Revision as of 00:27, 10 February 2018

Basics

The Universal Power Supply should provide these functions:

Inverter
Solid state transformer - 1200V, short range transmission lines - $60 cost of 45 kW transformer. [1]
Induction furnace
Plasma cutter
Welder
Laser cutter
Charge controller to batteries
Power conditioning from a windmill
Induction heater
Contactor
Electric motor speed contoller
Stepper motor controller

What is the minimum number of electronic parts required to build the Universal Power Supply?

Arduino for control. Arduino can also measure frequency to 50kHz for feedback - [2]
IGBTs - choose one that can be scaled extensively, 10kW range (20A x5, 100V)
Resistors
Capacitors (filters)
Small transformers
Current sensors - Hall Effect Sensors
Terminal blocks, 50A [3]
Wire (8 ga, 55A, 600V) [4]
Switches. Small switches, with IGBT serving as larger switch or contactor
200A contactor relay - 48DC - [5]
Go for 600V on components, at 50A for wires, need 7 wires for 210kW - manageable as a modular system

BOM for high frequency up to 65kHz is done with Arduino.

Arduino has 500hz pulse width modulation - [6]. And 1000hz modulation - [7]. Up to 62.5 kHz - [8]
PWM.h library for arduino lets you select frequency - [9]
PWM library for Arduino - 65kHz, or up to 2Mhz - but is i/o fast enough at above 65kHz? -[10]
More about Arduino PWM, but this doesn't go above 1kHz in examples - [https://www.arduino.cc/en/Tutorial/SecretsOfArduinoPWM
Or you can obtain PWM at the software level - [11]

Needs Arduino, 4 gate drivers, and 4 transistors as a minimum set.

Excellent overview of a basic system - [13]. Diagram of this - [14]
Melting calculator- Temperature rise calculator. Steel melts at 1400C. [15]
ZVS induction on Hackaday - [16]
ZVS Induction heater - 1 kW - $40 - [17]. Is this scalable simply by larger components?
IGBT for ZVS - 20kW capacity - $4 - [18]

@@ Line 48: / Line 48: @@
 =Induction Heating Frequency and Voltage=
 *'''Excellent overview of a basic system''' - [https://www.rmcybernetics.com/science/diy-devices/diy-induction-heater]. Diagram of this - [https://forum.allaboutcircuits.com/threads/zvs-induction-heater.97571/]
+*'''Melting calculator'''- Temperature rise calculator. Steel melts at 1400C. [https://www.rmcybernetics.com/science/physics/useful-facts-formula/heater-power-temperature-calculations]
 *ZVS induction on Hackaday - [https://hackaday.com/2015/10/23/a-small-1000w-induction-heater/]
 *ZVS Induction heater - 1 kW - $40 - [https://www.aliexpress.com/item/ZVS-induction-heater-High-frequency-heating-machine-Need-to-bring-their-own-power/32604845135.html?src=google&albslr=202360148&isdl=y&aff_short_key=UneMJZVf&source=%7Bifdyn:dyn%7D%7Bifpla:pla%7D%7Bifdbm:DBM&albch=DID%7D&src=google&albch=shopping&acnt=708-803-3821&isdl=y&albcp=653153647&albag=34728528644&slnk=&trgt=61865531738&plac=&crea=en32604845135&netw=g&device=c&mtctp=&gclid=EAIaIQobChMIieq8o_WZ2QIVk7fACh0YvQ9iEAQYASABEgKY-_D_BwE]. '''Is this scalable simply by larger components?'''