Induction Furnace: Difference between revisions

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{{Template:Category=Induction furnace}}
{{Template:Category=Induction furnace}}


* [[:Category: Induction Furnace]]
=Overview=
* [http://openfarmtech.org/weblog/category/global-village-construction-set/induction-furnace/ Induction Furnace blog posts]
* [http://openfarmtech.org/weblog/forum/induction-furnace/ Induction Furnace Forum]
 
Project management site: http://openpario.mime.oregonstate.edu/projects/osif
 
 
==Introduction==
 
The Open Source Induction Furnace Project seems to be the most promising way to implement the [[foundry]].
This project involves the design of:
* a high-power induction furnace circuit (between 20 and 50 kW), and
* the melting chamber proper.
 
Well, we could buy a turnkey system perhaps for $5k total used, and run it from the LifeTrac generator. The only disadvantage to this route is that if it breaks we’re dead-in-the-water – either with the impossibility of fixing closed-source technology, or a high repair bill. A single component which blows and is inaccessible for fixing could in principle turn a working power supply into worthless junk. Thus, it is worthwhile to tame this technology by open-sourcing the design.
 
==Goals==
 
To fulfill our [[foundry]] goals,
The furnace should have the following characteristics:
 
#Induction furnace or any other technology that can do this within a budget of 20 kW of electric input, with minimal pollution
#Suitable for melting all metals and alloying
#300 lb per hour steel melting furnace for casting
#240 v ac, 20 kW power source available
 
==Conceptual Diagram==
 
This is a conceptual diagram of the entire Induction Furnace system from the [[Global Village Construction Set]]. The furnace is powered by 20 kW of 240VAC electricity from the [[LifeTrac]] generator. The entire system includes the power electronics, induction coil, and heating vessel - into which metal for melting is inserted. This diagram intends to document the relationship of functional components in the induction furnace system, as a basis for technical development of components and their integration.
 
The electronics part should be adaptable to different metals and different metal melting coil  geometries. Melting coils should also be modular, such that the power electronics can feed different coils. Basic functions include selection of heating frequencies, which are required for melting different metals or metal geometries. There should be a feedback in the electronics, where the amount of power given to the coil should match the quantity/geometry of metal being melted.
 
[[Image:induction_concept.jpg]]
 
 
==Details==
The complete design should include all of the following:
 
===Induction Furnace Circuit===
# Scalable from 20 up to 50 kW in units of 1 or 5 kW
# Allows for power and frequency selection
# Power source may be either 1 or 3 phase electrical power
 
===Heat Dissipation System===
Specifications of a cooling or heat dissipation system.


===Coil===
[[Image:InductionFurnace.png|right|400px|[[Induction Furnace]]]]
# Modular, adaptable design specifications for primary coil windings


===Melt Chamber===
An induction furnace is an electrical furnace in which the heat is applied by induction heating of metal.
# Geometical design of melt chamber and basic power transfer calculations
# Should include provisions for loading and pouring
# Given our goals, which is best: a coreless or a channel induction furnace type [http://www.wisegeek.com/what-is-an-induction-furnace.htm] ?
## channel: useful in the melting of lower melt temperature metals; less turbulence at the surface.
## coreless: stronger stirring
# Pouring: manual pouring methods are more suited to low volume production lines.
====Crucible====
* See: Crucibles for Induction Melting - Guidelines for Selection and Use: http://www.engineeredceramics.com/crucible.htm


===Other Considerations===
{{Video}}
# Complete bill of materials
# Fabrication files for circuit and other components
# Sourcing information for components
# System design and process flow drawings


==Notes==
[[Image:2b-Genfabecology.png|600px|right]]
===Benny===
I just read that you plan to build up an induction furnace. That´s a an interesting and exciting plan.While reading the article some remarks came to my mind.


But before I want to introduce myself:
=Requirements=
*Meets [[OSE Specifications]]
*Modular in power units of 5 or 10 kW
*Microcontroller-driven - ideally an Arduino brain with power elements


I am Benny from Germany, Hannover.
=Details=
I am diploma engineer for electrotechnology and working at the university. I am dealing with some induction heating/ melting applications like induction melting of glasses (that is possible!) and induction furnaces for cast iron.
The advantage of the induction furnace is a clean, energy-efficient and well-controllable melting process compared to most other means of metal melting. Most modern foundries use this type of furnace and now also more iron foundries are replacing cupolas with induction furnaces to melt cast iron, as the former emit lots of dust and other pollutants. Induction furnace capacities range from less than one kilogram to one hundred tonnes capacity and are used to melt iron and steel, copper, aluminium and precious metals. Since no arc or combustion is used, the temperature of the material is no higher than required to melt it; this can prevent loss of valuable alloying elements.[1] The one major drawback to induction furnace usage in a foundry is the lack of refining capacity; charge materials must be clean of oxidation products and of a known composition and some alloying elements may be lost due to oxidation (and must be re-added to the melt).


Some remarks from my point of view:
Operating frequencies range from utility frequency (50 or 60 Hz) to 400 kHz or higher, usually depending on the material being melted, the capacity (volume) of the furnace and the melting speed required. Generally, the smaller the volume of the melts, the higher the frequency of the furnace used; this is due to the skin depth which is a measure of the distance an alternating current can penetrate beneath the surface of a conductor. For the same conductivity, the higher frequencies have a shallow skin depth - that is less penetration into the melt. Lower frequencies can generate stirring or turbulence in the metal.
A preheated, 1-tonne furnace melting iron can melt cold charge to tapping readiness within an hour. Power supplies range from 10 kW to 15 MW, with melt sizes of 20 kg to 30 tonne of metal respectively.


# It is possible to build up a low cost furnace with the mentioned parameters.
An operating induction furnace usually emits a hum or whine (due to magnetostriction), the pitch of which can be used by operators to identify whether the furnace is operating correctly or at what power level.
# The frequency of 9,6 kHz is much to high. The efficiancy will be so bad, that it will be hardly possible to melt steel or iron. Due to the small penetration depth of about 2 mm with this frequency and this electrical resistance. So it needs a really small diameter of the crucible, and thats not helpful. Also the refractory material will be strained too much, so that a small lifetime is given. This will raise the cost for the operating.
# 50 Hz or 60 Hz is a better solution. And you can save the cost for the hf-converter.
# How much material do you want to cast at one time? The maximum, what i expect to be possible with 50 kW will be about 50 to 60 kg.
# What kind of raw material should be charged? It is important for the starting, because the initial density should not be too small (packing density). And the other question is, what kind of scrap it will be.
There are so many problems known with content of zinc (hot zinc dipped) and other materials. The lifetime of common refractory material is really small. And what is more important the security for the personal is not given without a strong exhaust system, due to the toxic steam. I expect this as a strong cost factor.


===Power Supply===
=Development Notes=
*50 kW for $1600 - [http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=200415768835&rvr_id=&crlp=1_263602_263622&UA=L*F%3F&GUID=1357ab741250a0265337bec7ff94d6a7&itemid=200415768835&ff4=263602_263622]
*20 kw STC 3 phase 120 - 480V, also 1 phase - generator - $692 -[http://cgi.ebay.com/20kw-STC-3-Phase-277-480-12-Wire-generator-Head-altern_W0QQitemZ160369799644QQcmdZViewItemQQptZBI_Generators?hash=item2556c8f1dc]
*50 kw STC 3 phase- $1300 - [http://cgi.ebay.com/50KW-STC-3-Phase-12-Wire-generator-alternator_W0QQitemZ160357088416QQcmdZViewItemQQptZBI_Generators?hash=item255606fca0]
**LifeTrac 55 hp can produce 38 kW with this head


===Melt Calculations===
Read a commercial description of an induction furnace [http://www.voltamptransformers.com/induction_furnace_trans.html from Voltamptransformers]
[[Image:inductioncalc.jpg]]


==Wiki Links==
Read about 3-phase electrical power [https://en.wikipedia.org/wiki/Three-phase_electric_power at its wikipage]


[[Foundry]]
Read about 3-phase electrical standards in north America [http://www.control.com/thread/999290407 at control.com forums]


[[Induction Furnace Request for Bids]]


==External Links==
=Product Ecology=
* [http://openfarmtech.org/weblog/?p=1373 Original Blog Post]


===Resources===
'''Uses'''
* [http://www.articlesfactory.com/articles/hobbies/induction-furnace-and-cupola-furnace-information.html  Articlesfactory: Furnace Selection]
*{{UPS}} - Power
* [http://inductionheater.org/ Inductionheater.org]
* [http://www.dansworkshop.com/electricity-and-electronics/induction-heating.htm Dansworkshop: Induction Heating]
* [http://www.educypedia.be/electronics/electricityinduction.htm Educypedia: Induction-related Articles]
* [[Appropedia: Induction Heating]]
* [http://webpages.charter.net/dawill/tmoranwms/Elec_IndHeat7.html] Home made induction heater
* [http://www.allaboutcircuits.com/ Allaboutcircuits: Articles on Electricity and Electronics]
* [http://www.freepatentsonline.com/3798344.html 1974 US Patent 3798344] Channel Type Induction Furnace (Many induction furnace patents are more than 20 years old, and therefore public domain.)


===DIY Furnaces===
'''Creates'''
*http://www.richieburnett.co.uk/indheat.html
*[[Steel]] - [[GVCS]] (pretty much every machine depends on this)
*http://www.hvguy.4hv.org/ih/
*http://webpages.charter.net/dawill/tmoranwms/Elec_IndHeat1.html
* [http://webpages.charter.net/dawill/tmoranwms/Elec_IndHeat9.html Achieved 10 kW]; Induction Furnace Kit: http://webpages.charter.net/dawill/tmoranwms/Elec_IndHeat8.html
*http://www.dansworkshop.com/electricity-and-electronics/induction-heating.htm


===Commercial===
See [[Product Ecologies]] for more information.
*Commercial induction furnace power supplies from Superior Induction - [http://www.superiorinduction.com/?gclid=CO2fgNqPtZkCFRAhDQodqjeo5Q]
*EPRI works with induction - The EPRI Center for Materials Production at Carnegie Mellon, Pittsburgh, PA, 412-268-3243
* [http://www.made-in-china.com/productdirectory.do?subaction=hunt&mode=and&style=b&isOpenCorrection=1&word=induction+furnace&comProvince=nolimit&code=QimLEmnJSxJQ List of chinese induction furnace manufacturers]


===Forum Posts===
=Components=
* You can start your own discussions on our [http://openfarmtech.org/weblog/forum/induction-furnace/ Open Source Induction Furnace Forum]
[[Image:InductionComponents.jpg|400px|right]]
* CNC Zone - Induction furnace topic: http://www.cnczone.com/forums/showthread.php?t=13545
* Metal Casting Zone - Furnace Info: http://www.metalcastingzone.com/metal-casting-forum/casting-furnaces
* Metal and Metallurgy engineering Forum: http://www.eng-tips.com/threadminder.cfm?pid=330&page=1
* Electronics and electricity: http://forum.allaboutcircuits.com/
* Electronics: http://www.electro-tech-online.com/
If you think there are missing or incorrect details here, please help correct that.


*Induction Furnace Circuit
*Heat Dissipation System
*Coil
*Melt Chamber
*Feeder
*Crucible


==Status==
=Status=
The '''Induction Furnace''' is currently in the [[Induction Furnace/Research Development research phase of product development]].
The '''Induction Furnace''' is currently in the [[Induction Furnace/Research Development|research phase of product development]].


==See Also==
=Internal Links=
*[[Spectrometer]]
*[[Spectrometer]]
*[[Foundry]]
*[[Foundry]]


=External Links=
*[http://en.wikipedia.org/wiki/Induction_furnace Wikipedia: Induction Furnace]
*[http://en.wikipedia.org/wiki/Investment_casting Wikipedia: Investment Casting]
*[https://www.bostonmetal.com/moe-technology/ Molten Oxide Electrolysis - carbon free process that goes directly from ore to pure metal with pure oxygen as a byproduct]
*[https://www.nasa.gov/feature/molten-oxide-electrolysis/ NASA's page on MOE]
*[https://www.youtube.com/watch?v=-pYNzxorJs0 Youtube: Better Metal from Bill Gates youtube channel]
*[https://www.youtube.com/watch?v=pg5M5WjGx5M Youtube: Donald Sadoway at EmTech MENA 2019: Steel Production without Co2 Emissions]
*[https://www.youtube.com/watch?v=DbZZD6J_AK0 An Open Source Design for a 3kw Induction Heater]


[[Category:Induction Furnace]]
[[Category:Induction Furnace]]

Latest revision as of 00:22, 17 March 2021


Induction Furnace
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Main > Digital Fabrication > RepLab Tools > Induction furnace

Overview

Induction Furnace

An induction furnace is an electrical furnace in which the heat is applied by induction heating of metal.

2b-Genfabecology.png

Requirements

  • Meets OSE Specifications
  • Modular in power units of 5 or 10 kW
  • Microcontroller-driven - ideally an Arduino brain with power elements

Details

The advantage of the induction furnace is a clean, energy-efficient and well-controllable melting process compared to most other means of metal melting. Most modern foundries use this type of furnace and now also more iron foundries are replacing cupolas with induction furnaces to melt cast iron, as the former emit lots of dust and other pollutants. Induction furnace capacities range from less than one kilogram to one hundred tonnes capacity and are used to melt iron and steel, copper, aluminium and precious metals. Since no arc or combustion is used, the temperature of the material is no higher than required to melt it; this can prevent loss of valuable alloying elements.[1] The one major drawback to induction furnace usage in a foundry is the lack of refining capacity; charge materials must be clean of oxidation products and of a known composition and some alloying elements may be lost due to oxidation (and must be re-added to the melt).

Operating frequencies range from utility frequency (50 or 60 Hz) to 400 kHz or higher, usually depending on the material being melted, the capacity (volume) of the furnace and the melting speed required. Generally, the smaller the volume of the melts, the higher the frequency of the furnace used; this is due to the skin depth which is a measure of the distance an alternating current can penetrate beneath the surface of a conductor. For the same conductivity, the higher frequencies have a shallow skin depth - that is less penetration into the melt. Lower frequencies can generate stirring or turbulence in the metal. A preheated, 1-tonne furnace melting iron can melt cold charge to tapping readiness within an hour. Power supplies range from 10 kW to 15 MW, with melt sizes of 20 kg to 30 tonne of metal respectively.

An operating induction furnace usually emits a hum or whine (due to magnetostriction), the pitch of which can be used by operators to identify whether the furnace is operating correctly or at what power level.

Development Notes

Read a commercial description of an induction furnace from Voltamptransformers

Read about 3-phase electrical power at its wikipage

Read about 3-phase electrical standards in north America at control.com forums


Product Ecology

Uses

Creates

  • Steel - GVCS (pretty much every machine depends on this)

See Product Ecologies for more information.

Components

InductionComponents.jpg
  • Induction Furnace Circuit
  • Heat Dissipation System
  • Coil
  • Melt Chamber
  • Feeder
  • Crucible

Status

The Induction Furnace is currently in the research phase of product development.

Internal Links

External Links


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