Work Coils for ZVS Induction Heater

Last updated: August 2, 2019

ZVS induction heater work coil
A newly made 2 Turn by 3 layer Work Coil

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Objectives/span for this page:

Help people to understand the importance of proper coil design
Show folks some ways to make the work coils

My personal priorities:

---Learn How to predict whether a coil designs will stress the induction heater to its breaking point or not.
---Learn How to predict usefulness of a coil design

Work Coil Data, Observed, so far (spreadsheet)

Work Coil-Related Videos:

Testing Brass Cartridge Casing Annealing of 3 Turn 2 Layer, 1 3/8 inch ID Work Coil
Making a 2 Turn 3 Layer, 1 inch ID Work Coil
Test 2 Turn 3 Layer Work Coil & Summarize Progess to Date
Test 3 Layer X 3 Turn X 5/8 inch ID coil Using 1/8 inch OD Tubing
Extending Copper Tubes by Swaging and Soldering (No Fittings Needed!!!)
Testing a 10 Inch Diameter Pancake Coil

How to make work coils:
---the way I do it
As they say, "there are many ways to skin a cat", so I am not telling you that this is the only way that work coils can be made. What follows here is simply the way I choose to make them, so far:
-I make all of my coils using a material called "(soft) copper refrigeration tubing".
-Almost all of my coils, so far, have been made with 1/4 inch OD tubing, but I just made one using 1/8 inch OD tubing, so I could make it smaller in ID without it flattening.
-I always water cool my work coils.
-I always insulate my work coils.
-Basically, I simply wind them around various mandrels. In my experience, the minimum inside diameter is limited to about 3/4 of an inch for the 1/4" OD tubing with the process that I use. But inside diameters below about 1 3/8 inches require some special care.
-For the one coil made from 1/8" OD tubing, I easily wound it on a 5/8" diameter mandrel with no flattening issues.

Coming Soon:

Re-annealing copper tubing as needed to make it bend easier for certain purposes
I will show, (and maybe demonstrate) the various coil winding tools and methods I have used/tried with varying results
I will show (and maybe demonstrate) my homemade coil making forms- and things I still do to make them better.
I will discuss the way that others make coils, but why I don't do it that way.

This page will be under construction forever.