## Friday, January 12, 2024

How to make Powerful 3000W Induction Heater || How To Make Electric Oven

When you think of a way to heat up a metal object, you think of fire -right? Fire is an inefficient, old fashioned, and slow way to heat up metal objects. It wastes lots of energy as heat and creates lots of dirty smoke. Well, what if you could have a way to heat up metal objects that solves all these issues - it would be great, right? In this instructable, I am going to show you how to build a ZVS induction heater. This is a device that heats most metals using a ZVS driver circuit and electromagnetism. It is very efficient, produces no smoke, and can heat up objects like paper clips in a matter of seconds. The video below gives a demonstration of this induction heater in action, along with another type of instruction on how to build it.

Many of you who are reading this may be asking "What is a ZVS driver"? Well, it is an extremely efficient oscillator circuit that is able to create an extremely powerful electromagnetic field that heats up the metal. It is the backbone of the induction heater that this instructable is showing you how to make.

To understand how this power supply works, I will explain the different sections of it. The first section is the 24 volt power supply. The power supply needs to produce 24 volts at a current of 10 amps. For my power supply, I will be using two sealed lead acid batteries wired in series. The power is then fed into the ZVS driver board. The ZVS oscillator pushes and pulls current though a coil around the object that is being heated. This constant changing of the current's direction creates a fluctuating magnetic field. This induces many small eddy currents in the metal (refer to the diagram above). All of these currents are relatively high, and because of the low resistance of the target metal, heat is generated. According to ohms law, power converted to heat in a resistive circuit is P=I^2*R.

Now, the metal type of the object that is being heated is very important. Ferrous metals have a higher magnetic permeability, so they are able to harness more energy from the magnetic field. This allows them to be heated faster than other materials. Metals, like aluminum, have a lower magnetic permeability, so it takes longer for them to heat up. Things that have a high resistance and low magnetic permeability, like a human finger, will not be heated at all by an induction heater. The resistance of the material is also very important. If you have a higher resistance in the target metal, then less current will flow, so the power converted to heat gets exponentially smaller. If you have a metal with a lower resistance, then the current will be higher, but power loss will be lower due to ohms law. It is a little bit complicated, but because of the relationship between resistance and power output, the highest power output is achieved when the resistance of the object approaches 0.

The ZVS oscillator is the most complex part of this circuit, so I am going to explain how it works. First of all, when the current is switched on, it flows though 2 inductive chokes into each side of the coil. The choke is to make sure the circuit does not draw to much amperage on start up. The current also flows thought the two 470 ohm resistors into the gates of the two Mosfets. Now, because no component is perfect, one Mosfet is going to turn on first. When this happens, it hogs all the gate current from the other Mosfet. It will also draw the drain of that Mosfet that is on the ground. This will not only let current flow though the coil to ground, but it will also let current flow though one of the fast diodes form the other gate of the other Mosfet, locking it off. Because there is a capacitor in parallel with the coil, it creates a resonant tank circuit that starts oscillating. Because of this resonant action, the drain of the other Mosfet will swing back and forth in its voltage, eventually reaching 0 volts. Once this voltage is reached, the gate charge from the Mosfet that is on will discharge though the fast diode into the drain of the opposite Mosfet, effectivly shutting it off. With this Mosfet off, the other Mosfet has the opportunity to turn on. After this, the cycle repeats thousands of times per second. The 10K resistor is meant to deplete any excess gate charge on the Mosfet, because it is like a capacitor, and the Zener diode is meant to keep the gates of the mosfets at 12 volts or under so they do not explode. This high frequency high power oscillator is what allows metal objects to be heated.

To build this power supply, you will need a few parts, fortunately, most can be salvaged for free. If you have ever seen an old CRT TV laying on the side of the road, pick it up, because it has most of the parts needed for this project in it. If you want higher quality components, you can buy them at the LCSC online store. Click the parts to bring up the product links in LCSC.

How to make Powerful 3000W Induction Heater || How To Make Electric Oven

When you think of a way to heat up a metal object, you think of fire -right? Fire is an inefficient, old fashioned, and slow way to heat up metal objects. It wastes lots of energy as heat and creates lots of dirty smoke. Well, what if you could have a way to heat up metal objects that solves all these issues - it would be great, right? In this instructable, I am going to show you how to build a ZVS induction heater. This is a device that heats most metals using a ZVS driver circuit and electromagnetism. It is very efficient, produces no smoke, and can heat up objects like paper clips in a matter of seconds. The video below gives a demonstration of this induction heater in action, along with another type of instruction on how to build it.

Many of you who are reading this may be asking "What is a ZVS driver"? Well, it is an extremely efficient oscillator circuit that is able to create an extremely powerful electromagnetic field that heats up the metal. It is the backbone of the induction heater that this instructable is showing you how to make.

To understand how this power supply works, I will explain the different sections of it. The first section is the 24 volt power supply. The power supply needs to produce 24 volts at a current of 10 amps. For my power supply, I will be using two sealed lead acid batteries wired in series. The power is then fed into the ZVS driver board. The ZVS oscillator pushes and pulls current though a coil around the object that is being heated. This constant changing of the current's direction creates a fluctuating magnetic field. This induces many small eddy currents in the metal (refer to the diagram above). All of these currents are relatively high, and because of the low resistance of the target metal, heat is generated. According to ohms law, power converted to heat in a resistive circuit is P=I^2*R.

Now, the metal type of the object that is being heated is very important. Ferrous metals have a higher magnetic permeability, so they are able to harness more energy from the magnetic field. This allows them to be heated faster than other materials. Metals, like aluminum, have a lower magnetic permeability, so it takes longer for them to heat up. Things that have a high resistance and low magnetic permeability, like a human finger, will not be heated at all by an induction heater. The resistance of the material is also very important. If you have a higher resistance in the target metal, then less current will flow, so the power converted to heat gets exponentially smaller. If you have a metal with a lower resistance, then the current will be higher, but power loss will be lower due to ohms law. It is a little bit complicated, but because of the relationship between resistance and power output, the highest power output is achieved when the resistance of the object approaches 0.

The ZVS oscillator is the most complex part of this circuit, so I am going to explain how it works. First of all, when the current is switched on, it flows though 2 inductive chokes into each side of the coil. The choke is to make sure the circuit does not draw to much amperage on start up. The current also flows thought the two 470 ohm resistors into the gates of the two Mosfets. Now, because no component is perfect, one Mosfet is going to turn on first. When this happens, it hogs all the gate current from the other Mosfet. It will also draw the drain of that Mosfet that is on the ground. This will not only let current flow though the coil to ground, but it will also let current flow though one of the fast diodes form the other gate of the other Mosfet, locking it off. Because there is a capacitor in parallel with the coil, it creates a resonant tank circuit that starts oscillating. Because of this resonant action, the drain of the other Mosfet will swing back and forth in its voltage, eventually reaching 0 volts. Once this voltage is reached, the gate charge from the Mosfet that is on will discharge though the fast diode into the drain of the opposite Mosfet, effectivly shutting it off. With this Mosfet off, the other Mosfet has the opportunity to turn on. After this, the cycle repeats thousands of times per second. The 10K resistor is meant to deplete any excess gate charge on the Mosfet, because it is like a capacitor, and the Zener diode is meant to keep the gates of the mosfets at 12 volts or under so they do not explode. This high frequency high power oscillator is what allows metal objects to be heated.

To build this power supply, you will need a few parts, fortunately, most can be salvaged for free. If you have ever seen an old CRT TV laying on the side of the road, pick it up, because it has most of the parts needed for this project in it. If you want higher quality components, you can buy them at the LCSC online store. Click the parts to bring up the product links in LCSC.