Homemade induction smelting furnace. The principle of an induction furnace for smelting various metals. Induction oven on transistors

Induction furnaces were invented in 1887. And after three years later, the first industrial development appeared, with the help of which melted various metals. I would like to note that in those distant years these stoves were in the wonder. The thing is that scientists of that time did not quite understand what processes occur in it. Today they figured out this. We will also be interested in the topic - an induction furnace with your own hands. How easy is its design, is it possible to assemble this unit at home?

Principle of operation

It is necessary to start the assembly, understanding in principle of operation and device device. From that and begin. Pay attention to the drawing above, on it and we will understand.

The device includes:

The G generator that creates an alternating current.
Condenser with along with the coil L creates a oscillating circuit, which provides a high temperature setting.

Attention! Some structures use the so-called auto-oscillator. This makes it possible to remove the capacitor from the scheme.
The coil in the surrounding space forms a magnetic field, in which there is a voltage marked in our drawing of the letter "H". The magnetic field itself exists in the free space, and may close through a ferromagnetic core.
It also acts on the mixture (W), in which the magnetic flux (F) creates. By the way, instead of the mixture can be installed any billet.
The magnetic flux induces a secondary voltage equal to 12 V. But this occurs only if W is an electrically conductive element.
If the heated billet is large and solid, then the so-called Foucault current begins inside it. It is a vortex type.
At the same time, the vortex currents transmit heat energy from the generator through the magnetic field, thereby heating the workpiece.

The electromagnetic field is wide enough. And even the multistage of energy conversion, which is present in homemade induction furnaces, has a maximum efficiency - up to 100%.

Tigel oven.

Varieties

There are two main designs of induction furnaces:

Channel.
Crucible.

We will not show all their distinctive features here. It is simply noted that the channel version is a design that is similar to the welding machine. In addition, to melting the metal in such furnaces, I had to leave a little melt, without which the process simply did not work. The second option is an improved scheme where the technology is used without residual melt. That is, the crucible is simply installed directly into the inductor.

How it works

Why do you need such a furnace?

In general, the question is quite interesting. Let's look at this situation. There is quite a large number of Soviet electrical and electronic devices, which used gold or silver contacts. You can withdraw these metals in different ways. One of them is an induction stove.

That is, take contacts, fold them into a narrow and long crucible, which is installed in the inductor. After 9-20 minutes, it is 15-20, reducing the power, having cooled the machine and breaking the crucible, you get the rod, at the end of which you will find a gold or silver tip. Cut and rent in Lombard.

Although it should be noted that with the help of this homemade unit you can conduct various processes with metals. For example, you can handle or vacation.

Coil with battery (generator)

Components stove

In the "Principle of Work", we have already mentioned all parts of the induction furnace. And if everything is clear with the generator, then with the inductor (coil) it would be necessary to figure it out. A copper tube is suitable for it. If you collect a capacity of 3 kW, then you will need a tube with a diameter of 10 mm. The coil itself is twisted with a diameter of 80-150 mm, with the number of turns from 8 to 10.

Please note that the copper tubes should not come into contact with each other. The optimal distance between them is 5-7 mm. The coil itself should not touch the screen. The distance between them is 50 mm.

Usually industrial induction furnaces have a cooling node. At home this is not possible. But for an aggregate with a capacity of 3 kW, work before half an hour is not threatened. True, over time, copper scale will be formed on the tube, which reduces the efficiency of the device. So periodically the coil will have to change.

Generator

In principle, make a generator with your own hands - not a problem. But this is possible only if you have sufficient knowledge in electronics at the level of the average radio amateur. If there is no knowledge, then forget about the induction stove. Most importantly, it should also be able to operate this device.

If you have stood before the generator schema selection dilemma, then take one board - it should have a hard spectrum of the current. In order to be clearer what we are talking about, we offer the most simple generator scheme for an induction furnace in the photo below.

Generator scheme

Necessary knowledge

The electromagnetic field is valid for all living things. As an example, you can bring meat in the microwave. Therefore, it is worth taking care of security. And, no matter, you collect the oven and test it or work on it. There is such an indicator as energy flow density. So it depends on it from the electromagnetic field. And the higher the radiation frequency, the worse the human body.

Many countries adopted security measures in which the energy flow density is taken into account. There are permissible limits. This is 1-30 MW per 1 m² of human body. These indicators act if irradiation occurs no more than one hour per day. By the way, the set galvanized screen reduces the ceiling density of 50 times.

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Heating and melting of metals in induction furnaces occur due to internal heating and changing crystalline ...

How do you collect the induction oven for melting metal at home

Metal smelting by induction is widely used in different industries: metallurgy, mechanical engineering, jewelry. A simple induction type oven for melting metal at home can be collected with their own hands.

Operating principle

Heating and melting of metals in induction furnaces occur due to internal heating and changes in the crystal metal lattice when high-frequency vortex currents passing through them. The basis of this process is the phenomenon of resonance, in which the vortex currents have the maximum value.

To cause the flow of vortex currents through the melted metal, it is placed in the zone of action of the electromagnetic field of the inductor - coils. It may have the shape of a spiral, eight or a shader. The form of the inductor depends on the size and shape of the heated billet.

The inductor coil connects to the AC source. In the production melting furnaces, industrial frequency currents are used 50 Hz, for melting small volumes of metals in jewelry, high-frequency generators are used as more efficient.

Views

The vortex currents are closed along the contour bounded by the magnetic field of the inductor. Therefore, the heating of the conductive elements is possible both inside the coil and from the external side.

channels, in which the container for melting metals are channels located around the inductor, and the core is located inside it;
crucible, they use a special container - a crucible made of heat-resistant material, usually removable.

Channel oven. Too overall and designed for industrial volumes of melting metals. It is used when smelting cast iron, aluminum and other non-ferrous metals.

Tigel oven. It is quite compact, she enjoyed jewelers, radio amateurs, such a furnace can be collected with their own hands and apply at home.

Device

high frequency alternator;
inductor - a spiral winding of copper wire or tube, made with their own hands;
crucible.

The crucible is placed in the inductor, the winding ends are connected to the current source. When the current flow overlooks it, an electromagnetic field with a variable vector occurs around it. In a magnetic field, vortex currents appear, directed perpendicular to its vector and passing along the closed contour inside the winding. They pass through the metal, laid in the crucible, while heating it to the melting point.

The advantages of the induction furnace:

fast and uniform metal heating immediately after the installation is turned on;
the direction of heating - only metal is heated, not all installation;
high melting speed and melt homogeneity;
there is no evaporation of the alloying components of the metal;
installation is environmentally friendly and safe.

As a generator of an induction furnace for melting metal, a welding inverter can be used. You can also collect the generator according to the schemes below with your own hands.

Metal smelting furnace on a welding inverter

This design is simplicity and safety, as all inverters are equipped with internal overload protection. The entire assembly of the furnace in this case comes down to the manufacture of the inductor with their own hands.

It is usually performed in the form of a helix of a copper thin-walled tube with a diameter of 8-10 mm. It is flexed according to the pattern of the desired diameter, there is a coil at a distance of 5-8 mm. The amount of turns - from 7 to 12, depending on the diameter and characteristics of the inverter. The general resistance of the inductor should be so as not to cause current overload in the inverter, otherwise it will turn off internal protection.

The inductor can be fixed in a graphite or textolite housing and install the crucible. You can simply put the inductor on the heat-resistant surface. The housing should not be conducted, otherwise the closure of the vortex currents will pass through it, and the installation power will decrease. For the same reason, it is not recommended to have extraneous objects in the melting area.

When working from the welding inverter, its housing must be grounded! The socket and wiring must be calculated on the current consumed by the inverter.

The maintenance system of the private house is based on the work of the furnace or boiler, high performance and the long uninterrupted life of which depends on both the brand and the installation of the heating devices themselves and the proper chimney mounting.

Induction oven on transistors: scheme

There are many different ways to collect induction heater with your own hands. A fairly simple and proven furnace scheme for metal smelting is presented in Figure:

two IRFZ44V field transistors;
two UF4007 diode (UF4001 can also be used);
resistor 470 Ohm, 1 W (you can take two sequentially connected 0.5 watts);
film capacitors for 250 V: 3 pieces with a capacity of 1 μF; 4 pieces - 220 NF; 1 piece - 470 NF; 1 piece - 330 NF;
copper winding wire in enamel isolation Ø1.2 mm;
copper winding wire in enamel isolation Ø2 mm;
two rings from chokes removed from a computer power supply.

Assembly sequence with your own hands:

Field transistors are installed on radiators. Since the scheme in the process of work is greatly heated, the radiator must be quite large. You can install them and one radiator, but then you need to isolate transistors from metal using gaskets and washers from rubber and plastic. The field of field transistors is shown in the figure.

It is necessary to make two chokes. For their manufacture, the copper wire with a diameter of 1.2 mm is wound on the rings taken from the power supply of any computer. These rings consist of their powder ferromagnetic iron. They need to be hounded from 7 to 15 turns of the wire, trying to withstand the distance between the turns.

Collect the above capacitors in the battery with a total capacity of 4.7 μF. Constressor connection is parallel.

Perform the winding of the inducer from the copper wire with a diameter of 2 mm. Wash the cylindrical item 7-8 turns of the winding on the diameter of the trigger, the long ends are left for connecting to the diagram.
Connect elements on the board in accordance with the scheme. As a power source, the battery is 12 V, 7.2 A / H. Current current in operation mode - about 10 A, the battery capacity in this case is enough for about 40 minutes. We need to make the chassis of the furnace from heat-resistant material, for example, the textolite. The device memory can be changed by changing the number of turns of the inductor winding and their diameter.

With prolonged operation, the elements of the heater may overheat! To cool it, you can use the fan.

Induction Metal Melting Heater: Video

Induction oven on lamps

A more powerful induction furnace for melting metals can be collected with their own hands on electronic lamps. The diagram of the device is shown in the picture.

To generate high-frequency current, 4 radial lamps are used, connected in parallel. A copper tube with a diameter of 10 mm is used as an inducer. Installation is equipped with a trimmed capacitor for power adjustment. The output frequency is 27.12 MHz.

To assemble the scheme, it is necessary:

4 Electronic lamps - Tetrode, you can use 6L6, 6P3 or G807;
4 chokes per 100 ... 1000 μH;
4 condenser by 0.01 μF;
neon lamp indicator;
strong capacitor.

Assembling the device with your own hands:

The inductor is performed from the copper tube, bending it in the form of a spiral. The diameter of turns is 8-15 cm, the distance between the turns is at least 5 mm. Ends are broken for soldering to the scheme. The diameter of the inductor should be larger than the diameter of the tag of 10 mm.
Place the inductor in the case. It can be made from heat-resistant non-conductive material, or from metal, providing thermo- and electrical insulating from the elements of the circuit.
Collect the cascades of lamps according to the scheme with capacitors and chokes. Cascades are connected to the parallel.
Connect the neon lamp indicator - it will signal the readiness of the scheme to work. The lamp is displayed on the installation housing.
The diagram includes a stroke capacitor of the variable capacity, its handle is also displayed on the body.

For all fans of delicacies cooked by the method of cold smoking, we suggest to learn how quickly and just make your own hands to make a smokehouse, and here to get acquainted with the photo and video instructions for the manufacture of smoke generator for cold smoking.

Cooling scheme

Industrial smelting installations are equipped with a system of forced cooling on water or antifreeze. Water cooling at home will require additional costs comparable for price with the cost of the installation of metal melting.

Air cooling with a fan can be provided with a sufficiently remote location of the fan. Otherwise, the metallic winding and other elements of the fan will serve as an additional circuit for closing the vortex currents, which will reduce the efficiency of the installation.

Elements of the electronic and lamp circuit are also capable of actively heated. For their cooling, heat sink radiators are provided.

Security measures when working

The main danger when working with self-made installation is the risk of burning burns from the heated elements of the installation and molten metal.
The lamp circuit includes high-voltage elements, so it must be placed in a closed case, eliminating a random touch to the items.
The electromagnetic field can affect the items outside the body of the device. Therefore, before work, it is better to wear clothes without metal elements, remove complex devices from the zone: phones, digital cameras.

The furnace for melting metals at home can also be used for rapid heating of metal elements, for example, when they are tinned or molding. The characteristics of the operation of the presented installations can be adjusted under a specific task, changing the parameters of the inductor and the output signal of the generator settings - so you can achieve their maximum efficiency.

Induction furnaces are used to smell metals and feature that the heating in them occurs by electrical current. Current excitation occurs in the inductor, or rather in the non-heated field.

In such structures, energy turns several times (in this sequence):

in electromagnetic;
electric;
thermal.

Such furnaces make it possible to use heat with maximum efficiency, which is not surprising, because they are the most perfect of all existing models working on electricity.

Note! Induction structures are two types - with a core or without it. In the first case, the metal is placed in a tubular chute, which is located around the inductor. The core is placed in the inductor itself. The second option is called crucible, because in it, the metal with a crucible is already inside the indicator. Of course, no core in this case can not be a speech.

In today's article, we will talk about how it is manufacturedinduction oven do it yourself.

Pros and cons of induction structures

Among numerous advantages is to highlight the following:

environmental purity and safety;
increased melt homogeneity due to the active movement of the metal;
speed - the furnace can be used almost immediately after switching on;
zone and focused energy orientation;
high melting speed;
lack of fusion from alloying substances;
the ability to adjust the temperature;
numerous technical capabilities.

But there are also their cons.

The slag is heated from the metal, as a result of which has low temperatures.
If the slag is cold, then it is very difficult to remove phosphorus and sulfur from the metal.
Between the coil and melting metal, the magnetic field is dissipated, so it will be necessary to reduce the thickness of the feet. This will soon lead to the fact that the futures itself fails.

Video - induction oven

Industrial application

Both design options are used in the smelting of cast iron, aluminum, steel, magnesium, copper and precious metals. The useful amount of such structures can be both a few kilograms and several hundred tons.

Industrial furnaces are divided into several types.

The design of medium frequency is commonly used in mechanical engineering and metallurgy. It is melted with steel, and when using graphite crucibles and non-ferrous metals.
The design of industrial frequency is used in the smelting of cast iron.
Resistance designs are intended for melting aluminum, aluminum alloys, zinc.

Note! Induction technology was based on more popular devices - microwave ovens.

Household application

In view of the obvious reasons, the induction furnace for smelting is infrequently used in everyday life. But the technology described in the article is found in almost all modern homes and apartments. These are the above-mentioned microwaves, and induction plates, and electrophovka.

Consider, for example, plates. They heat the dishes at the expense of induction vortex currents, as a result of which heating occurs almost instantly. It is characteristic that it is impossible to turn on the burner on which there is no dishes.

The CPD of induction plates reaches 90%. For comparison: electric stoves it is approximately 55-65%, and gas is not more than 30-50%. But the sake of fairness should be noted that special dishes are required to operate the plates described.

Homemade induction oven.

Not so long ago, domestic radio amateurs visually demonstrating whether the induction furnace can be made himself. Today there are a lot of different schemes and technologies of manufacture, we also led the most popular of them, which means the most effective and simple in execution.

Induction furnace from high-frequency generator

Below is an electrical diagram for the manufacture of a homemade device from high-frequency (27.22 megahertz) generator.

In addition to the generator, the assembly will require four high-power electric bulbs and a heavy lamp for the readiness indicator.

Note! The main difference of the furnace made on this scheme is the handle of the condenser - in this case it is located outside.

In addition, the metal located in the coil (inductor) is melted in the device of the most insignificant power.

In the manufacture, it is necessary to remember certain important points that affect the rate of metal reign. It:

power;
frequency;
vortex losses;
heat transfer intensity;
losses on hysteresis.

The device will be powered by a standard network in 220 V, but with a pre-installed rectifier. If the furnace is designed to heat the room, it is recommended to use nichrome spiral, and if for smelting, then graphite brushes. You will get acquainted with each of the designs in more detail.

Video - Design of welding inverter

The essence of the design is as follows: a pair of graphite brushes is installed, and the powder granite is falling asleep between them, after which the eyeliner is carried out to the downstream transformer. It is characteristic that when smelting, you can not be afraid of the shock, since there is no need to use 220 V.

Build technology

Step 1. The basis is the base - boxing of chamotte brick size 10x10x18 cm, laid on a refractory tile.

Step 2. Boxing is frozen asbestokarton. After wetting, the material is softened, which allows it to give it any shape. If desired, the design can be wrapped with steel wire.

Note! Boxing dimensions may vary depending on the power of the transformer.

Step 3. The optimal version for the furnace on graphite is a transformer from a welding machine with a capacity of 0.63 kW. If the transformer is designed for 380 V, then it can be reworked, although many experienced electricians claim that you can leave everything as it is

Step 4. The transformer is winding with thin aluminum - so the design will not be very basked during operation.

Step 5. Graphite brushes are installed, a clay substrate is installed on the bottom of the box - so the molten metal will not be spread.

The main advantage of such a furnace is a high temperature that is suitable even for platinum or palladium melting. But among the minuses - the rapid heating of the transformer, a small volume (at a time can be paid no more than 10 g). For this reason, for smelting large volumes will require a different design.

So, for the smelting of large volumes of metal, the oven will be required with nichrome wire. The principle of operation of the structure is quite simple: the electric current is fed to the nichrome spiral, she heats up and melts the metal. The network has a lot of different formulas for calculating the wire length, but they are also the same.

Step 1. For the spiral used nichrome Ø0.3 mm of about 11 m.

Step 2. Wire must be coated. To do this, you will need a straight copper tube Ø5 mm - a spiral is wound on it.

Step 3. A small ceramic pipe Ø1.6 cm and a length of 15 cm is used as a trigger and a length of 15 cm. One end of the pipe is stuck asbestos - so the molten metal will not flow.

Step 4. After checking the workover and the spiral stacked around the pipe. At the same time, the same asbestos thread is put together between the turns - it will prevent the closure and limit the access of oxygen.

Step 5. The finished coil is placed in the cartridge from the high power lamp. Such cartridges are usually ceramic and have the necessary size.

Advantages of this design:

high productivity (up to 30 g per side);
fast heating (about five minutes) and long cooling;
ease of operation - metal is convenient to pour into molds;
operational replacement of the spiral in case of bravery.

But there is, of course, and cons:

nichrome blows up, especially if the spiral is poorly isolated;
insecure - the device is connected to 220 V electrical strokes

Note! It is impossible to add metal to the stove if the previous portion is already melted there. Otherwise, the entire material will split around the room, moreover, it can injure his eyes.

As a conclusion

As you can see, the induction oven can be done on their own. But if you are frank, the described design (like all on the Internet) is not really a furnace, and the laboratory inverter of the kitchen. It is simply impossible to assemble a full-fledged induction design at home.

chief Editor

How to make an induction heater with your own hands?

Electric heaters

Induction heaters work on the principle of "Obtaining current from magnetism". A variable high-power magnetic field is generated in a special coil, which generates vortex electrical currents in a closed conductor.

A closed conductor in induction plates is a metal tableware that is heated by vortex electric currents. In general, the principle of operation of such devices is not complicated, and in the presence of small knowledge in physics and electrics, to collect induction heater will not make a lot of work.

Alone, the following devices can be made:

Instruments To heat the coolant in the heating boiler.
Mini-stove For melting metals.
Plates for cooking food.

Induction stove with your own hands, must be made in compliance with all rules and rules for the operation of the instrument data. If, outside the body in the side directions, a hazardous electromagnetic radiation will be distinguished, then use such a device is strictly prohibited.

In addition, the greater complexity in the construction of the slab is the selection of material for the base of the hob, which should meet the following requirements:

Ideally carry out electromagnetic radiation.
Do not be conductive material.
Hold a high temperature load.

In domestic cooking induction surfaces, expensive ceramics are used, in the housework of induction plates, find a worthy alternative to such a material is quite difficult. Therefore, for a start, it is necessary to construct something easier, for example, an induction oven for hardening the metals.

Instructions for manufacture

Figure 1. Electric circuit induction heater

Figure 2. Device.

Figure 3. Scheme of a simple induction heater

For the manufacture of the furnace, the following materials and tools will be needed:

soldering iron;
solder;
textolite fee.
mini drill.
radio elements.
thermal Pasta.
chemical reagents to etching board.

Additional materials and their features:

For the manufacture of coilwhich will radiate the alternating magnetic field necessary for heating, it is necessary to prepare a segment of the copper tube with a diameter of 8 mm, and a length of 800 mm.
Powerful power transistors Are the most expensive part of the homemade induction installation. To mount the frequency generator scheme, it is necessary to prepare 2 such elements. For these purposes, transistors of brands are suitable: IRFP-150; IRFP-260; IRFP-460. In the manufacture of the circuit, 2 of the same of the listed field transistors are used.
For the manufacture of oscillating contour We will need ceramic capacitors with a capacity of 0.1 MF and a working voltage of 1600 V. In order for an alternating current of high power in the coil, 7 such capacitors will be required.
When working such an induction deviceField transistors will be heated greatly and if the radiators made of aluminum alloy are not attached to them, then after a few seconds of operation at maximum power, these elements will fail. Put transistors on heat sinks should be put through a thin layer of thermal paste, otherwise the effectiveness of such cooling will be minimal.
Diodeswhich are used in the induction heater must necessarily be ultrafine. The most suitable for this scheme, diodes: MUR-460; UF-4007; HER - 307.
Resistors that are used in Scheme 3: 10 com power 0.25 W - 2 pcs. and 440 Ohm power - 2 W. Stabilians: 2 pcs. With a working voltage of 15 V. The power of stabilion should be at least 2 W. The throttle to connect to the power outputs of the coil is used with induction.
To feed the entire device, you will need a power supply up to 500. W. and voltage 12 - 40 V.You can save this device from a car battery, but get the highest power readings at such a voltage will not work.

The process of manufacturing an electron generator and coil occupies a little time and is carried out in such a sequence:

From copper pipe A spiral is made with a diameter of 4 cm. For the manufacture of the spiral, the copper tube should be turned on the rod with a flat surface with a diameter of 4 cm. The helix should have 7 turns that should not be in contact. At 2 end of the tube, fastening rings are soldered to connect to transistor radiators.
The printed circuit board is manufactured according to the scheme. If there is an opportunity to supply polypropylene capacitors, then due to the fact that such elements have minimal losses and sustainable work at large voltage fluctuations, the device will work much more stable. Capacitors in the diagram are installed in parallel forming an oscillating circuit with a copper coil.
Heating Metal It happens inside the coil, after the scheme is connected to the power supply or battery. When the metal heated, it is necessary to ensure that there is no short circuit of the springs windings. If you touch the heated metal 2 turns of the coil at the same time, the transistors fail instantly.

When conducting experiments on heat and hardening metals, inside induction spiral, the temperature can be significant and is 100 degrees Celsius. This thermal heating effect can be used to heat water for household needs or for home heating.
The diagram of the heater considered above (Figure 3)At maximum load, it is capable of providing radiation of magnetic energy inside the coil equal to 500 W. Such power is not enough to heat a large amount of water, and the construction of a high-power induction coil will require the production of a scheme in which it will be necessary to use very expensive radio elements.
Budget solution to the organization of induction heating of fluidis the use of several devices described above, located sequentially. At the same time, the spirals should be on the same line and not have a shared metal conductor.
As a heat exchanger Stainless steel pipe with a diameter of 20 mm is used. There are several induction spirals on the pipe "stand", so that the heat exchanger is in the middle of the spiral and did not come into contact with her turns. With the simultaneous inclusion of 4 such devices, the heating power will be about 2 kW, which is already sufficient for flowing fluid heating with a small circulation of water, to the values \u200b\u200ballowing the use of this construction in the supply of a small house.
If you connect such a heating element with a well-insulated tankwhich will be located above the heater, the result is a boiler system in which the heating of the fluid will be carried out inside the stainless pipe, the heated water will rise up, and its place will occupy a colder liquid.
If the area of \u200b\u200bthe house is significantThe number of induction spirals can be increased to 10 pieces.
The power of such a boiler can be easily adjusted. By turning off or turning on the spirals. The more at the same time enabled sections, the greater the power of the heating device that works.
To power this module, you will need a powerful power supply. If there is a DC inverter welding machine, then the voltage converter of the required power can be made of it.
Due to the fact that the system works on a constant electric currentwhich does not exceed 40 B, the operation of such a device is relatively safe, the main thing is to provide a fuse block in the generator in the power supply scheme, which in the case of a short circuit will de-energize the system, there is the easiest of the fire.
You can thus organize "free" home heating, subject to installation for powering induction devices of batteries, charging which will be carried out by the energy of the sun and wind.
Batteries should be merged into the sections of 2 pcs., Connected sequentially. As a result, the supply voltage with such a connection will be at least 24 V., which will ensure the operation of the boiler at high power. In addition, the sequential connection will reduce the current strength in the chain and increase the service life of the batteries.

Operation of homemade induction heating devicesIt does not always eliminate the spread of electromagnetic radiation harmful to humans, so the induction boiler should be installed in a non-residential room and shielded galvanized steel.
Required when working with electricity safety regulations should be followedand, especially this concerns the AC network with a voltage of 220 V.
As an experiment you can make a cooking surface for cooking According to the scheme specified in the article, but to operate this device is constantly not recommended due to the imperfection of independent manufacture of the screening of this device, because of this, it is possible to effect on the human body of harmful electromagnetic radiation capable of negatively affecting health.

Determine the desired size of your oven. For casting small items weighing less than 1-2 kilograms, such as manual printing, etc., there will be a 30-centimeter (12 inches) of a melting chamber with a crucible capacity of 1 liter.

Pick up materials that will withstand the temperatures created in your oven. In our example, we use charcoal as fuel as fuel, since it is also available inexpensive. The temperature of its combustion (caloriness) in the air flow is about 1250 degrees Celsius. At the same time, the temperature coal combustion temperature in the air flow exceeds 1650 degrees Celsius, so the charcoal is more suitable as a fuel for a smelting furnace collected from easily accessible structural materials - after all, in the flame of stone coal, blown by air, even steel is melted. We use for the manufacture of a melting chamber leaf galvanized steel 14th caliber.

Make two cylinder from your material. The figure shows cylinders with a height of about 30 centimeters (12 inches), rolled from the sheet material, although aluminum can be melted and in the cans from the paint or metal buckets for garbage. But such unreliable tanks will be unusable after several melting, so better, putting small efforts, make a more reliable container that will withstand the number of melting you planned.

The inner cylinder should be large enough to accommodate your melting crucible, leaving the place for fuel around the crucible; It should also be deep enough so that you can cover this cylinder together with a crucible cover, as will be described below. For a trigger with a diameter of 20 centimeters (8 inches), the camera is needed with a diameter of 36 centimeters (14 inches), and if the depth of vague is also 20 centimeters (8 inches), the height of the chamber must be at least 30 centimeters (12 inches).
The outer wall of the chamber (larger cylinder) is designed to provide additional safety in the case of moltening the inner wall, as well as for better thermal insulation of the inner chamber. The outer chamber should be greater in diameter by 10 cm (4 inches), and at least 5-10 cm (several inches) is higher than the internal one. According to the above scheme, the diameter of the external cylinder is 41 cm (16 inches), and its height is 41-46 cm (16-18 inches).

Attach the outer cylinder to the metallic DNU. This can be done by welding, or screwing screws. If the bottom size is significantly higher than the diameter of the cylinder, it will make the design more stable and safe.

Put the bottom of the outer cylinder into refractory bricks, achieving as much resistance as possible. These heat-resistant bricks will support your oven during smelting and thermally insulated it hot bottom.

Insert the inner cylinder into the external, tracing so that it fit exactly in the middle. The space between the cylinder walls can be filled with refractory lime solid or dry sand, which will give the design b aboutso much stability; You can simply fix the cylinders relative to each other with metal wedges.

Drill or cut a hole in the outer and inner cylinders with a diameter of about 6 cm (2 1/4 inches) near the bottom under the tilt inside and up, so that the air freely proceeds to the crucible, providing burning fuel with oxygen.

Cut the metal tube with a diameter of 6 cm and the length of the half or more (the thin-walled metal tube for wires is suitable) - it will serve for supplying air to the melting chamber; We weld it to the hole in the external cylinder or attach screws.

Cut the wheel of the sheet metal, large enough so that it completely covered the camera from above. Cut in this circle a hole with a size of 15x15 cm (6x6 inches), which will serve for free air circulation and to add metal to the crucible; A cut fragment will serve as a lid. For convenience, you can attach the circuit cover to the outer wall of the furnace, and also to attach a handle to the lid.

Make a crucible (melting boiler). You can use the suitable metal cylinder from the old thermos, or stainless steel boiler. In order to be able to pour the molten metal from the crucible, attach a steel handle to it, which would perform on top of the melting chamber.

Connect the blower to the metal tube, built earlier near the bottom of the housing. You can use the old hairdryer or a low-power machine to blow the leaves, attaching them to the tube scotch. If you do not have a hair dryer, nor the machine will suit any device that will provide the necessary air flow through the tube. At the same time, remember that too much air flow can lead to intense and rapid coal combustion, and the insufficient air flow will suppress the burning and will not provide you with the necessary temperature.

Now the furnaces with the induction system are used everywhere in the process of melting metals. The current produced in the inductor field contributes to the heating of the substance, and this feature of such devices is not only the main, but also the most important. Processing leads to the fact that the substance undergo several transformations. The first stage of the transformation is the electromagnetic stage, after it is electrical, and then thermal. The temperature that the stove highlights is applied to almost no residue, so such a solution is the best among all others. Many may be interested in the furnace made. Next will be told about the possibilities of implementing a similar solution.

Types of furnaces for melting metals

This type of equipment can be divided into major categories. At the first, the heart canal acts as a base, and the metal is placed in such furnaces with an annular way around the inductor. The second category does not have such an element. This species is the name of the crucible, and the metal is placed here inside the inductor itself. A closed core in this case is technically impossible to use.

Basic principles

The melting furnace in this case runs on the basis of the phenomenon of magnetic induction. And here there are several components. Inductor is the most important component of this device. It is a coil, conductor in which is not ordinary wires, and copper tubes. This requirement exhibits the design of melting furnaces. The current that passes in the inductor generates a magnetic field that affects the crucible, inside which is the metal. In this case, the material is assigned the role of secondary transformer winding, that is, there is a current heats it through it. So the melting is carried out, even if the induction furnace is made with their own hands. How to build such a type of furnace and increase its effectiveness? This is an important question that is the answer. The use of high frequency currents allows noticeable to increase the degree of efficiency of the equipment. To do this, it is appropriate to use special power supplies.

Features of induction furnaces

This type of equipment has certain characteristic features that are both advantages and disadvantages.

Since the distribution of the metal should be uniform, the resulting material is characterized by a good homogeneous mass. This type of furnace works due to the transportation of energy along zones, and the energy focus function is also presented. For use, such parameters such as a container, operating frequency and method of lining, as well as temperature control, at which metal melting occurs, which significantly facilitates the workflow. The existing technological potential of the furnace creates a high pace of melting, devices are environmentally friendly, completely safe for humans and ready to work at any time.

The most notable disadvantage of such equipment is the complexity of its cleaning. Since the heating of the slag occurs solely due to the heat released by the metal, this temperature is not enough to ensure its full use. The high difference in the temperature of the metal and slag does not allow to make the waste disposal process as simple as possible. As another drawback, it is customary to allocate the gap, due to which it is necessary to always reduce the thickness of the lining. Because of such actions, some time, it may be faulty.

The use of induction furnaces on an industrial scale

In industry, most often there are crucible and channel induction furnaces. In the first, there is a mock of any metals in arbitrary quantities. Capacities for metal in such embodiments are able to fit up to several tons of metal. Of course, induction melting furnaces are impossible in this case. Channel furnaces are designed to smell non-ferrous metals of different species, as well as cast iron.

This topic is often interested in fans of radio engineering and radio technologies. Now it becomes clear that you can create induction furnaces with your own hands - it is quite real, and it was able to do it very much. However, to create such equipment, it is necessary to implement the effect of the electrical circuit, which would contain the adventures of the oven itself. Such solutions require attracting capable of producing wave oscillations. A simple induction furnace with their own hands according to the scheme can be built using four electronic lamps in combination with one neon, the signal that the system is ready for operation.

In this case, the AC condenser handle is not inside the instrument. Due to this, an induction furnace can be created with their own hands. The instrument diagram describes in detail the location of each individual element. Ensure that the device is powerful enough, you can, if you use a screwdriver, which must come up to a hotsture literally in a few seconds.

Features

If you are created by an induction furnace with your own hands, the principle of operation and the assembly of which is being studied and produced according to the relevant scheme, you should know that one or more factors listed in this case may affect the melting speed in this case:

Pulse frequency;

Hysteresis losses;

Generator power;

The exit period of heat outwards;

Losses associated with the occurrence of vortex currents.

If you are going to the furnace induction with your own hands, then when using lamps it is necessary to remember that their power should be distributed so that four pieces are enough. When using the rectifier, the network will be in about 220 V.

Household applying furnaces

In everyday life, such devices are rare enough, although such technologies can be found in heating systems. They can be seen in the form of microwave ovens and in the medium of new technologies this development has been widely used. For example, the use of vortex induction currents in induction plates allows you to prepare a huge variety of dishes. Since it takes very little time for heating, it cannot be turned on, if nothing is worth it. However, special dishes are required to use such special and useful plates.

Assembly process

Induction with his own hands consists of an inductor, which is a solenoid produced from a water-cooled copper tube and a crucible, which can be made of ceramic materials, and sometimes from steel, graphite and others. In such a device, cast iron can be paid, steel, precious metals, aluminum, copper, magnesium. Induction furnaces are made with their own hands with a tagger capacity from a couple kilogram to several tons. They can be vacuum, gas-filled, open and compressor. Feed furnaces with high, medium and low frequency currents.

So, if you are interested in the induction oven with your own hands, the scheme involves the use of such main nodes: a melting bath and an induction unit, which includes a litron, inductor and a magnetic core. The channel furnace differs from crucible because the electromagnetic energy is converted to heat in the heat generation channel, in which the electrically conductive body must always be. To produce a primary launch of a channel oven, a molten metal is poured into it or insert a pattern from a material that can crack in the furnace. When the melting is completed, the metal is not completely merged, but remains "swamp", designed to fill the heat generation channel for starting in the future. If an induction furnace is assembled with her own hands, then to facilitate the replacement of the subsidence for the equipment, it is made separately.

Components of the furnace

So, if you are interested in the induction mini-oven with your own hands, it is important to know that its main element is the heating coil. In the case of a homemade version, it is enough to use the inductor made of a naked copper tube, the diameter of which is 10 mm. For the inductor, an internal diameter of 80-150 mm is used, and the number of turns is 8-10. It is important that the turns do not come into contact, and the distance between them was 5-7 mm. Parts of the inductor should not come into contact with its screen, the minimum clearance must be 50 mm.

If you are going to the furnace induction with your own hands, then you should know that water or antifreeze is engaged in the cooled inducers. In the case of low power and short work of the device being created, you can do without cooling. But during operation, the inductor is very heated, and the copper on copper may not just sharply reduce the efficiency of the device, but also lead to a complete loss of its performance. It is independently impossible to make an inducer with cooling, so it will be required to be regularly replaced. It is impossible to use forced air cooling, since the fan body placed near the coil, "will attract" the EMF, which will lead to overheating and the fall of the KPD of the furnace.

Generator

When the induction furnace is assembled with her own hands, the scheme involves the use of such an important element as an alternator. You should not try to make a stove if you do not own the foundations of radio electronics at least at the level of the average unqualified radio amateur. The selection of the generator schema should be such that it does not give a hard spectrum.

Using induction furnaces

This type of equipment was widespread in areas such as foundry, where the metal has already passed the cleaning and it is required to give it some particular shape. You can also get some alloys. In jewelry, they also got distribution. A simple principle of work and the possibility that the induction furnace is collected with their own hands, allow you to increase the profitability of its use. For this area, you can use instruments with a tang-5 kilogram capacity. For small production, this option will be optimal.

From 75.000 rub.

Below in the table indicates some of the possible complete sets and prices for them.
Dealer prices are negotiated separately.

Induction smelting furnaces SL Mellecto and under the order are made. This is the most affordable series of stoves with simple design and high reliability.
Desktop Induction Melting Furnace for Melting Of Non-Ferrous Metal. Graphite Crucibles 0.5 -2 Are Used. Below is a table with parameters.

A possible range includes the entire line of smelting furnaces used in small workshops, in particular in the jewelry industry. Desktop induction melting furnaces can be made to melting metal weighing up to 2 kg. In the title of the furnace reflects its power and mass of the melted metal. For example: SL2200-1. This means that the 2.2kW oven is calculated for the smelting of non-ferrous metal weighing 1kg.

In the "Gallery" section there are photos of induction furnaces: Gallery.
Cooling systems specially developed for desktop furnaces :.
In the "Loading" section of the video autonomous melting complex with a cooler on the base of a table furnace: a stove with a cooler video.

Test table stove: YouTube:

Download: Video Work Desktop Induction Furnace

Induction smelting furnaces SLB Made under the order. Customer requirements and working conditions are very different. The outdoor option can be made under the Tigel to 5kg. Power can reach 12 kva. The cooling system can be mounted at the bottom of the furnace. If necessary, you can install a tag lift device. The time of manufacture of an outdoor furnace is from two weeks.

In the "Gallery" section, you can see photos of induction furnaces: gallery.

In the "Downloads" section, you can download video operation of the floor induction furnace in the foundry workshop: the work of the outdoor induction furnace video.

We are pleased to help customers in their work. We answer any questions on the phone and email, we will organize test launches of furnaces, deliver equipment to any region payment and delivery.

The table presents possible options for the configuration.

parameters	SL1800-0.5	SL2500-1.	SL2500-2.	SLB6000-3.
Power consumption, VA (pOWER)	1800	2500	2500	6000
Metal mass in crucible, kg (crucible kg.)
Nominal frequency of circuit current, kHz (frequency)	70-120	70-120	70-120	70-120
Maximum temperature (temperature. )	1200ºC.	1200ºC.	1200ºC.	1200ºC.
Heating time from 20 to 1000 º, min (hEATING TIME. )
Water inductor cooling(Water Cooling)
Network Network (Supply)	220 V, 50 Hz	220 V, 50 Hz	220 V, 50 Hz	380 B.
Temperature controller (temperature Controller )	AUTONICS TC4W.	AUTONICS TC4W.	Aries TRM10	Aries TRM10
Idling protection (iDle Protection. )
Water flow sensor (water Flow Sensor )
Dimensions (Case Dimensions )	460 x 240 x 260	460 x 240 x 260	460 x 240 x 260	710 x 600 x 1000
Price, thousand rubles.

We can make the stove under the graphite crucible of any size.

Water cooling is required for furnaces. We make special coolers. With the help of them, it turns out a complete autonomous smelting complex coolers for induction furnaces.

You can download video in "downloads" - a stove with a cooler video

Furnaces for metal volume, more than 1kg, are manufactured in outdoor options in coordination with the customer.

The maximum temperature is determined by the power and thermal insulation of the crucible. For the SL series furnaces, 1200 degrees are indicated, since the controller cannot measure the temperature above. In addition, graphite crucibles are greatly overtaken at higher temperatures.
The furnaces can be equipped with the temperature controllers "Aries" or "Autonics". Aries controllers are more accurately calibrated by temperature, and "Autonics" have a simpler interface.

Furnaces can be equipped with ceramic caps for crucible.

Covers can be purchased separately.

Floor furnaces can be equipped with trigger lifting devices with a pedal drive.

For mirroring of metals it is convenient to use a granulator. It is filled with water, mellal is needed to pour a thin jet. Small granules are obtained, which are convenient to weigh, mix and use in further production.

Induction melting theory:

There are two principle of induction melting of metal. At the first frequency of the pump pumping, the inductor is relatively not large. Tigel is made of graphite. The energy of the inductor is absorbed and the crucible and partly the metal inside the crucible. As a result, the metal melts, heating from the hot crucible and heating independently. With the second variant, the crucible is made of non-conductive material. Thus, the inductor suggests the vortex currents only in the metal itself. For such a method of induction heating, a higher pump frequency is required.

In any of the above cases, an electrical transformer obtains, in the primary circuit of which the inductor is located, and the secondary is the heated object. The case can still be complicated by ferromagnetic properties of materials. The complexity lies in the distributed nature of the fields and changing the properties of ferromagnets during the transition through the Curie point. Because of all this, a stove for non-ferrous metal differs fundamentally from stoves for steels, nickel, etc.

The main problem of induction smelting furnaces is the heating of the inductor. Although there are currents of hundreds and thousands of amps flow in it, but this is not the most basic cause of the inductor overheating. It's all in the emission of the heated object. For example, if a crucible is inserted into the inductor, then at high temperature it begins to "glow" in the infrared range. Thus, he begins to warm the inductor. Since it is impossible to make a big gap between the inductor and the crucible, it is necessary to cool the inductor. To increase the efficiency of the stove, you need to make a minimum clearance and have minimal heat loss from the heated object. Consequently, the entire system (inductor, crucible, thermal insulation, cooling) must be thought out and is well balanced both by electrical and thermal parameters. This should be simple, but an important thought: the stove is created under a completely specific crucible. If you stuff in the inductor induction stove alien crucible, then at best it will simply be bad heating, in worst - there is a chance to spoil the stove.

Masters working with metal, as a rule, go to induction furnaces due to their high qualities. In this case, reserves of crucibles from previously used furnaces can remain. In addition, several furnaces can be used for different purposes. In this case, it is convenient to have universal crucibles that are suitable for all stoves. We offer the manufacture of induction furnaces to order, for different sizes of crucibles, within the framework of technological limitations of the body and the cooling system.

In our desktop furnaces made in small-sector, the uniform case is used. It allows you to use cubic with a container to one kilogram of non-ferrous metal. Structurally, the housing is made of two compartments. In one there is all the electronics, the other is a worker, it contains an inductor and a thermal insulation system. The inductor compartment has double steel walls for emission shielding. Thus, you do not need to outline the chalk on the floor safe zone for the operator. On the face of saving chalk and paper on sick leave.

The electrical safety of the stove is determined by the electroplating of the inductor from the network. The inductor is powered by an internal converter through a special pulse transformer. The housing of the stove structures does not allow the operator to touch any current parts. Transistors inside the stoves are used only in isolated cases, which does not allow the potential even to internal radiators. The stove power cord contains ground wire. If the ground is missing on your network, you can connect an external ground.