahmadzarara3149 Год назад

Can you tell me what I need to modify to make the circuit 7kw? Does it work for melting gold in this case as well?

@earendel2113 Год назад

beautiful

@ticktock8751 3 года назад

YOUR THE MAN!!

@user-zt4lv3gl2m Месяц назад

hi, how about make it the siplest one? i mean not using the additional power supply, but using directly from the power outlet, and supposed to be about 310vdc, please advise me wich needs to be modified? thanks. cheers.

@motherjoon 3 года назад

I’ve seen people use gate drivers in ZVS circuits to turn the half sinusoid mosfet gate drive of the regular ZVS into a a square-wave one to reduce switching losses. Maybe attempt that next time?