Week 4: Electronics Design

Making an Induction Heater Circuit

"There are only four rules you need to remember. Make the plan, execute the plan, expect the plan to go off the rails… throw away the plan." - Leonard Snart

So, the plan was to make the inductor heater circuit from last week. There was only one slight problem: the circuit I made last week had placeholder parts that didn't match what was available in shop - so my first step was to find appropriate parts and size them appropriately so that I didn't blow up the circuit. After all, nothing bad has ever happened from linking a bunch of capacitors together and forcing the current through a small wire, right?

My first gif

I created a little sizing tool in desmos so that I could get a target frequency of about 70 kHz with a 1-amp resonant current. The capacitors available were good enough (100 nF) to get the capacitance I needed. To get the corresponding inductance, I jankily made my own inductor using 22 AWG wire and hot glue... doesn't look pretty, but it get's the job done.

My first gif

At first, manufacturing went pretty well: I exported my gerber and drill (.xln) files from Fusion, created a png using gerber2img, created the tool path using modsproject (selecting a 1/64" end mill), and uploaded my G-code to the carvera. A quick aside on gerber2img: the process worked best for me when I uploaded the .xln file with the outline of the board first, then locked the dimensions and origin, and then uploaded the .xln with the traces. For some reason, when I did the opposite, the scaling would be off. Anyway, back to my notes.

My first gif

I hooked up the circuit to five volts and... nothing happened.

My first gif

I checked everything: there were no shorts, my diodes were oriented correctly, the voltage was live - but a telltale sign of the issue was the there was absolutely no current going through the circuit. And that's when I decided to go back to simulate the circuit. That's when I learned that I had put no way of initially charging the coil: current would, as it usually does, take the path of least resistance, which was around the capacitor bank and coils right through the n-type mosfets back to ground. As such, I did a little bit of messing around with the simulation, referenced a couple of other inductor circuits, and...

My first gif

Huzzah! Time to remake everything...

Half circuit Half circuit Half circuit

This time, current flowed through the board, but, I'm afraid that I still didn't manage to achieve resonance. The culprit this time? Fried mosfets. Whether they were friend before I turned on the power supply or after, I'm still not too sure, but I'll replace the fried MOSFETs later, ad it appears I have run out of time. Until next timme!

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