Universal Power Supply/Bill of Materials: Difference between revisions
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*Resonant LC circuit - [https://www.allaboutcircuits.com/textbook/alternating-current/chpt-6/parallel-tank-circuit-resonance/] | *Resonant LC circuit - [https://www.allaboutcircuits.com/textbook/alternating-current/chpt-6/parallel-tank-circuit-resonance/] | ||
*'''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/] | *'''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/] | ||
*Royer Oscillator, Wikipedia - [https://en.wikipedia.org/wiki/Royer_oscillator] | |||
*'''Melting calculator'''- Temperature rise calculator. Steel melts at 1400C. [https://www.rmcybernetics.com/science/physics/useful-facts-formula/heater-power-temperature-calculations] | *'''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 on Hackaday - [https://hackaday.com/2015/10/23/a-small-1000w-induction-heater/] | ||
Revision as of 04:20, 10 February 2018
Basics
- This page explores what is needed to make the Universal Power Supply
Funtions
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
Part Reduction
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
Pulse Width Modulation
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]
Inverter
Needs Arduino, 4 gate drivers, and 4 transistors as a minimum set.
- Modified Sinusoidal pulse width modulation - http://www.theorycircuit.com/arduino-inverter-circuit/
- Sample inverter using a transformer
- Transformerless - [12]
Induction Heating Frequency and Voltage
- Typical - 10kHz to 1 Mhz frequency - [13]
- Resonant LC circuit - [14]
- Excellent overview of a basic system - [15]. Diagram of this - [16]
- Royer Oscillator, Wikipedia - [17]
- Melting calculator- Temperature rise calculator. Steel melts at 1400C. [18]
- ZVS induction on Hackaday - [19]
- ZVS Induction heater - 1 kW - $40 - [20]. Is this scalable simply by larger components?
- IGBT for ZVS - 20kW capacity - $4 - [21]
OCI Pages
- Page with design request on the Open Circuit Institute Page (Here)
- Finished design published on the Open Cicuit Institute Page (Here)