Universal Power Supply/Bill of Materials

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Basics

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

BoM for Non-isolated 9V Power Supply (280 mA)

Cac = 10 uF

Cac discharge resistor: 1 MOhm

Bridge diodes (x4): UPL4.004

Filter capacitor: 680 uF

Output zener: UPL4.009

Voltage reference: IC VREF SHUNT 4.096V TO92-3

Voltage reference resistor: 5.6 kOhm

BoM for 800W Power Supply /w 12-24V DC Output

Transformer:

Rectifier: GBJ3510TB or similar

PWM switching transistor: IGBT 650V 208A 892W T-MAX

Zener Diode for Reference Voltage: DIODE ZENER 4.7V 1W DO41

Diode for Buck Converter: DIODE RECT 100V 40A TO220AB

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.

  • Sample inverter using a transformer
  • Transformerless - [12]

Voltage Amplification

  • Doubler - Voltage Doubling Rectifiers and Switched Diode Circuits - [13]
  • Boost converter - practical gain limit of 6 - [14]
  • AC to DC - Cascade of half-wave doublers (Cockcroft-Walton multiplier) appears scalable - [15]
  • DC to DC - Take DC-> high frequency AC -> small transformer -> rectify to DC [16]

Inverter Welder

  • 10 kHz, about 15-30V [17]

Plasma Cutter

  • 400VDC for cutting. 5000VAC for spark. [18]

Laser

  • CO2
  • Solid State

Induction Heating Frequency and Voltage

  • Small induction heater with explanation and author email on website - [19]
  • Tiny 30W induction heater with part list, air solder - [20]
  • $1-2k for 10kW induction furnace. Arduino controlled - but missing open source software - [21]
  • Typical - 10kHz to 1 Mhz frequency - [22]
  • Resonant LC circuit - [23]
  • Excellent overview of a basic system - [24]. Diagram of this - [25]
  • Royer Oscillator, Wikipedia - [26]
  • Melting calculator- Temperature rise calculator. Steel melts at 1400C. [27]
  • ZVS induction on Hackaday - [28]
  • ZVS Induction heater - 1 kW - $40 - [29]. Is this scalable simply by larger components?
  • IGBT for ZVS - 20kW capacity - $4 - [30]
  • Furnace, tuning by a pot, tuned condition by diode light - [31]. Youtube Channel - ex, detailed explanation of a 12V power supply - [32]
  • Paper. Their resonant loop locking method is too complicated - [33]
  • 2015 paper on fuzzy logic for maximum power output of induction furnace - [34]
  • Patent on frequency control - [35]
  • Algorithm is in principle simple: measure phase between I and V of load. If phase is greater than 0, decrease the frequency; if phase is less than 0, increase the frequency. Is Arduino or Raspberry Pi fast enough to do this at about 100kHz? - [36]. Pi Zero is 700 Mhz - 100 kHz should be achievable readily.
  • Zero point crossing and phase control - [[37]]

OCI Pages

  • Page with design request on the Open Circuit Institute Page (Here)
  • Finished design published on the Open Cicuit Institute Page (Here)

See Also

Useful Links

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