Talk:Induction Furnace - Revision history

Eric: Added some more information

2025-12-10T13:08:54Z

Added some more information

← Older revision		Revision as of 13:08, 10 December 2025
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	Serial.println();		Serial.println();
	}		}

			=Neat Group out of Latvia that MAY be able to collaborate=
			*Recently i saw something on YouTube doing all sorts of neat stuff with Induction Furnaces and whatnot
			*I’ll grab the link and maybe make a page etc, but seemed like some sort of research institute/university lab in Latvia
			*Either way main interesting bits were:
			**[[Magnetohydrodynamic Stirring]] of the Molten Metal
			**[[Stir Casting]] of [[Metal Matrix Composites]]
			**All sorts of other interesting stuff
			*Need to reach out on them, and i wouldn’t be too surprised if some of that stuff is locked down with patents and/or too complex/expensive for OSE use, but still though
			*[https://youtu.be/6tHBntFsEDA?si=ujVXrYvS7w0MuI2P A Video by the YouTube Channel “MHD Technology Laboratory” Titled “Aluminum Tornado for Metal Matrix Composites” ] ( ‘’’~5 Minute Watch’’’ )
			**This was the video i saw

Marcin at 08:48, 8 December 2025

2025-12-08T08:48:31Z

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JacksonL at 05:01, 8 December 2025

2025-12-08T05:01:33Z

← Older revision		Revision as of 05:01, 8 December 2025
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	== The boys Induction Furnace ==		== The boys Induction Furnace ==
			[[File:InductionFurnaceCore.fcstd\|thumb]]

	= Induction Furnace Development Update =		= Induction Furnace Development Update =

JacksonL: Undo revision 315153 by JacksonL (talk)

2025-12-08T04:12:03Z

Undo revision 315153 by JacksonL (talk)

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JacksonL at 04:11, 8 December 2025

2025-12-08T04:11:06Z

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JacksonL: /* Arduino Control */

2025-12-08T04:06:42Z

Arduino Control

JacksonL: /* Arduino Control */

2025-12-08T04:05:21Z

Arduino Control

← Older revision		Revision as of 04:05, 8 December 2025
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	// --- Pin Definitions ---		// --- Pin Definitions ---
	const int PIN_VOLT_SENSOR = A0; // Voltage Divider Input		const int PIN_VOLT_SENSOR = A0; // Voltage Divider Input

	const int PIN_CURR_SENSOR = A1; // ACS712 or Hall Sensor		const int PIN_CURR_SENSOR = A1; // ACS712 or Hall Sensor

	const int PIN_TEMP_SENSOR = A2; // NTC Thermistor (Coolant)		const int PIN_TEMP_SENSOR = A2; // NTC Thermistor (Coolant)

	const int PIN_SAFETY_SW = 2; // Emergency Stop (NC)		const int PIN_SAFETY_SW = 2; // Emergency Stop (NC)


	const int PIN_RELAY_POWER = 8; // Main Contactor		const int PIN_RELAY_POWER = 8; // Main Contactor

JacksonL: /* Arduino Control */ new section

2025-12-08T04:04:49Z

Arduino Control: new section

← Older revision		Revision as of 04:04, 8 December 2025
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	* Source Code: `Antigravity_24_Freecad/generators/`		* Source Code: `Antigravity_24_Freecad/generators/`
	* Output Models: `Antigravity_24_Freecad/outputs/InductionFurnace.FCStd`		* Output Models: `Antigravity_24_Freecad/outputs/InductionFurnace.FCStd`

			== Arduino Control ==

			* Induction Furnace Controller
			* Platform: Arduino Uno / Nano
			* Description: Monitors safety sensors and controls cooling/power relays.
			*/

			// --- Pin Definitions ---
			const int PIN_VOLT_SENSOR = A0; // Voltage Divider Input
			const int PIN_CURR_SENSOR = A1; // ACS712 or Hall Sensor
			const int PIN_TEMP_SENSOR = A2; // NTC Thermistor (Coolant)
			const int PIN_SAFETY_SW = 2; // Emergency Stop (NC)

			const int PIN_RELAY_POWER = 8; // Main Contactor
			const int PIN_RELAY_PUMP = 9; // Cooling Pump
			const int PIN_FAN_PWM = 10; // Radiator Fan (PWM)

			// --- Constants ---
			const float TEMP_CRITICAL = 60.0; // Celsius
			const float TEMP_IDLE = 30.0; // Celsius
			const int FAN_MIN_SPEED = 50; // 0-255
			const int FAN_MAX_SPEED = 255;

			// --- Globals ---
			bool safety_ok = false;
			float coolant_temp = 0.0;

			void setup() {
			Serial.begin(9600);

			pinMode(PIN_SAFETY_SW, INPUT_PULLUP);
			pinMode(PIN_RELAY_POWER, OUTPUT);
			pinMode(PIN_RELAY_PUMP, OUTPUT);
			pinMode(PIN_FAN_PWM, OUTPUT);

			// Safe State
			digitalWrite(PIN_RELAY_POWER, LOW);
			digitalWrite(PIN_RELAY_PUMP, LOW);
			analogWrite(PIN_FAN_PWM, 0);

			Serial.println("Furnace Controller Initialized");
			}

			void loop() {
			// 1. Read Sensors
			readSensors();

			// 2. Safety Logic
			checkSafety();

			// 3. Control Outputs
			controlCooling();
			controlPower();

			// 4. Telemetry
			sendTelemetry();

			delay(100);
			}

			void readSensors() {
			// Simplified Temp Calculation (Steinhart-Hart would be better)
			int raw_temp = analogRead(PIN_TEMP_SENSOR);
			// Map 0-1023 to approx 0-100C for demo
			coolant_temp = map(raw_temp, 0, 1023, 0, 100);

			// Safety Switch (Active LOW if NC switch is closed)
			// If switch opens (pressed), pin goes HIGH (internal pullup? No, usually NC to GND)
			// Let's assume NC switch to GND. Closed = LOW = OK. Open = HIGH = STOP.
			safety_ok = (digitalRead(PIN_SAFETY_SW) == LOW);
			}

			void checkSafety() {
			if (coolant_temp > TEMP_CRITICAL) {
			safety_ok = false;
			Serial.println("ERROR: Overheat!");
			}
			}

			void controlCooling() {
			// Pump Logic: Always ON if Power is ON, or if Temp > IDLE (Cool down mode)
			bool power_is_active = (digitalRead(PIN_RELAY_POWER) == HIGH);

			if (power_is_active \|\| coolant_temp > TEMP_IDLE) {
			digitalWrite(PIN_RELAY_PUMP, HIGH);

			// Fan Logic: Proportional Control
			int fan_speed = map(coolant_temp, TEMP_IDLE, TEMP_CRITICAL, FAN_MIN_SPEED, FAN_MAX_SPEED);
			fan_speed = constrain(fan_speed, 0, 255);
			analogWrite(PIN_FAN_PWM, fan_speed);
			} else {
			digitalWrite(PIN_RELAY_PUMP, LOW);
			analogWrite(PIN_FAN_PWM, 0);
			}
			}

			void controlPower() {
			if (safety_ok) {
			// In a real system, we might wait for a "Start" command via Serial
			// For this safety controller, we just enable the contactor allowance.
			// The actual ZVS might be triggered separately.
			// Here we assume this relay cuts main DC power.
			digitalWrite(PIN_RELAY_POWER, HIGH);
			} else {
			digitalWrite(PIN_RELAY_POWER, LOW);
			}
			}

			void sendTelemetry() {
			Serial.print("TEMP:"); Serial.print(coolant_temp);
			Serial.print(",SAFETY:"); Serial.print(safety_ok);
			Serial.println();
			}

JacksonL: /* Full System Model */

2025-12-08T03:46:09Z

Full System Model

← Older revision		Revision as of 03:46, 8 December 2025
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	* '''Description:''' A complete industrial setup including the structural frame, concrete platform, safety railings, hydraulic tilting mechanism, and full control panel.		* '''Description:''' A complete industrial setup including the structural frame, concrete platform, safety railings, hydraulic tilting mechanism, and full control panel.
	* '''High-LOD Features:'''		* '''High-LOD Features:'''
	Hydraulics: Hydraulic Power Unit (HPU) with reservoir, motor, valve block, and hoses connecting to the tilt cylinder.		Hydraulics: Hydraulic Power Unit (HPU) with reservoir, motor, valve block, and hoses connecting to the tilt cylinder.
	Electronics: Detailed ZVS Driver module with PCB, heatsinks, capacitor bank, and choke inductors mounted on an open-frame rack.		Electronics: Detailed ZVS Driver module with PCB, heatsinks, capacitor bank, and choke inductors mounted on an open-frame rack.
	Cooling: Explicit water cooling loop with pump, radiator, fan, tank, and hoses.		Cooling: Explicit water cooling loop with pump, radiator, fan, tank, and hoses.
	Hardware: Hex bolt heads at frame joints and pivot points.		Hardware: Hex bolt heads at frame joints and pivot points.
	Casting: Double-crucible system (Inner Melting Pot + Outer Chamber) with a pouring spout and steel ramp.		Casting: Double-crucible system (Inner Melting Pot + Outer Chamber) with a pouring spout and steel ramp.

	=== Focused Core Model ===		=== Focused Core Model ===
	* '''Script:''' `generators/induction_furnace_core.py`		* '''Script:''' `generators/induction_furnace_core.py`

JacksonL: /* Focused Core Model */

2025-12-08T03:45:28Z

Focused Core Model

← Older revision		Revision as of 03:45, 8 December 2025
Line 20:		Line 20:
	* '''Description:''' A simplified model focusing strictly on the functional components required for melting.		* '''Description:''' A simplified model focusing strictly on the functional components required for melting.
	* '''Components:'''		* '''Components:'''
	* Induction Circuit (ZVS, Bus Bars)		Induction Circuit (ZVS, Bus Bars)
	* Heat Dissipation System (Radiator, Pump, Tank)		Heat Dissipation System (Radiator, Pump, Tank)
	* Coil (Copper Tubing)		Coil (Copper Tubing)
	* Melt Chamber (Outer Crucible)		Melt Chamber (Outer Crucible)
	* Feeder (Hopper)		Feeder (Hopper)
	* Crucible (Inner Pot)		Crucible (Inner Pot)

	== Bill of Materials (BOM) ==		== Bill of Materials (BOM) ==
	We have sourced real-world parts for the core components. Prices are estimates.		We have sourced real-world parts for the core components. Prices are estimates.

← Older revision		Revision as of 04:06, 8 December 2025
Line 82:		Line 82:

	const int PIN_RELAY_POWER = 8; // Main Contactor		const int PIN_RELAY_POWER = 8; // Main Contactor

	const int PIN_RELAY_PUMP = 9; // Cooling Pump		const int PIN_RELAY_PUMP = 9; // Cooling Pump

	const int PIN_FAN_PWM = 10; // Radiator Fan (PWM)		const int PIN_FAN_PWM = 10; // Radiator Fan (PWM)


	// --- Constants ---		// --- Constants ---
	const float TEMP_CRITICAL = 60.0; // Celsius		const float TEMP_CRITICAL = 60.0; // Celsius

	const float TEMP_IDLE = 30.0; // Celsius		const float TEMP_IDLE = 30.0; // Celsius

	const int FAN_MIN_SPEED = 50; // 0-255		const int FAN_MIN_SPEED = 50; // 0-255

	const int FAN_MAX_SPEED = 255;		const int FAN_MAX_SPEED = 255;

Line 130:		Line 136:
	void readSensors() {		void readSensors() {
	// Simplified Temp Calculation (Steinhart-Hart would be better)		// Simplified Temp Calculation (Steinhart-Hart would be better)

	int raw_temp = analogRead(PIN_TEMP_SENSOR);		int raw_temp = analogRead(PIN_TEMP_SENSOR);

	// Map 0-1023 to approx 0-100C for demo		// Map 0-1023 to approx 0-100C for demo

	coolant_temp = map(raw_temp, 0, 1023, 0, 100);		coolant_temp = map(raw_temp, 0, 1023, 0, 100);

	// Safety Switch (Active LOW if NC switch is closed)		// Safety Switch (Active LOW if NC switch is closed)

	// If switch opens (pressed), pin goes HIGH (internal pullup? No, usually NC to GND)		// If switch opens (pressed), pin goes HIGH (internal pullup? No, usually NC to GND)

	// Let's assume NC switch to GND. Closed = LOW = OK. Open = HIGH = STOP.		// Let's assume NC switch to GND. Closed = LOW = OK. Open = HIGH = STOP.

	safety_ok = (digitalRead(PIN_SAFETY_SW) == LOW);		safety_ok = (digitalRead(PIN_SAFETY_SW) == LOW);
	}		}
Line 149:		Line 161:
	void controlCooling() {		void controlCooling() {
	// Pump Logic: Always ON if Power is ON, or if Temp > IDLE (Cool down mode)		// Pump Logic: Always ON if Power is ON, or if Temp > IDLE (Cool down mode)

	bool power_is_active = (digitalRead(PIN_RELAY_POWER) == HIGH);		bool power_is_active = (digitalRead(PIN_RELAY_POWER) == HIGH);

Line 155:		Line 168:

	// Fan Logic: Proportional Control		// Fan Logic: Proportional Control

	int fan_speed = map(coolant_temp, TEMP_IDLE, TEMP_CRITICAL, FAN_MIN_SPEED, FAN_MAX_SPEED);		int fan_speed = map(coolant_temp, TEMP_IDLE, TEMP_CRITICAL, FAN_MIN_SPEED, FAN_MAX_SPEED);
	fan_speed = constrain(fan_speed, 0, 255);		fan_speed = constrain(fan_speed, 0, 255);
Line 167:		Line 181:
	if (safety_ok) {		if (safety_ok) {
	// In a real system, we might wait for a "Start" command via Serial		// In a real system, we might wait for a "Start" command via Serial

	// For this safety controller, we just enable the contactor allowance.		// For this safety controller, we just enable the contactor allowance.

	// The actual ZVS might be triggered separately.		// The actual ZVS might be triggered separately.

	// Here we assume this relay cuts main DC power.		// Here we assume this relay cuts main DC power.

	digitalWrite(PIN_RELAY_POWER, HIGH);		digitalWrite(PIN_RELAY_POWER, HIGH);
	} else {		} else {