Development of 50 kW Induction Heating Inverter PCB
Budget: $15 – $25 USD
Objective
Design and develop a complete electronic system for a 50 kW induction heating inverter, powered by a 220 VAC three-phase input, using IGBT power modules and controlled by an STM32 microcontroller. The output will drive a resonant LC load at an operating frequency of 100 kHz.
⸻
? Technical Specifications
1. Input:
• Input voltage: 3 x 220 VAC
• Line frequency: 50/60 Hz
• Protections: undervoltage, overvoltage, phase loss
• Three-phase rectification with intermediate DC bus
2. Inverter Stage:
• Topology: Full-bridge with IGBTs
• Output power: 50,000 W
• Estimated DC bus voltage: ~310 VDC
• Switching frequency: ~100 kHz
• Load inductance: ~200 µH
• Output current: up to 100 A peak
3. Control:
• Microcontroller: STM32 (F or G series)
• Control functions:
• PWM generation with resonant modulation (preferably ZVS)
• Dead-time control between IGBTs
• Voltage and current sensing
• Protection functions (overcurrent, overtemperature, IGBT fault, etc.)
• UART/USB communication for debugging or interface
• Digital isolation for feedback is recommended
4. Drivers and Protection:
• Gate drivers with galvanic isolation (e.g., opto-isolated or transformer-based)
• RC snubbers on each leg and MOVs on the DC bus
• Current sensing via shunt or Hall-effect sensors
• Temperature monitoring on IGBTs and heat sinks
5. PCB Design:
• Combined layout for power stage + control logic
• Preferably split board (high-power and logic separated)
• Proper thermal dissipation design (heat sinks + forced air)
• Reinforced copper tracks for high current paths
⸻
? Expected Deliverables
• Complete circuit schematic (protection, control, power)
• PCB layout files (Gerber, BOM, CAD)
• Switching and thermal simulation (if possible)
• STM32 firmware (basic PWM functional code)
• Documentation: pinout, components, test procedures
⸻
? Freelancer Requirements
• Proven experience in power electronics design
• Solid knowledge of IGBTs, resonant control, snubber circuits, protections
• Experience with STM32 microcontrollers and C/C++ development
• PCB design experience with mixed-signal boards (power + logic)
⸻
⚠️ Additional Notes
• This system will drive a 200 µH heating coil for industrial induction heating
• Stable switching frequency required: 95–105 kHz
• Emphasis on thermal and electrical reliability
• Portfolio or relevant previous projects will be a strong asset
Design and develop a complete electronic system for a 50 kW induction heating inverter, powered by a 220 VAC three-phase input, using IGBT power modules and controlled by an STM32 microcontroller. The output will drive a resonant LC load at an operating frequency of 100 kHz.
⸻
? Technical Specifications
1. Input:
• Input voltage: 3 x 220 VAC
• Line frequency: 50/60 Hz
• Protections: undervoltage, overvoltage, phase loss
• Three-phase rectification with intermediate DC bus
2. Inverter Stage:
• Topology: Full-bridge with IGBTs
• Output power: 50,000 W
• Estimated DC bus voltage: ~310 VDC
• Switching frequency: ~100 kHz
• Load inductance: ~200 µH
• Output current: up to 100 A peak
3. Control:
• Microcontroller: STM32 (F or G series)
• Control functions:
• PWM generation with resonant modulation (preferably ZVS)
• Dead-time control between IGBTs
• Voltage and current sensing
• Protection functions (overcurrent, overtemperature, IGBT fault, etc.)
• UART/USB communication for debugging or interface
• Digital isolation for feedback is recommended
4. Drivers and Protection:
• Gate drivers with galvanic isolation (e.g., opto-isolated or transformer-based)
• RC snubbers on each leg and MOVs on the DC bus
• Current sensing via shunt or Hall-effect sensors
• Temperature monitoring on IGBTs and heat sinks
5. PCB Design:
• Combined layout for power stage + control logic
• Preferably split board (high-power and logic separated)
• Proper thermal dissipation design (heat sinks + forced air)
• Reinforced copper tracks for high current paths
⸻
? Expected Deliverables
• Complete circuit schematic (protection, control, power)
• PCB layout files (Gerber, BOM, CAD)
• Switching and thermal simulation (if possible)
• STM32 firmware (basic PWM functional code)
• Documentation: pinout, components, test procedures
⸻
? Freelancer Requirements
• Proven experience in power electronics design
• Solid knowledge of IGBTs, resonant control, snubber circuits, protections
• Experience with STM32 microcontrollers and C/C++ development
• PCB design experience with mixed-signal boards (power + logic)
⸻
⚠️ Additional Notes
• This system will drive a 200 µH heating coil for industrial induction heating
• Stable switching frequency required: 95–105 kHz
• Emphasis on thermal and electrical reliability
• Portfolio or relevant previous projects will be a strong asset