Induction Heater

Project Title

Induction Heater

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

Induction is the most efficient method of heating available nowadays whether it’s related to household or industrial heating.

An induction heater is a device that can heat a metal piece red hot within a couple of seconds which further can be used to forge, purify or completely de-form that metal.

An Alternating current is used as input which is feed to the transformer from which it goes through a circuit of rectifiers, MOSFETs, resistors, inductors, and capacitors which at the end provides an efficient induced magnetic juice that heats the workpiece.

Here’s a difference between induction and the traditional heating method:

“A type of carbon steel material called CS 8620 is used to manufacture Gears for industrial machines. However, before installing the edges of the gear are tempered so that it may become further harder. The original idea is only to heat the edges but on flame, all of the gear is heated, moreover, the heating is not uniform.”

Here is what induction does:

“Induction only heats the desired area providing uniform heating in a short amount of time ”

induction made this easy and efficient by introducing an efficient heating technique in which only the outer edges are heated on a uniform heat. 

Project Objectives

The original objective of the project is to be energy efficient so it can be incorporated in small or medium scale industries. Various of our industries still follow the old school flame or burner heating method as the induction is costly.

Allowing small or medium scales industries to install our product will raise the quality of work and save tons of useful hours.

For example:

“Gear made with a material of Carbon Steel (CS 8620) needs its edges to be heated red hot and then cooled in cool water for 6-8 hours on the old school method.  While heating it on regular flame all of the gear is heated to red hot however the original need was just to heat the edges.”

Induction made this easy and efficient by introducing an efficient heating technique in which only the outer edges are heated on a uniform heat. 

For heavy industry, if we are supported, we may be able to develop to powerful design that meets their huge requirements.

Project Implementation Method

• Project implementation involves multiple stages. Making a software-based working prototype that provides leads us near to desired values.
• Making a rough model by varying the components and installing some others.
• Till now Project involves the use of a DC Supply and an inverter that helps us to vary the frequency, as the higher the frequency higher the rate of induced heating.
• The finalized model will be presented on PCB (Insha Allah) in which we plan on adding some timer circuits, a movable arm and some temperature sensors is we managed to cover the original model in the stipulated amount of time.

Benefits of the Project

• A engineering project doesn’t benefit a single individual rather the whole industry.
• The same goes with our model. It can be utilized by metal industries or certain of those industries where heating the metal quarterly, partially, or completely is of prime purpose.
• It can even be used by goldsmiths to heat gold to melt it, purify, or dilute it.
• In short, any such industry that involves or has a need to heat metals will be benefited.

Technical Details of Final Deliverable

• Right now, the model we are working with uses an 18V – 4.5A DC Battery. A power supply is required to implement a more powerful model. Increasing the input power increases the cost of electricity which in turn causes the mass to boycott our product. Designing has never been an easy task moreover adding a power amplifier increases the difficulty.
• Creating a matching circuit that provides sufficient resonant frequency that varies with the load type.
• Working on a series-parallel inductor formula.
• The tank circuit that involves the control system

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Energy , Others Core Technology OthersOther TechnologiesSustainable Development Goals Affordable and Clean Energy, Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	16131
Mosfets	Equipment	8	350	2800
Uf4007 diode	Equipment	10	19	190
Capacitors	Equipment	15	28	420
Electrolytic Capacitors	Equipment	6	85	510
Inductors	Equipment	15	25	375
Ferrite Core	Equipment	4	320	1280
Igbt	Miscellaneous	8	300	2400
DC - Supply	Miscellaneous	1	2500	2500
Breadboard	Miscellaneous	5	205	1025
Vero board	Miscellaneous	5	40	200
LED	Equipment	4	5	20
Fan	Equipment	3	100	300
Resistors	Equipment	20	6	120
Regulators	Equipment	4	18	72
Fuses	Equipment	12	25	300
Copper wire 12 Gauge	Equipment	1	490	490
Copper Wire 18 gauge	Equipment	1	619	619
Multimeter	Miscellaneous	1	1200	1200
Soldering Iron	Miscellaneous	2	600	1200
Soldering paste	Miscellaneous	2	30	60
Zennor Diode	Equipment	10	5	50