Electronic – Very high current very low voltage application

power

I'm not an electrical engineer. I have an unusual need and would like suggestions as to how to proceed. I have an application that needs very high currents at very low voltages. I'm trying to heat a thin strip of aluminum to temperatures near 100C quickly and then control the temperature. My calculations suggest about 150 to 200 amps at less than 0.1 volt. About the only idea I have is using a toroidal transformer with maybe 1000 turns and thick copper bar passing through the center of the toroid connected to the aluminum strip. I can use either AC or DC current and if AC, I'm not necessarily limited to 60hz.

Any and all good suggestions are welcome.

Best Answer

Power supplies from arc welding devices are quite capable of what you describe. You may also try a soldering gun (the kind with a transformer inside) replacing the tip with your stuff.

Just be aware that you need really really thick wires for 100A. The problem will be worse with high frequency AC because of the skin effect.

As far as the regulation is concerned you should be able to use a simple PID regulator with a thyristor output for the soldering gun. The arc welding supplies may be more difficult depending on their internal construction.