Author Topic: Benjamin's DRSSTC 2 in progress  (Read 6411 times)

Offline Benjamin Lockhart

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Re: Benjamin's DRSSTC 2 in progress
« Reply #20 on: March 22, 2024, 03:57:54 AM »
Thanks Dave, I'll do that

Offline thedoc298

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Re: Benjamin's DRSSTC 2 in progress
« Reply #21 on: March 26, 2024, 01:50:42 AM »
Very nice looking gear, I was wondering on your primary, it looks like your connected to the outer and the inner. How are you moving the tap, as I don't see any.

Offline Benjamin Lockhart

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Re: Benjamin's DRSSTC 2 in progress
« Reply #22 on: March 26, 2024, 04:48:22 AM »
You can see the tap point here.


I've mostly finished rebuilding the coil now. Hopefully this aluminum block will be enough heatsinking for the rectifiers.








Making things fit.


I put a few extra CTs on the bridge outputs to check current sharing and it appears to be identical on 2 separate bridge outputs!





Offline Benjamin Lockhart

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Re: Benjamin's DRSSTC 2 in progress
« Reply #23 on: May 03, 2024, 10:59:34 PM »
Hi all, Here's an update on this project.

First light was making 7 foot sparks at 100us and 240V in with minimal tuning, but a primary strike and flashover to the bottom secondary turn seems to have killed the FPGA in the UD+.

I suspect that equidrive was a bad idea and the high voltage on the inner primary turn could have caused a spike on the ground line during flashover, but I really don't know.

I've since replaced the driver with a spare for now, reconfigured the MMC for higher primary impedance (now 0.296uF instead of 0.67uF) and no equidrive.
I simply paralleled the bridge outputs.
I also raised the secondary an inch to lower coupling to about .142


Here's the new test run at only half input voltage 340V bus, and 500us on time. It has hit 7 feet now at only 120V in and trips the 20A breaker quickly. There is 240V 50A available  for full power.
I'd like to build a better toroid with less unwanted breakouts before trying 240V in.
« Last Edit: May 03, 2024, 11:04:50 PM by Benjamin Lockhart »

Offline flyingperson23

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Re: Benjamin's DRSSTC 2 in progress
« Reply #24 on: May 04, 2024, 01:33:40 AM »
.296uF seems small enough to really limit your current. That also probably makes it sound fuzzier at low bus voltages. I think it'll sound a lot better at full power, especially if you turn up the duty cycle.

Offline Benjamin Lockhart

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Re: Benjamin's DRSSTC 2 in progress
« Reply #25 on: May 04, 2024, 04:21:02 AM »
Yes it is, I might change it to 0.44uF with a larger toroid. The initial current ramp up gets to 750A and the steady state current when I turn it up to 2ms is about 500A. This is just at 340V bus.
« Last Edit: May 06, 2024, 06:34:30 AM by Benjamin Lockhart »

Offline Benjamin Lockhart

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Re: Benjamin's DRSSTC 2 in progress
« Reply #26 on: May 13, 2024, 07:25:29 PM »
I added 2 more primary turns so I can experiment with a high impedance primary and larger toroid.
I'm still building the toroid at the moment.




Offline Benjamin Lockhart

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Re: Benjamin's DRSSTC 2 in progress
« Reply #27 on: October 16, 2024, 07:37:18 AM »
I've made some progress on a new 10x48 inch toroid, but if I were to do this over I'd buy aluminum tubing for a multi ring toroid instead.

It's made up of 60 cardboard strips hot glued into plywood and foam disks, and I'm going to wrap the surface with cloth soaked in glue to cover the bumps and gaps kind of like fiberglassing, then sand it down to make a smooth surface for aluminum tape.



« Last Edit: October 18, 2024, 05:53:14 AM by Benjamin Lockhart »

Offline Mads Barnkob

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Re: Benjamin's DRSSTC 2 in progress
« Reply #28 on: October 16, 2024, 08:56:15 PM »
Now it's getting real, the physical form taking up all the remaining space in your workshop. The size of your monster is slowly being realized. "Where can I even put these parts..." "Where can I even run such a large coil..."

Good work and ingenuity on the topload. I made my topload too hard underneath the aluminium tape, with automobile-filler. A topload is the part most prone to transport and storage damage, so it actually needs to be able to take a bit of abuse. It's no worse, than scratches and ripped tape, is fixed with new tape and flattened out with a plastic card of short.
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Offline Benjamin Lockhart

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Re: Benjamin's DRSSTC 2 in progress
« Reply #29 on: October 16, 2024, 10:29:05 PM »
Thanks Mads, Do you think I'd be better off using something softer like duct tape, rather than cloth and glue to smooth out the surface before aluminum tape?

Yes it's getting real now! It's quite big. Thankfully I have space to run it right in front of the shop.
« Last Edit: October 17, 2024, 04:18:03 AM by Benjamin Lockhart »

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Re: Benjamin's DRSSTC 2 in progress
« Reply #30 on: October 17, 2024, 04:19:01 PM »
Thanks Mads, Do you think I'd be better off using something softer like duct tape, rather than cloth and glue to smooth out the surface before aluminum tape?

Yes it's getting real now! It's quite big. Thankfully I have space to run it right in front of the shop.

I am not sure what the best approach is, but cloth and glue sounds semi-soft. Aluminium tape is not going to hide any bumps or imperfections, so it will take on the pattern of the layer underneath. It's more a appearance issue than an electrical issue. As long as you can smooth out any spikes that would cause corona, its all fine.

It's only going to look nice up until the first time you drop it :) I cracked my DRSSTC1 topload from a drop and bumped my large ring topload, so its not looking completely circular anymore. Noone sees this but me, so it takes a builder to know it.

Everything also looks nicer on pictures than in real life.
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Offline Benjamin Lockhart

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Re: Benjamin's DRSSTC 2 in progress
« Reply #31 on: October 18, 2024, 05:49:45 AM »
I decided to use the cloth and got it glued on.
I'll coat this with either more glue or varnish to make it stronger and hard enough.



Offline Benjamin Lockhart

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Re: Benjamin's DRSSTC 2 in progress
« Reply #32 on: October 24, 2024, 08:21:32 PM »
I finished the toroid and ran a test of the system!

The cloth and wood glue coating worked well.




I also made a water tank from polycarbonate for the primary cooling loop. You can also see my unfinished tesla guitar interface in the back!



Here's the whole coil standing outside.


And the tests. This is with the 0.296uF MMC and I'm not even hitting the current limit at 940A so I may need to increase capacitance.
Also only 10% primary detuning. I think I should detune the primary way more to take full advantage of this arrangement.

I had some explosions and racing sparks, and my run was cut short by snow blowing in. Also my scope wasn't set right so I don't know the exact primary current.

The biggest issue was the outer primary turn flashing over to the strike rail which caused the power plug to flash over (dumping the tank circuit between ground and the power feed line!) and melt some steel there.

Also, the sharp ends of the strike rail were initiating racing sparks. as can be seen here. Even though coupling is only 0.142
The strike rail has more clearance from the primary than my DRSSTC3 so I thought it would be ok, but I think I need to remake the strike rail with more clearance and no sharp ends.
An extra coat of epoxy on the secondary would also be a good idea even though it survived.







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Edit: Here is a picture of corona from the sharp end of the strike rail. I definitely need to do something about this!
« Last Edit: October 25, 2024, 06:36:21 AM by Benjamin Lockhart »

Offline Benjamin Lockhart

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Re: Benjamin's DRSSTC 2 in progress
« Reply #33 on: October 25, 2024, 11:18:22 PM »
I'm not sure what to do regarding the strike rail.

In any case I'm going to remove the existing one, and either make a new one with a larger diameter, maybe spaced lower down in order to be further away from the secondary.

Also maybe a large acrylic disk over the primary.

Or maybe I could get away with no strike rail (I have a 0.1uF bypass cap from the negative rail to ground.)

Offline davekni

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Re: Benjamin's DRSSTC 2 in progress
« Reply #34 on: October 28, 2024, 04:12:35 AM »
Quote
Also, the sharp ends of the strike rail were initiating racing sparks. as can be seen here. Even though coupling is only 0.142
The strike rail has more clearance from the primary than my DRSSTC3 so I thought it would be ok, but I think I need to remake the strike rail with more clearance and no sharp ends.
Quote
Also maybe a large acrylic disk over the primary.

Or maybe I could get away with no strike rail (I have a 0.1uF bypass cap from the negative rail to ground.)
I had the same issue with strike rail arcs triggering racing sparks when I first built my DRSSTC even though my primary was covered with polycarbonate plates.  Made larger diameter strike rails using larger diameter tubing (19mm).  Solved the issue for several years.  Recently a top-load defect on bottom of toroid caused many arcs to strike rail, ionizing enough air to eventually start racing sparks.  Fixed my top load now.

Electronics would hopefully survive strike to primary coil.  Initial hit from top load is often near peak top load voltage.  Top rapidly discharges causing short high-current pulse.  Electronics survival depends on path of that short high-current pulse and its resulting inductive drop through wiring.
David Knierim

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Re: Benjamin's DRSSTC 2 in progress
« Reply #34 on: October 28, 2024, 04:12:35 AM »

 


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October 20, 2024, 11:11:13 PM
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[Solid State Tesla Coils (SSTC)]
Mads Barnkob
October 20, 2024, 09:34:52 PM

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