Open Source Induction Furnace Project

Introduction

This project involves the design of:

• a high frequency, 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

The furnace should have the following characteristics:

1. Induction furnace or any other technology that can do this within a budget of 20 kW of electric input, with minimal pollution
2. Suitable for melting all metals and alloying
3. 300 lb per hour steel melting furnace for casting
4. 240 v ac, 20 kW power source available

Details

The complete design should include all of the following:

Induction Furnace Circuit

1. Scalable from 20 up to 50 kW in units of 1 or 5 kW
2. Allows for power and frequency selection
3. Power source may be either 1 or 3 phase electrical power

Heat Dissipation System

Specifications of a cooling or heat dissipation system.

Coil

1. Modular, adaptable design specifications for primary coil windings

Melt Chamber

1. Geometical design of melt chamber and basic power transfer calculations
2. Should include provisions for loading and pouring.

Other Considerations

1. Complete bill of materials
2. Fabrication files for circuit and other components
3. Sourcing information for components
4. System design and process flow drawings

Notes

Power Supply

• 50 kW for $1600 - [1]
• 20 kw STC 3 phase 120 - 480V, also 1 phase - generator - $692 -[2]
• 50 kw STC 3 phase- $1300 - [3]
  • LifeTrac 55 hp can produce 38 kW with this head

Melt Calculations

See Also

• Original blog post: http://openfarmtech.org/weblog/?p=1373
• Furnace selection: http://www.articlesfactory.com/articles/hobbies/induction-furnace-and-cupola-furnace-information.html

DIY Furnaces

• http://www.richieburnett.co.uk/indheat.html
• http://www.hvguy.4hv.org/ih/
• http://webpages.charter.net/dawill/tmoranwms/Elec_IndHeat1.html
• 1 kW Induction Furnace Kit: http://webpages.charter.net/dawill/tmoranwms/Elec_IndHeat8.html
• http://www.dansworkshop.com/electricity-and-electronics/induction-heating.htm

Commercial

• Commercial induction furnace power supplies from Superior Induction - [4]
• EPRI works with induction - The EPRI Center for Materials Production at Carnegie Mellon, Pittsburgh, PA, 412-268-3243

If you think there are missing or incorrect details here, please help correct that.