Induction Furnace
An Induction Furnace is basically an electric furnace in which induction process is used to heat the metal using the arising Eddy Currents. Metal heats up itself when a specific frequency (differs from metal to metal) induction is generated by the inverter circuit in the output coil
2025-06-28 16:33:06 - Adil Khan
Induction Furnace
Project Area of Specialization Shared EconomyProject SummaryAn Induction Furnace is basically an electric furnace in which induction process is used to heat the metal using the arising Eddy Currents. Metal heats up itself when a specific frequency (differs from metal to metal) induction is generated by the inverter circuit in the output coil. The major advantages of induction furnace are clean, well-controllable and energy-efficient melting process as compared to other processes for melting of metal. Now-a-days modern industries and foundries use induction furnace, instead of earlier designed furnaces, as they emit dust as well as large amount of heat that causes pollution. Hence, we tend to design an efficient low-cost induction furnace for melting metal. The main advantage of such furnace is that it does not use combustion method hence its temperature does not rise above the required temperature for melting a specific metal. The metals can be melted in a fairly clean and affordable manner using induction furnaces. Such furnace has low operation cost so it can be used widely and primarily.
Block Diagram / Organization of the Project
The main objective of the proposed project is to design an efficient and low-cost induction furnace capable of heating and melting metal. The circuitry required to convert a high voltage low ampere current to a low voltage, high ampere current will be designed and implemented for induction heating of the metal. A circuit delivering output power of up to 2000W will be designed for melting of small amounts of metal at a time.
The designed induction furnace would be efficient and inexpensive as compared to industrial furnaces. It is to be designed in less cost and would have low operational cost as well.
The whole project comprises of 3 portions
1.The first one is the power supply section that will provide dc volatge for the inverter circitary
2. The second one is the implemetation of inverter section that will provide low voltage and high ampere current
3. The third portion is the resonant circuit which is the combination of capactiors and output inductor coil. Both capacitor bank and inductor coil are responsible for frequency selection that has important role in melting process
Benefits of the ProjectThe main advantage of such furnace is that it does not use combustion method hence its temperature does not rise above the required temperature for melting a specific metal. The metals can be melted in a fairly clean and affordable manner using an induction furnaces. Such furnace has low operation cost so it can be used widely and primarily.
Energy Consumption Analysis :
Daily Units = wattage × Usage hours per day / 1000
Monthly Units = Units × Usage hours per day ×30 (or 28, 29, 31 based on months)
Wattage Calculation for Induction Furnace:
Let the induction wattage is 2kVA.
Unit consumption = (2,000 × 1) / 1000 kwh = 2kwh = 2 units (where 1kwh = 1 unit)
One unit cost =Rs.18/- (for domestic use)
Total Bill for 1 hour = 2 × 18 = Rs. 36/-
Technical Details of Final DeliverableTechnical Details :
- As we made first made power supply using step down transformer, bridge rectifier and filtering capacitor which would be giving the pure DC voltage at its output .Which would be further given to the inverter circuit that we made for providing us low voltage, high current and high frequency AC signal for producing the induction in the output coil (copper tubing).
- Inverter circuit includes high voltage and amperes rating diodes, Zener diodes of 5watt in order to regulate the voltage at the input of the MOSFETs to prevent them getting burned, some resistors for the working and protection of the zener diodes, MOSFETs and heat sinks attached with the MOSFETs to prevent them from overheating (as overheating cause damage), Inductor Choke coil for the power management of the inverter that is made up of the specific insulated copper coil wounded on specific diameter core so that it would be giving the required inductance at its output and divides the power.
- Further it included the number of capacitors (capacitor bank) connected in parallel to the output of the inverter (drains of both the MOSFETs) and the inductor coil for the furnace to produce induction inside it and helps generating the required resonant frequency in the output coil so that it could be easily penetrated inside the metal.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 71200 | |||
| Transformer (3KVA) | Equipment | 1 | 15000 | 15000 |
| Transformer (1KVA) | Equipment | 1 | 10000 | 10000 |
| Capacitor (Ceramic-frequency =1MHZ) | Equipment | 200 | 50 | 10000 |
| Inductor Coil (for capacitor bank + output coil) | Equipment | 2 | 2500 | 5000 |
| Inverter+PLL (include diodes +resistors +3/29,7/29 wires+thimbles | Equipment | 50 | 100 | 5000 |
| Bridge rectifiers + Metal Diodes | Equipment | 6 | 1200 | 7200 |
| MOSFETS (high current rating) | Equipment | 34 | 150 | 5100 |
| Heat Sinks (with fan for cooling) | Equipment | 4 | 1500 | 6000 |
| UPS plates for MOSFET driver | Miscellaneous | 2 | 500 | 1000 |
| Shipping Cost (capacitors + MOSFETS + Heat Sinks) | Miscellaneous | 3 | 2300 | 6900 |