DIY induction stove for melting

Are you considering creative do-it-yourself projects in addition to modernizing your home’s heating system? For melting, look no farther than the realm of do-it-yourself induction stoves. Thanks to its accuracy and efficiency, induction heating has become more and more popular. You can now use this technology to melt metals and other materials in the comfort of your own home. This post will explain how to build a do-it-yourself induction stove for melting, which is an affordable and green way to meet your heating needs.

The process of induction heating involves producing a magnetic field that heats the material being heated directly. Because induction heating heats the material itself rather than the surrounding air, it is far more efficient than traditional heating techniques that rely on heating elements or flames. This translates into shorter heating times, more accurate temperature regulation, and less energy usage. Using this technology, do-it-yourselfers can design induction stoves that meet their own melting needs.

Although building your own DIY induction stove for melting may seem difficult, it is completely doable with the correct help and supplies. An induction heating coil is one of the essential parts you’ll need since it creates the electromagnetic field required for heating. Shaped to fit the container containing the material you plan to melt, this coil can be constructed from copper tubing or other conductive materials.

The power supply, which transforms standard household electricity into the high-frequency alternating current needed for induction heating, is another crucial part. Although commercial-grade power supplies are available, do-it-yourselfers can also construct their own circuits using easily accessible parts or recycle components from outdated electronics. When working with electricity, safety is of the utmost importance. Take the necessary safety precautions and seek advice from reputable sources.

Once the required parts are put together, building a housing for the induction coil and power supply is the next step in assembling your do-it-yourself induction stove. To ensure optimal performance and safety, proper insulation and ventilation must be provided. Once your induction stove is installed, you’ll have an adaptable tool for trying out different do-it-yourself projects, recycling scrap materials, and melting metals for casting. Your creativity and inventiveness are the only things limiting the possibilities.

Materials Needed	Steps to Build
Induction Cooktop	1. Purchase an induction cooktop.
Steel Container	2. Get a steel container to hold the metal for melting.
Graphite Crucible	3. Acquire a graphite crucible suitable for high-temperature melting.
Power Supply	4. Ensure a stable power supply compatible with the induction cooktop.
Heat-Resistant Gloves	5. Wear heat-resistant gloves for safety.
Fire Extinguisher	6. Have a fire extinguisher nearby for emergencies.
Setup	7. Place the steel container on the induction cooktop.
Prepare Metal	8. Place the metal to be melted inside the graphite crucible.
Initiate Melting	9. Turn on the induction cooktop and set it to the desired temperature.
Monitor and Stir	10. Monitor the melting process and stir the metal occasionally for even heating.

Literature

• Babat g. AND., Svenchansky a. D. Electric industrial stoves. – M. : Gosenergozizdat, 1948. – 332 p.
• Burak me. AND., Ogirko and. IN. The optimal heating of the cylindrical shell with the characteristics of the material dependent on temperature // Mat. Methods and physical.-fur. Fields. – 1977. – Issue. 5 . – WITH. 26-30 .
• Vasiliev a. WITH. Lamp generators for high -frequency heating. – l. : Mechanical engineering, 1990. – 80 p. -(Library of a high-frequency Termist;. 15). – 5300 copies. -ISBN 5-217-00923-3.
• Vlasov in. F. Radio Engineering course. – M. : Gosenergozizdat, 1962. – 928 p.
• Izumov n. M., Linde d. P. Fundamentals of radio engineering. – M. : Gosenergozizdat, 1959. – 512 p.
• Lozinsky m. G. Industrial use of induction heating. – M. : Publishing house of the USSR Academy of Sciences, 1948. – 471 p.
• The use of high frequency currents in electrothermia / Ed. A. E. Asso. – l. : Mechanical engineering, 1968. – 340 p.
• Asso A. E. Inducers. – l. : Mechanical Engineering, 1989. – 69 p. -(Library of a high-frequency Termist;. 12). – 10,000 copies. -ISBN 5-217-00571-8.
• Fogel a. A. The induction method of retaining liquid metals in a suspended state / Ed. A. N. Shamova. -2nd ed., CRECH. – l. : Mechanical Engineering, 1989. – 79 p. -(Library of a high-frequency Termist;. eleven). – 2950 copies. – .

The last edit to this page was made at 04:35 am on October 17, 2018.

Operating principle

The final option, which is most frequently utilized in boiler heating, has grown in popularity because of how easy it is to implement. The transfer of magnetic field energy to the coolant (water) is the fundamental working principle of an induction heating installation. In the inductor, a magnetic field is created. Vortex flows produced by a fluctuating current flowing through the reel convert energy into heat.

The induction heating installation’s basic working principle

Energy transfer causes the water that is supplied through the lower pipe into the boiler to warm up. The heated water then enters the heating system through the upper pipe. The pressure is produced by an integrated pump. The boiler’s continuous water circulation prevents overheating of the components. Furthermore, coolant is produced (at low noise levels) during operation, making it impossible for scale to build up on the boiler’s interior walls.

One can use induction heaters in a variety of ways.

Calculation of power

The induction furnace’s calculation starts with figuring out how much power the device has because the induction method of smelting steel is less expensive than comparable techniques based on the use of fuel oil, coal, and other energy sources.

The induction furnace’s power is separated into two categories: active and useful, each with a unique formula.

As the source data, you should be aware of:

• The capacity of the furnace, in the case considered, for example, it is 8 tons;
• The power of the unit (its maximum value is taken) – 1300 kW;
• current frequency – 50 Hz;
• furnace productivity – 6 tons per hour.

It is also necessary to consider the molten metal or alloy, which in this case is zinc based on the condition. The thermal balance of melting cast iron and other alloys in an induction furnace is a crucial point.

Power that is usefully transferred to liquid metal:

• Ropo = Woteor × T × P,
• Woteor is a specific energy consumption, it is theoretical, and shows overheating of the metal to 10s;
• P – the performance of the furnace installation, t/h;
• t is the temperature of the alloy or metal workpiece in the bathroom, 0c
• ROPO = 0.298 × 800 × 5.5 = 1430.4 kW.

• P = Rol/YouTherm,
• ROPO – taken from the previous formula, kW;
• Youngerm – efficiency of foundry furnace, its limits from 0.7 to 0.85, on average accept 0.76.
• P = 1311.2/0.76 = 1892.1 kW, the value is rounded up to 1900 kW.

The inductor’s power is computed at the last step:

• Rind = p/n,
• P is the active power of the furnace installation, kW;
• N – the number of inducers provided for the furnace.
• Rind = 1900/2 = 950 kW.

The efficiency and kind of inductor used in an induction stove determine how much power it uses to melt steel.

The components of the furnace

Therefore, it’s crucial to understand that the heating coil in an induction mini-fluff is its primary component if you’re interested in making one yourself. If you choose to do it yourself, all you need to do is use a 10 mm-diameter bare copper tube as an inductor.

Eight to ten turns and an internal diameter of 80 to 150 mm are used for the inductor. It’s crucial that the turns are separated by 5-7 mm and do not come into contact with one another. The minimum distance between an inductor’s parts and its screen should be 50 mm.

If you are going to an induction stove with your own hands, then you should know that on an industrial scale, water or antifreeze is engaged in cooling inducers. In case of low power and short operation of the created device, you can do without cooling. But when working, the inductor heats up greatly, and scale on copper can not only sharply reduce the efficiency of the device, but also lead to a complete loss of its performance. It is impossible to make an inductor with cooling independently, so it will require its regular replacement. It is impossible to use compulsory air cooling, since the fan housing located nearby with the coil will “pull” the EMP, which will lead to overheating and falling of the efficiency of the furnace.

The problem of induction heating of blanks made of magnetic materials

If an inverter for induction heating is not an auto generator, does not have a frequency auto adjustment scheme (FAP) and works from an external set generator (at a frequency close to the resonant frequency of the oscillatory circuit “inductor – compensating battery of capacitors”). At the time of introduction of the workpiece from the magnetic material to the inducer (if the size of the workpiece is quite large and commensurate with the size of the inducer), the inductance of the inductor increases sharply, which leads to a abrupt decrease in its own resonance frequency of the oscillatory circuit and its deviation from the frequency of the defining generator. The outline comes out of resonance with a deferred generator, which leads to an increase in its resistance and a abrupt decrease in the power transmitted to the harvesting. If the installation power is regulated by an external power source, then the natural reaction of the operator is to increase the supply voltage of the installation. When the workpieces are heated to the Curie point, its magnetic properties disappear, its own frequency of the oscillatory circuit returns back to the frequency of the assigning generator. The contour resistance is sharply reduced, the current consumption increases sharply. If the operator does not have time to remove the increased supply voltage, then the installation overheats and fails.
If the installation is equipped with an automatic control system, then the control system must track the transition through the Curie point and automatically reduce the frequency of the defining generator, adjusting it to resonance with the oscillatory contour (or reduce the supplied power if the frequency change is unacceptable).

The aforementioned does not apply if non-magnetic materials are heated. There is no need for a control system because the application of the non-magnetic workpiece essentially has no effect on the inductor’s inductance or the working oscillatory circuit’s resonant frequency.

It also does not significantly change the resonance of the working circuit if the workpiece is substantially smaller than the inductor.

Induction slabs

Article focus: Induction cooker

An electric kitchen stove known as an induction cooker uses induced vortex currents produced by a high-frequency magnetic field with a frequency of 20–100 kHz to warm metal dishes.

When compared to the TEN using electric stoves, this plate is much more efficient because less heat is used to heat the case, and there is also no acceleration or cooling phase (which is the time when energy that is not developed but not absorbed in the dishes is used).

Induction melting furnaces

Article focus: Tiger furnace with induction

Non-contact induction melting furnaces are electric furnaces used to melt and overheat metals. In these furnaces, heating happens as a result of vortex currents in the metal itself, either alone or in combination with other metals (if the crucible is not made of metal; in this case, the heating process is more efficient if the crucible is not made of metal).

It is used to obtain premium steel castings in factory casting workshops and precise casting and repair shops of machine-building plants. Non-ferrous metals, such as aluminum, brass, and bronze, and their alloys, can be melted in a graphite tiger. The induction furnace operates on the same principle as a transformer, with the metal housed in the crucible serving as both the secondary and primary windings. The primary winding of the transformer is a water-cooled inductor. Currents that flow through the metal and arise because of the inducer’s electromagnetic field cause the metal to heat up and melt.

The history of induction heating

Michael Faradey is credited with the discovery of electromagnetic induction in 1831. Both when the conductor moves within the magnet field and when the magnet moves and its power lines cross the circuit, the electromagnetic field is blocked. The circuit’s current is referred to as induction. Many inventions, such as the definition of generators and transformers that produce and distribute electric energy, are based on the Law of Electromagnetic Induction, which forms the fundamental basis of the entire electrical industry.

"The heat power released in the unit of the medium when the electric current is proportional to the production of electric current density by the power of the electric field" (Joule Law – the Law Lenza), was the quantitative evaluation of the thermal action of the electric current developed in 1841 by James Joule (and independently of Emil Lenz). The need for non-contact metal heating devices arose from the thermal effect of the induced current. The first induction current heating experiments were conducted on steel. Kolby in the United States.

The first channel induction stove for melting steel was constructed in 1900 at the Swedish city of Gysing by the "Benedics Bultfabrik" company. On July 8, 1904, in the reputable journal "The Engineer." the well-known, where Swedish inventor engineer f made an appearance. A. Kjellin discusses how he has evolved. One-phase transformers were used to power the stove. The metal inside the crucible, which was shaped like a ring, represented a secondary winding of a transformer that was fed with current at a frequency of 50–60 Hz. The melting process was conducted in this manner.

Launched on March 18, 1900, the first furnace had a 78 kW capacity and proved to be extremely unprofitable, as the swimming trunks could only produce 270 kg of steel per day. In November of the same year, a second furnace with a 58 kW capacity and a 100 kg steel capacity was built. 600–700 kg of steel were produced daily by the swimming trunks, demonstrating the furnace’s high efficiency. But the amount of wear caused by temperature changes was intolerable, and regular lining replacement decreased overall economy.

The inventor concluded that in order to maximize smelting productivity, a substantial portion of the melt must be left behind during draining. This prevents a number of issues, including lining wear. In some industries where large capacitance furnaces are used, the steel-smelting process that started out as known as the "swamp" is still in use.

In May 1902, a significantly advanced oven with a capacity of 1800 kg was put into operation, the drain was 1000-1100 kg, the remainder of 700-800 kg, the power of 165 kW, the performance of the steel melting could reach 4100 kg per day! This result of energy consumption 970 kWh/T is impressive with its efficiency, which is little inferior to modern performance of about 650 kWh/t . According to the calculations of the inventor from the power consumption of 165 kW, 87.5 kW took the loss, the useful thermal capacity was 77.5 kW, a very high full efficiency was obtained, equal to 47 %. Economicity is explained by the ring structure of the tie, which made it possible to make a multi -tight inductor with a low current and high voltage – 3000 V. Modern stoves with a cylindrical crucible are much more compact, require smaller capital investments, easier to operate, are equipped with many improvements over a hundred years of development, however, the efficiency is irrelevant. True, the inventor in his publication was ignored by the fact that electricity fee is not for active power, but for the full one, which at a frequency of 50-60 Hz is about half the active power. And in modern furnaces, reactive power is compensated by the condenser battery.

F. A. Kjellin, an engineer, created an invention that paved the way for the industrial canal furnaces used in the industrialized nations of America and Europe to melt steel and non-ferrous metals. Between 1900 and 1940, channel furnaces operating at 50–60 Hz gave way to contemporary high-frequency crucibles.

Heating system

Understanding masters use a basic welding inverter, which changes a constant voltage into alternating, to create an induction heater. In these situations, a cable with a 6–8 mm cross section is used; however, a 2.5 mm cable is not typical for welding machines.

These heating systems have to be of the closed type with automatic control. You also need air forces and a pump to ensure system circulation for additional safety. Such a heater needs to be kept at least one meter away from the floor, the ceiling, and wooden furniture.

Implementation in domestic conditions

Due to the high cost of the heating system itself, induction heating has not yet gained enough traction in the market. Therefore, a system of that kind would cost, for instance, 100,000 rubles for industrial enterprises and from 25,000 rubles and up for domestic use. Thus, it’s evident that people are interested in programs that let them build an induction heater at home themselves.

Boiler with induction heating

Based on the transformer

With its primary and secondary windings, the induction heating device is the primary component of the transformer-powered induction heating system. The primary winding will produce vortex flows that produce an electromagnetic induction field. The secondary, which is actually an induction heater and is physically implemented as a heating boiler housing, will be impacted by this field. The secondary short-circuit winding is responsible for the coolant’s energy transfer.

Transformer with secondary short-closed windings

The following are the primary components of an induction heating installation:

• core;
• winding;
• Two types of insulation- heat and electrical insulation.

The core is made up of two ferrimesty tubes that have been welded into each other and have varying diameters and walls that are at least 10 mm thick. On the outer tube, copper wire is wound in a toroidal fashion. Applying between 85 and 100 turns with the same amount of space between them is required. In a closed circuit, a variable current that varies over time produces vortex flows that heat the coolant and the core, causing induction heating.

Using a high -frequency welding inverter

An AC generator, an inductor, and a heating element make up the main circuitry of a welding inverter, which can be used to create an induction heater.

The generator is used to change the standard frequency into a higher frequency current with a power supply network of 50 Hz. This modulated current is fed into a cylindrical reel-inducer, which is wound with copper wire.

Use copper wire to wind

A variable magnetic field is produced by the coil, and its vector varies according to the frequency provided by the generator. A metal element is produced by magnetically induced vortex currents, which transfer energy to the coolant. You therefore carry out another induction heating scheme on your own.

Alternatively, you can make the heating element by hand using a section of polymer pipe and some chopped metal wire that measures 5 mm in length. Make sure there is no empty space when installing the valves from above and below the pipe by checking the filling density. The inducer pipe that connects to the generator’s terminals has approximately 100 copper wiring turns layered on top of it, as shown in the diagram. A fluctuating magnetic field creates vortex currents that cause induction heating of copper wire.

Note: You can build your own induction heaters using any design you like, but the most important thing to keep in mind is that you need to install sturdy thermal insulation; if not, your heating system’s efficiency will drop dramatically.

The advantages and disadvantages of the device

The vortex induction heater has a plethora of "pluses." This scheme is simple to self-manufacture and offers several benefits like increased reliability, high efficiency, low electricity costs, long service life, low breakdown probability, etc. P.

The metallurgical industry successfully uses units of this type, and the productivity of the device can be substantial. When it comes to heating the heat carrier, this kind of device competes confidently and competently with conventional electric boilers; the system’s water temperature rises to the necessary level fast.

The heater vibrates a little bit when the induction boiler is operating. Such a device is very rarely needed because this vibration shakes the lime precipitation and other potential pollutants from the metal pipe walls. Naturally, a mechanical filter should be used to shield the heating system from these impurities.

Using high-frequency vortex currents, the induction coil heats the metal (pipe or wire segments) inserted inside; contact is not necessary.

Maintaining continuous contact with water reduces the likelihood of the heater burning out, an issue that affects traditional boilers with heat exchangers rather frequently. The boiler operates so silently that extra sound insulation won’t be required where the device is installed, even with the vibration.

If the system is installed correctly, another benefit of induction boilers is that they hardly ever occur. The heater receives thermal energy from a contactless method, which accounts for the lack of leaks. With the help of the technology mentioned above, the coolant can be heated nearly to the point of steam.

This produces enough heat convection to encourage the coolant to move through the pipes in an efficient manner. Although it depends on the features and design of a specific heating system, in most cases the heating system won’t need to have a circulation pump.

A circulation pump may be required at times. The device is reasonably simple to install. However, you will need some experience installing heating pipes and electrical appliances for this.

However, there are a number of drawbacks to this dependable and practical gadget that must also be taken into account. For instance, the boiler heats the entire working area around it in addition to the coolant. Such an unit must have its own room, which must be cleared of all unnecessary items. An extended stay in close proximity to a functional boiler may also pose a risk to an individual’s safety.

Induction heaters require an electric source to function. The household alternating current network is connected to both homemade and factory manufacturing equipment.

The device requires electricity to function. The induction boiler is worthless in places where free access to this modern convenience is unavailable. Additionally, if there are frequent power outages, the system will be less efficient.

An explosion could happen if the device is handled carelessly.

The coolant will turn into steam if it gets too hot. The system’s pressure will consequently rise rapidly, beyond the pipes’ ability to withstand, leading to their failure. As a result, the device needs to have a pressure gauge at the very least, and ideally an emergency shutdown device, thermostat, etc., for the system to function normally. P.

All of these factors may cause an induction boiler built at home to cost much more. Even though the gadget is said to be nearly silent, this isn’t always the case. Certain models may continue to publish some noise for a variety of reasons. This kind of result is more likely for an independently made device.

Both homemade and factory-made induction heaters are designed with almost no wear parts. They are long-lasting and operate without a hitch.

Homemade induction boilers

The most basic schematic of the device that is gathered shows a section of plastic pipe with different metal components arranged in the cavity to form a core. This can be a ribbon with a diameter of 6 to 8 mm, a thin piece of stainless steel wire rolled into balls, or even a drill bit that fits the inside diameter of the pipe. It has fiberglass sticks adhered to the outside, around which a wire twisted to a thickness of one is wound. 5-1.7 mm of insulation for glass. About 11 meters is the length of the wire. One way to learn about production technology is to watch this video:

• The author worked well and his product undoubtedly works.
• No calculations on the thickness of the wire, the number and diameter of the turns of the coil were made. The winding parameters were adopted by analogy with the hob, respectively, the induction water heater will turn out to be not higher than 2 kW.
• In the best case, a home -made unit will be able to heat water for two heating radiators of 1 kW each, this is enough for heating one room. In the worst case, heating will be weak or generally disappeared, because the tests were carried out without a coolant duct.

Since there is no information available regarding additional testing of the device, it is challenging to make more precise conclusions. The following video illustrates another way to independently set up induction heating of water for heating:

The same induction hob’s coil generates vortex currents, which are then externally centered by the radiator made from multiple metal pipes. The following are the conclusions:

• Thermal power of the resulting heater does not exceed the electrical power of the panel.
• The number and size of the pipes were chosen by accident, but provided a sufficient surface for the transfer of heat that occurs from vortex currents.
• This circuit of the induction heater was successful for a particular case when the apartment is surrounded by premises of other heated apartments. In addition, the author did not show the installation in the cold season with fixing the air temperature in the rooms.

Watching the following video, in which the author attempts to install a similar heater in a different insulated building, is suggested as confirmation of the conclusions drawn:

Operating principle

The process of heating materials using electric currents that are generated by a fluctuating magnetic field is known as induction heating. Thus, the heating of products made of conductive materials (conductors) by inducers (sources of alternating magnetic field) is what this is.

The process of induction heating looks like this. An electric workpiece (metal or graphite) is inserted into the so-called inductor, which is made up of one or more turns of wire (usually copper). Strong currents ranging in frequency from several MHz to a dozen Hz are introduced into the inductor using a specialized generator, creating an electromagnetic field surrounding the inductor. Vortex currents are driven by the electromagnetic field within the workpiece. The workpiece warms up due to vortex currents and Juole Celsius.

The inducer is the primary winding of the ruthless transformer known as the "Inductor-Great" system. Precisely closed, the workpiece functions as a kind of secondary winding. Through the air, the magnetic flow between the windings is closed.

At a high frequency, the vortex currents are replaced by the magnetic field formed by them in the thin surface layers of the workpiece Δ (skin effect), as a result of which their density increases sharply and the workpiece is heated. The lower layers of the metal are heated due to thermal conductivity. Not current is important, but a high current density. In a skin-layer δ, the current density increases in E Once relative to the density of the current in the workpiece, while 86.4 % of the heat from the total heat release is released into the skin-layer. The depth of the skin-layer depends on the radiation frequency: the higher the frequency, the thinner the skin-layer. It also depends on the relative magnetic permeability of μ the workpiece material.

Its size ranges from several hundred to tens of thousands for iron, cobalt, nickel, and magnetic alloys at temperatures below the Curie μ point. μ is roughly equal to one for other materials (melts, non-ferrous metals, liquid fusible eutectic, graphite, electrically conductive ceramics, etc. D.).

Formula for figuring out the skin-layer depth in millimeters:

Where f is the frequency of the electromagnetic field produced by the inducer in Hz, and ρ is the specific electrical resistance of the workpiece material at processing temperatures, expressed as ohm · m.

For instance, the skin-layer depth for copper is approximately 0.047 mm at a frequency of 2 MHz, and for iron, it is approximately 0.0001 mm [].

As he absorbs his own radiation, the inductor heats up significantly while it is operating. Furthermore, he takes in heat from a red-hot workpiece. Utilizing copper tubes cooled by water, create inducers. Water is supplied under suction, which guarantees safety in the event that the inductor burns or experiences other depressurization.

Operating principle

Numerous metals and alloys can be heated at the induction furnace’s melting node. The following components make up the classic design:

1. Drain pump.
2. Water inducer.
3. Stainless steel or aluminum frame.
4. Contact platform.
5. Frying concrete.
6. Support with a hydraulic cylinder and a bearing knot.

Foucault’s vortex induction currents serve as the foundation for the action’s principle. These currents typically result in appliance malfunctions when used to operate appliances, but in this instance, they are utilized to heat the water to the proper temperature. When operating, almost all electronics start to get hot. This drawback of using electricity is when it is used to its maximum capacity.

Advantages of the device

The use of stove melting induction dates back only a short while. Production sites are equipped with a variety of equipment, including domain stoves and famous Martins. The following benefits of a comparable stove for metal swimming are as follows:

1. The use of the principle of induction allows you to make equipment compact. That is why there are no problems with their placement in small rooms. An example can be called domain furnaces that can be installed exclusively in prepared rooms.
2. The results of the studies indicate that the efficiency is almost 100%.
3. High swimming speed. The high indicator of the efficiency determines the fact that it takes much less time for the warming up of the metal, when compared with other stoves.
4. Some stoves during smelting can lead to a change in the chemical composition of the metal. Induction takes first place in terms of melt purity. Fucko"s currents created are heated by the workpieces from the inside, due to which the probability of falling into various impurities is excluded.

Since even a tiny concentration of an unrelated impurity can have a detrimental effect on the outcome, this benefit is the last one that decides how widely used induction furnaces are in the jewelry industry.

The circuit of the induction heater

Since the discovery of electromagnetic induction by Michael Faraday in 1831, a plethora of devices have been developed to warm water and other media.

Since people use this discovery on a daily basis in their daily lives:

• Electric kettle with a disk heater for heating water;
• Stove multicooker;
• Induction hob;
• Microwaves (plate);
• Heater;
• Heating column.

Additionally, the extruder (which is not mechanical) uses the opening. It was previously extensively employed in metallurgy and other sectors related to the processing of metals. The internal coil of the factory inductive boiler uses a unique core situated inside it to generate vortex currents for operation. Foucault currents vorthy are superficial, so it is preferable to use a metal hollow pipe as a core that the coolant element passes through.

Electric currents arise from the winding’s supply of alternating electronics, which results in the formation of an alternating electric magnetic field. This field modifies potential at a standard promotive frequency of 50 Hz by 50 times per second.

In this instance, the rumorf’s induction coil is designed to allow direct connection to an alternating current power source. It is very challenging to get the device to operate at 50 Hz because high-frequency electric currents, up to 1 MHz, are used in the production for such heating. Using a unique method for the required heat power, the device calculates the wire thickness and the number of wrapping turns for each unit individually. A robust, handcrafted device should work efficiently, warming the water passing through the pipe quickly without overheating.

Since organizations devote substantial financial resources to the creation and application of these products,

• All tasks are solved successfully;
• The efficiency of the heating device has 98%;
• Functions without interruptions.

Its maximum efficiency is accompanied by an inexorable attraction to the rate at which the medium heats up in the core. A proposed schematic of an induction water heater designed at the factory is shown in Fig. One unit of the Win brand, which is manufactured at the Izhevsk factory, is included in this scheme.

According to the manufacturer, this is a fairly significant period of up to 30 years, depending only on how sealed the housing is and is not harmed by the insulation of the wires.

You will need to invest a significant amount of money to take advantage of all these benefits, which the device offers 100% of the time. An inductor is a magnetic water heater, which is the priciest type of heating installation. As a result, a lot of masters choose to put together a super-economic heating unit themselves.

Equipment manufacturing rules independently

The current for such a product must match the power in order for the installation of induction heating to function properly (it should compose at least 15 amperes, if required, then you can more).

• The wire should be cut into pieces of no more than five centimeters. This is necessary for effective heating in a high -frequency field.
• The case should be no less in diameter than the prepared wire, and possess thick walls.
• A special adapter is attached to the heating network on one side of the structure.
• At the bottom of the pipe you need to put a net to prevent wire loss.
• The latter is needed in such quantities that it fills out the entire interior space.
• The design is closed, the adapter is placed.
• Then the coil is built from this pipe. To do this, wrap it with already prepared wire. The number of turns must be observed: at least 80, maximum 90.
• After connecting to the heating system, water is poured into the device. The coil is connected to the prepared inverter.
• The pump is installed for water supply.
• The temperature controller is mounted.

Consequently, the following factors will affect the induction heating calculation: length, diameter, temperature, and processing time.

The inductance of tires that lead to the inductor should be taken into consideration, as it may be significantly greater than the inductor’s own indicators.

High -precision induction heating

Because this heating is contactless, its principle is the simplest. The highest temperature range, where the hardest metals to smelt can be processed, can be reached through high-frequency impulse heating. In order to carry out induction heating, the necessary 12V (volt) voltage and inductance frequency must be created in electromagnetic fields.

This is achievable in an inductor, a unique device. It is powered by 50 Hz industrial power grid electricity.

For this, separate power sources like converters and generators can be used. An insulated conductor spiral, which can be wound around or inserted inside a metal pipe, is the most basic type of low-frequency device. The living room will eventually receive heat from the pipe that is warmed by walking currents.

It is uncommon to employ induction heating at minimum frequencies. the most popular method of processing metals more frequently than average. The magnetic wave in these devices is different in that it travels to the surface and fades there. Heat is produced from energy. Both elements need to have a similar shape for the best effect. Where is the use of heating?

High-frequency heating is used widely these days:

• For melting metals, and their soldering with a contactless method;
• Machine -building industry;
• Jewelry;
• The creation of small elements (boards) that can be damaged when using other techniques;
• Hardening of the surfaces of parts, different configurations;
• Heat treatment of parts;
• Medical practice (disinfection of instruments/tools).

You can find solutions to a lot of issues with heating.

What is induction heating

The working principle of the induction water heater.

The electromagnetic field-produced energy induction device functions. After being absorbed by the heat carrier, it is transferred to the premises:

1. Creates an electromagnetic field in such a water heater inductor. This is a multi -pin cylindrical wire coil.
2. Flowing through it, the alternating electricity around the coil generates the magnetic field.
3. Its lines are placed perpendicular to the vector of electromagnetic flow. When moving, they recreate a closed circle.
4. Vortex flows created by alternating current convert the energy of electricity into heat.

Induction heating uses thermal energy efficiently and at a slow rate of heating. As a result, the induction device raises the temperature of the water used in the heating system for a brief period of time.

Features of the device

The primary winding is connected to the electricity.

A transformer is used for induction heating. It is made up of two windings:

• external (primary);
• short -term internal (secondary).

In the transformer’s deepest section, vortex currents occur. The developing electromagnetic field is redirected to the secondary circuit by them. He serves as the water’s heating element in addition to fulfilling the role of the case.

The core gets heated first on its own, then the entire heat element, as the density of vortex streams directed towards it increases.

The induction heater has two pipes that are used to supply cool water and remove prepared coolant from the heating system:

1. The lower of them is installed on the inlet part of the water supply.
2. Upper pipe – on the supply site of the heating system.

What elements the device consists of, and how works

The structural components of the induction water heater are as follows:

Photo	Structural node
	Inductor.

It is made up of numerous turns of copper wire. The electromagnetic field is produced in them.

Inside the inductor is a metal pipe or cutting steel wire.

He converts regular home electricity to high-frequency electricity. An inverter from the welding machine may be utilized by the generator.

The heating system’s operation plan for an induction water heater.

Thermal energy is produced and transferred to water through the interaction of all the device’s components. The following is the operation scheme:

1. The generator produces a high -frequency electric. Then he transfers it to an induction coil.
2. That, taking the current, transforms it into an electric magnetic field.
3. The heater located inside the coil is hot from the action of vortex flows that appear due to the change in the magnetic field vector.
4. Water circulating inside the element heats up from it. Then it enters the heating system.

Advantages and disadvantages of the induction method of heating

The device is small and requires little room.

The following benefits come with induction heaters:

• high level of efficiency;
• do not need frequent maintenance;
• They take a little free space;
• Due to the vibrations of the magnetic field, the scale does not settle inside them;
• devices are silent;
• They are safe;
• Due to the tightness of the case, leaks do not appear;
• The functioning of the heater is fully automated;
• The unit is environmentally friendly, does not emit soot, soot carrier gas, etc.

The factory water heating induction boiler is shown in the picture.

The device’s primary drawback is the pricey factory models.

This disadvantage, though, can be mitigated if you put together an induction heater by hand. The readily accessible element unit is mounted, and their cost is minimal.

Advantages of using all types of induction heaters

Without a doubt, the induction heater is the best of all kinds of devices and has many advantages. This benefit consists of the following:

• It consumes less electricity and does not pollute the surrounding space.
• Convenient to manage, it provides high quality work and allows you to control the process.
• Heating through the walls of the chamber provides special cleanliness and the ability to obtain ultra -large alloys, while the melting can be made in different atmosphere, including inert gases and in vacuum.
• With its help, uniform heating of parts of any form or selective heating is possible
• Finally, induction heaters are universal, which allows them to be used everywhere, displacing obsolete energy -consuming and ineffective installations.

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Safety of inductor heater tips for professionals

You must be concerned about the induction heater’s safety because you made it with your own hands. In order to do this, adherence to the following guidelines is required, which raise the general system’s level of reliability:

1. In the upper tee it is worth placing a safety valve, which grows excess pressure. Otherwise, when the circulation pump fails, the core will simply burst under the influence of steam. As a rule, the scheme of a simple induction heater provides for such moments.
2. The inverter is included in the network only through the RCD. This device works in critical situations and will help to avoid a short circuit.
3. The welding inverter must be grounded, displaying the cable to a special metal circuit mounted in the ground behind the walls.
4. The case of the induction heater must be placed at a height of 80 cm above the floor level. Moreover, the distance to the ceiling should be at least 70 cm, and to other furniture items – more than 30 cm.
5. An induction heater is a source of a very strong electromagnetic field, so such an installation must be kept away from residential premises and aviary with pets.

The circuit of the induction heater

Many devices that heat water and other media have appeared since Michael Faraday first described the phenomenon of electromagnetic induction in 1831, which has greatly impacted our modern way of life. We use an induction hob, a slow cooker, and an electric kettle with a disk heater every day because these innovations were only made possible in our lifetimes. It was previously employed in the metallurgical and other metal-processing industries.

The effects of vortex currents on a metal core positioned inside the coil are the basis for the operation of the factory induction boiler. Since Foucault’s vorthery currents are surface-level, it makes sense to use a metal pipe as the core, through which heated coolant passes.

The induction heater’s operating principle

Currents arise from the winding receiving an alternating electrical voltage, which results in the formation of an alternating electromagnetic field. This field shifts potential 50 times per second at an average industrial frequency of 50 Hz. In this instance, the induction coil’s construction allows for a direct connection to the AC network. Attaining the device at a frequency of 50 Hz is difficult since high-frequency currents, up to 1 MHz, are utilized in industry for this kind of heating.

Water heaters use a specific method to calculate the amount of winding turns and copper wire thickness needed to produce the necessary thermal power for each unit. The device should function well, heat the water passing through the pipe quickly, and avoid overheating. Businesses spend a lot of money developing and implementing these products, which ensures that every task is completed successfully and that the heater operates at a 98% efficiency.

The rate at which the environment leaks through the core is extremely high in addition to its high efficiency. The factory-made induction heater’s operating scheme is depicted in the figure. Units bearing the renowned "Win" trademark, manufactured by the Izhevsk factory, employed a similar scheme.

The heater’s design

The manufacturers claim that the heat generator’s durability can last up to 30 years, and that it is solely dependent on the tightness of the body and the integrity of the insulation of the wire turns. The water heater is the most expensive kind of heating electrical installation, so it is necessary to pay a high price for all the benefits that these devices genuinely offer. Because of this, a few artisans started creating a device at home that they could use to heat the house.

DIY manufacturing process

The following implements are useful in the workplace:

• welding inverter;
• welding generating current by force from 15 amperes.

Additionally, a copper wire that is wound around the core body will be required. It will function as an inductor. In order to prevent twisting, the wire’s contacts are linked to the inverter’s terminals. The piece of material required to put the core together must be the proper length. The wire has a diameter of 3 millimeters and an average of 50 turns.

Various diameters of copper wire for winding

Let’s go on to the main topic now. A polymer pipe composed of polyethylene will be part of his role. This kind of plastic can tolerate quite high temperatures. Wall thickness must be at least 3 mm, and the core diameter must be 50 mm. This component serves as a caliber for hanging copper wire to create an inductor. The most basic induction heater is accessible to almost anyone.

You will see in the video how to set up induction heating independently for heating:

First option

After cutting the wire into 50 mm lengths, a plastic tube is filled. Use a wire net to clog the ends of the pipe to prevent it from coming out. Adapters are inserted at the ends of the pipe where the heater is connected.

The final copper wire wire’s case is where the winding is wound. You will need about 17 meters of wire for this purpose, as the pipe has a diameter of 60 millimeters and you must make 90 turns. 3.14 × 60 × 90, or 17 meters.

It’s critical to understand! As you examine the device to make sure it is working properly, pay close attention to the presence of water (coolant). If not, there will be a rapid melting of the device body. The pipeline is struck by the pipe.

The inverter and heater are connected. It is still necessary to add water to the device and turn it on. Everything is set!

The pipeline is struck by the pipe. The inverter and heater are connected. It is still necessary to add water to the device and turn it on. Everything is set!

The second option

This is a much easier option. A section of the meter that is straight and sized for the vertical portion of the pipe is chosen. Sandpaper should be used to remove all paint from it. Three layers of electrical fabric are also covering this portion of the pipe. An induction coil is wound with copper wire. The connection system as a whole is highly isolated. The assembly process is now finished and a welding inverter can be connected.

Wrapped in copper wire is an induction coil

It is advisable to familiarize yourself with the features of the factory products and study their drawings before beginning to manufacture a water heater yourself. This will assist in handling the initial data of equipment that is made at home and help to prevent potential errors.

The third option

This more complex method of creating a heater requires the use of welding. You still require a three-phase transformer in order to work. Two pipes, which will serve as the heater and core, must be welded into one another. On the induction body, the winding is wound. As a result, the device’s productivity rises and its small size makes it incredibly practical to use at home.

The induction body’s winding

There are two pipes that are welded into the induction housing for drainage and water supply. You must insulate in order to keep heat from escaping and to guard against potential electrical leaks. She’ll prevent the issues mentioned above and get rid of any noise that comes from the boiler while it’s operating.

Stock placement recommendations

There are differences between desktop and floor induction furnaces based on structural characteristics. Whichever option was chosen, there are a few fundamental installation guidelines that stand out:

1. When working equipment on the power grid, a high load turns out to be. In order to exclude the likelihood of a short circuit due to wear of insulation, a high -quality ground must be carried out during installation.
2. The design has a water cooling circuit, which excludes the probability of overheating of the main elements. That is why a reliable rise in water should be ensured.
3. If the desktop furnace is installed, then the attention of the stability of the base used should be paid.
4. The metal swimming oven is represented by a complex electric device, when installing which you need to follow all the recommendations of the manufacturer. Particular attention is paid to the parameters of the power source, which should correspond to the model of the apparatus.
5. Do not forget that there should be quite a lot of free space around the furnace. During operation, even a small melt in volume and mass can accidentally splash out of the form. At a temperature of more than 1000 degrees Celsius, he will cause irreparable harm to various materials, and can also cause fire.

The gadget has the potential to overheat while in use. For this reason, there shouldn’t be any explosives or flammable materials close by. Additionally, a fire shield ought to be included in the fire safety procedure.

Safety regulations

For heating systems, where induction heating is used, it is important to follow several rules in order to avoid leaks, loss of efficiency, consumption of electricity, accidents. . In induction heating systems, the presence of a safety valve for discharge of water and steam is necessary in case of failure of the pump.
Manometer and RCDs are required for the safe operation of the heating system assembled by yourself.
The presence of grounding and electrical insulation of the entire induction heating system will prevent lesion with electric shock.
In order to avoid the harmful effects of the electromagnetic field on the human body, such systems are best taken outside the residential area, where the installation rules should be observed, according to which the induction heating device should be placed at a distance of 80 cm from horizontal (floor and ceiling) and 30 cm from vertical surfaces.
Before turning on the system, it is necessary to check the presence of a coolant.
To prevent failures in the operation of the mains, it is recommended to connect a boiler with induction heating, made by yourself according to the proposed schemes, to a separate supply line, the cable section of which will be at least 5 mm2

It’s possible that conventional wiring cannot handle the necessary energy usage.

1. In induction heating systems, the presence of a safety valve for discharge of water and steam is necessary in case of failure of the pump.
2. Manometer and RCD are required for the safe operation of a heating system assembled by yourself.
3. The presence of grounding and electrical insulation of the entire induction heating system will prevent electric shock.
4. In order to avoid the harmful effects of the electromagnetic field on the human body, it is better to take away such systems outside the residential area, where the installation rules should be observed, according to which the induction heating device should be placed at a distance of 80 cm from horizontal (floor and ceiling) and 30 cm from vertical surfaces.
5. Before turning on the system, it is necessary to check the presence of the coolant.
6. To prevent failures in the operation of the power grid, it is recommended to connect a boiler with induction heating, made by yourself according to the proposed schemes to a separate supply line, the cable section of which will be at least 5 mm2. Conventional wiring may not withstand the required energy consumption.

Creation of complicated devices

Installing a TVRHA’s heating system yourself is more challenging, but it is only accessible to radio amateurs since a multivibrator system is needed to collect the data. Similar principles apply: the coil’s high magnetic field interacts with a metal filler at its center to create vortex currents that heat the surface.

Designing of TVHCs

As even a tiny coil can generate up to 100 A of current, you will also need to connect a resonating container in order to balance induction traction. There are two different ways that TVH can be heated in 12 V:

• targeted electric;
• network.

• targeted electric;
• network.

An hour can be spent gathering a mini tweeter in the first scenario. You can use such a generator anywhere, even without a 220 V network, as long as there are car batteries available for power. It can warm up to high temperatures required for small operations, such as heating knives and screwdrivers to a blue color, but it is obviously not strong enough to melt metal. In order to make it, you must buy:

• Field transistors BUZ11, IRFP460, IRFP240;
• car battery from 70 a/h;
• High -voltage capacitors.

Because of the metal’s resistance, the power source’s 11 A current during heating drops to 6 A. However, thick wires are still required to withstand 11–12 A of current in order to prevent overheating.

Although the second plan, which uses an IR2153 driver to install heating through induction, is more complicated, it is more practical to create a resonance using a 100k regulator. Controlling the circuit requires a network adapter that has a 12 V voltage. With the use of a diode bridge, the power component can be connected directly to the main network at 220 V. The frequency of resonance is 30 kHz. The ensuing components will be necessary:

• ferrite core 10 mm and throttle 20 turns;
• a copper tube as a hub coil of 25 turns per mandrel 5-8 cm;
• capacitors 250 v.

Vorthy heaters

A straightforward plan can be used to assemble a more potent installation that has the ability to warm the bolts to yellow. However, transistors will release a significant amount of heat when they are operating, so radiator installation is advised. A throttle, which can be borrowed from any computer’s power supply, and the following extra supplies are also required:

• steel ferromagnetic wire;
• Copper wire of 1.5 mm;
• Field transistors and diodes for reverse voltage from 500 V;
• zener diode 2-3 watts with a calculation of 15 V;
• Simple resistors.

The number of turns that the wire is wound on the copper base ranges from 10 to 30, depending on the desired outcome. The assembly of the plan and the setup of the heater’s coil-output, which is made of roughly seven turns of 1.5 mm copper wire, come next. It first connects to the circuit, then to the power source.

Expert welders with experience operating a three-phase transformer can further boost the device’s efficiency while minimizing its bulk and weight. In order to accomplish this, it is required to boil two pipes in order to carry out the supply and removal of coolant into the case following the winding, as well as to cook the bases of two pipes, which will function as a core and a heater.

It is advised by masters that this design be completed in order to prevent heat and current leaks. Additionally, it will lessen noise while in use.

Advantages and disadvantages

After understanding the induction heater’s working principle, you can evaluate its advantages and disadvantages. It can be assumed that he has far more benefits than drawbacks given the widespread use of heat generators of this kind. Among the most notable benefits are the following:

• Simplicity of design.
• High efficiency of efficiency.
• Long life.
• Small risks of device breakdown.
• Significant energy savings.

You won’t have any trouble selecting the induction boiler for a particular building’s heating system because its performance indicator spans a large range. These gadgets are a strong rival to conventional boilers since they can swiftly heat the coolant to a predetermined temperature.

There is a slight vibration that occurs while the induction heater is operating, and this vibration helps to shake scale out of the pipes. You can clean the unit less frequently as a result. The coolant has very little chance of failing because it is in continuous contact with the heating element.

Section 1: Homemade induction boiler – it’s simple. Tile with induction.

Leaks are essentially ruled out if there were no mistakes made when installing the induction boiler. This has to do with the heater’s contactless heat transfer. You can almost completely gasify water by heating it with induction technology. As a result, water can flow through pipes effectively, and in certain cases, circulation pumping plants are not even necessary.

Sadly, there are no perfect devices on the market today. Induction heaters come with a long list of benefits, but they also have some drawbacks. Since the device runs on electricity, it cannot function as efficiently as possible in areas where there are frequent disruptions in the electrical supply. The system’s pressure rises rapidly and the pipe may burst when the coolant overheats. The induction heater needs to have an emergency shutdown mechanism installed in order to prevent this.

Do-it-yourself induction heater

The principle of operation of induction heating

The electromagnetic field energy is absorbed by the heated object and transformed into thermal energy for the induction heater to function. An inductor, such as a multiple cylindrical coil, is used to create a magnetic field. An alternating magnetic field is produced around the coil by the alternating electric current flowing through this inductor.

Rapid and extremely high temperature heating is possible with a homemade inverter heater. These tools allow you to melt different metals in addition to heating water.

The magnetic induction vector’s flow, which is continuously changing over time, will be penetrated by the heated object if it is inside or close to the inductor. In this instance, an electric field is created, moving along the closed circle at a perpendicular angle to the direction of the magnetic flow. The object heats up as a result of the conversion of electric energy into thermal energy by these vortex flows.

As opposed to resistance furnaces, this method transfers the inductor’s electrical energy to the target without the need for contacts. Thermal energy is used more effectively as a result, and the rate of heating rises noticeably. In the field of metal processing, this idea is frequently applied to tasks like sailing soldering, forging, and swimming. You can also heat water with a vortex induction heater, albeit with no less success.

A fun way to learn about metalworking and casting in the comfort of your own home is to build your own DIY induction stove for melting. With the correct supplies and a little bit of expertise, you can make a multipurpose tool that will allow you to safely and effectively melt a variety of metals.

The versatility of a do-it-yourself induction stove is one of its main benefits. You can melt metals more quickly and accurately with an induction stove because it provides rapid heating and precise temperature control, in contrast to more laborious and less accurate traditional methods like gas or electric furnaces.

Building your own induction stove also gives you the flexibility to modify it to fit your needs and budget. Whether you’re a professional seeking to enhance your skills or a hobbyist experimenting with small-scale projects, DIY induction stoves can be customized to fit crucibles of different sizes and kinds, making them versatile for a range of uses.

But it’s imperative that you approach do-it-yourself projects like this with caution and consideration for safety precautions. It’s important to follow the right protocols and guidelines to protect your safety and the integrity of your equipment when working with electrical components and high temperatures because these tasks carry inherent risks.

To sum up, creating a do-it-yourself induction stove for melting can be a satisfying and useful project for both beginners and experts. An induction stove gives metalworkers endless possibilities to explore their craft with more control and creativity from the comforts of their own workshop. Its precision, efficiency, and versatility make this possible.

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