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Messages - Michael_DA

Pages: [1]
1
Sorry that I have reported back so late, but the last few weeks have been very stressful due to various exams, as well as the presentation and demonstration of our Tesla coil.

Quote
3000 uF is too little for such a large coil, are you sure your calculated voltage drop is only 15-20V? Because that is what I expect in my large DRSSTC with 6000 uF, check out the calculations here: http://kaizerpowerelectronics.dk/tesla-coils/drsstc-design-guide/dc-bus-capacitor/

Yes you are right, the voltage drop is much higher. We will definitely replace the capacitor in the future.

Quote
I know a couple of different secondary circuit discharge measurements that have been done.
1: Terry Fritz with a antenna: https://deanostoybox.com/hot-streamer/TeslaCoils/MyPapers/planant/waveant3.html
2: Hydron with a battery driven data recorder: https://highvoltageforum.net/index.php?topic=117.0
3: Uspring with battery oscilloscope: http://4hv.org/e107_plugins/forum/forum_viewtopic.php?153922
4: Greg Leyh on the huge "Electrum" SGTC, where he could sit inside the topload and do measurements on a analogue scope, but many sites with this information is gone, you have to find a mirror or get lucky on archive.org (pictures here https://www.lod.org/electrum.html )


Thank you for listing the different possibilities. We will try using a field probe to measure the secondary voltage! :)

Quote
The phase between primary and secondary current determines how much and in which direction energy is transferred between primary and secondary coil.


That was really a very useful hint. We were asked exactly this question after our presentation and thanks to you we were able to answer it!  ;D

2
Hi Guys,
we have solved our problem. Our interrupter has a protective function, so that it does not transmit any more signal from a certain pitch. But with the help of audio programs, we can simply lower the pitch of a song completely an octave, so actually every song should be possible. :)
Alternatively, we now have a second functional Interupter with which we can choose between 3 different protection functions. So all sounds are possible. Here you can also set the maximum T_On time for the highest tone, we have this (for fear of continuous tones) limited to 100 us.

Here is a video of a complete song, but only at 200 V bus voltage, because we did not want to break the fluorescent tube. (It still broke in second 12 ::) ;D)

Thank you for your tips!  :)


3
Quote
How much DC bus capacitance do you have from those 4 cans?

The capacity of the bus capacitor is 3 mF. So we have voltage drops around  15-20 V in operation. We could probably increase that in the future. But it is not urgently needed or?

Quote
The copper busbar from DC bus capacitors to the IGBTs have much room for low inductance improvements! Instead of that huge piece flying over, you could just laminate between them with a insulating material and having them run parallel very close is perfect for the lowest inductance possible.

Yes that's true! We will definitely do that. :) As you can see on the scope below, we already have slight peaks or rather voltage dips. Could these come through a too small bus capacity? Or how would you interpret that? What is the reason for the phase shift between primary current (CH1) and secondary current (CH2)? What we also find very interesting would be a measurement of the secondary voltage. Has someone already experiences / possibilities with it? Suppose you leave a wire from a large high voltage divider 3 meters away from the breakout point of the coil and wait until a discharge hits there? Or should I prefer to open a new thread for this?



Quote
If you have noise problems, try using a large gauge wire for all the common ground bar wiring, you do not want that function limited by wire resistance :)

How do you mean? We've connected all the cases / heatsinks to a common star point (the copper bar to the left of the MMC). This is connected to the "protection earth" connection of our three-phase network. Do you think that we should build this connection with extra thick wires? So that the resistance of the ground connection decreases and the voltage drop over it is lower?

Thank you for your hints! :)

4
Here, as promised, pictures of our bus layout. A new heatsink for the IGBTs has already been ordered, this was only a provisional solution.

                           

5
Alright, thank you for the many tips!
We suspect that the Interupter has a security function at too high a sound, we will examine it more closely and see if we can disable it or at least partially bypass it. If necessary, we have another Interrupter, we still have to build, but that would be the alternative in any case.

Quote
I am really envious of your access to a HV hall like that, I am so limited by my small work shop  :'(

Haha yes, the many space and possibilities in the high-voltage hall are very beneficial. :) However, there are also some disadvantages. With the large Marx-Generator in the background more often gas breakdowns in eg SF6 with lightning impulses around 1.5 MV are produced. At the beginning, unfortunately, we also have some small electronics, such as Receiver for optical fibers, broke because of the high EMI. :(

Kind regards
Michael

6
Hello erdal,

aaah ye, that could also be a point, thanks for the hint!  :) The resonance frequency is designed low. It is arround 29 kHz.

7
Hi Guys,

finally the time has come. Yesterday we had our DRSSTC down to a few trifles (a bit cleaner wiring, thicker cables for the prime and some security mechanisms), we finished the coil yesterday and tested today. We only started again with a voltage of 200 V and worked our way up to 560 V. The results were already very impressive for us (this is our first Tesla coil):

                               

We have set the T_On time to 200 us. We have a current of approx. 500-600 A in the primary circuit (in the tests without secondary coil we were at the same T_on time already at approx. 1 kA) and a current of approx. 6A in the secondary coil. So in principle our IGBTs can switch a lot more current. According to the datasheet, they can have a pulse current of 800 A and we have 2 IGBTs connected in parallel. During the test, none of the elements was warmer than 23 °. But first we want do approach step by step, as none of us could accurately assess how the coil reacts. Here are our measurements during the test (yellow = primary current; magenta = secondary current; turquoise = bridge voltage:



However, there was something again, which disappointed us. Namely, in the MIDI playback mostly higher frequencies are not played. That all sounds then, for example. like here at "Imperial March" from Starwars.

/>
Does anyone know why that is? Our guess is that the Interupter will not pass these high frequencies to our controller. Therefore we want to try to lower the songs an octave and try it again. But that's just a guess ...

Here are a few other songs. A friend of us tried to play music via an electric guitar, which worked quite well. However, I would say the sparks were a bit smaller (at least on the video looks like), but in the high-voltage hall, the approximately 3.30 m high coil looks small in comparison to the rest, too.

Game of Thrones Intro:   
/>
Mario Theme: 
/>
Pirates of the carribean:   
/>
First tries with an electro guitar:   
/>
Kind regards,
Michael





8
Alright, thanks for the answer! That sounds good!  :) I've noticed by now that I've used much too undersized TVS diodes anyway with a breakdown voltage of 237 V (instead of the 442 V I was assuming). So no wonder it eventually crashed. ::) ;D

Sure, I like to upload some pictures of the setup here. I wanted to do that anyway in 1-2 weeks, when the whole coil is finished. Although I have already tested the coil as a SGTC, as a DRSSTC I have only used it without a secondary coil. But apart from a few little things, there is nothing left to do.  :)

Kind regards,
Michael

9
Hello,

I used another current transformer today and the signal was ok. Apparently the IGBTs are switching pretty close to the zero crossing. Obviously it was not a good idea to reduce the output voltage of the current transformer again with a voltage divider.  ::)



However, a new problem has emerged. I started today with a bus voltage of 200 V and this increased to 560 V. Up to 500 V, everything went well. At 560 V, there was a loud bang. After the first shock, I was fortunate enough to find out that only the TVS diodes I mounted antiparallel to the IGBTs explode. The IGBTs were apparently not damaged. Here you can see the moment the diodes exploded.




By the time the diodes failed, the T_On time had already passed. Therefore, my guess is that the current flowing through the TVS diodes was just too high for them. Nevertheless, I'm still a little skeptical. I increased the voltage from 200V to 560V in 50V - 60V increments each, but the amplitude of the bridge voltage measured was a maximum of 204V (for all tested bus voltages). Therefore, I suspect that the diodes may have already cut the voltage here. But the current has risen sharply with every increase in voltage. However, this would be very strange, since I actually assumed that a diode should cut the voltage only from 442 V and I have always used 2 in series.
The diodes I use are this one: 1.5KE250CA   442 V and 1,5 kW bi-directional TVS Diodes
(https://docs-emea.rs-online.com/webdocs/0469/0900766b80469a6e.pdf)

Then I set the voltage again to 200 V (stupidly back to 200 V, but since I had not noticed that in the previous experiments, the diodes may have cut off the voltage at 200 V) and turned on the coil without the diodes.



The rectangles still look pretty clean. Are TVS diodes necessary in this case? If yes, which have you used successfully so far? I use these IGBT bricks (1200V / 300A) in a full bridge in a parallel circuit.

http://www.europowercomponents.com/media/uploads/2MBi300UC-120.pdf

Thank you and kind regards,
Michael



10
Voltage Multipliers / Re: Marx Generator misfiring
« on: September 22, 2018, 01:59:16 PM »
Hello Andy,
how does the schematic of your Marx generator look like? To my knowledge, the most common is this one, but in principle there are several variations of it, so thats why I ask.



Normally, the output voltage of a Marx generator is the measurable voltage across the load capacitance (in the circuit diagram named C_b) This has the following shape (without a flashover of your main gap. With a flashover, the voltage collapses very quickly.):



This results from the fact that the surge capacitance (C_s) is discharged into the smaller capacitance C_b via the resistor R_d, resulting in the rapid increase of the voltage. The time of the rise can be increased or decreased by the variation of R_d. If the voltage is not large enough to produce a flashover in your main gap, the load capacitance (C_b) will discharge via the resistors R_d and R_e, causing the slower, falling voltage waveform. The drop in voltage (without flashover) is significantly slower, since the discharge resistance R_e is usually chosen to be greater than the resistance R_d.

For a better understanding, I have painted here the two possible paths. The red path is the case if your main gap does not flashover. And the blue path when your main gap rolls over. (Unfortunately, I am not a very good draftsman, but I hope it is obvious  :D).



I hope I could help you.

Kind regards,
Michael

11
Hello Mads,
that was a good tip, thanks!  :) I did not pay attention to this point.
I just looked for forum and the Internet for the keyword "skew" and found some interesting things. As soon as I'm back in the lab on Monday, I'll try to find the mistake. While searching, I noticed that I switched a high-impedance 1:2 voltage divider during the current measurement after the Pearson transformer so that the voltage on the oscilloscope does not become too high. I think that could be the mistake  :-X. This is definitely the first point I will investigate. If it does not, I'll probably compare the signal that the CT measures for feedback with the signal from my Pearson transformer. With the same cable lengths etc.

I'll get back to you after the tests on Monday! As soon as I have finished my exams and have more time, I will present the whole (hopefully working :D) DRSSTC here in the forum.

Thank you and kind regards,
Michael

12
Hello people,
I am currently testing the primary circuit of my DRSSTC and just trying to set the phase lead correctly before the final tests. As inductors I have small 7-slot inductors between 10 uH and 70 uH. However, the phase does not change, no matter which inductance I install. In the picture you could see the bridge voltage and the corresponding primary current, but the switching time is more towards the current maximum than in the vicinity of the zero crossing. Nevertheless, I can find almost no voltage peak. I did the pictures with 300 V bus voltage and a current maximum of approx. 200 A (the used probes are not considered on the oscilloscope pictures). The differential probe used has a bandwidth of 25 MHz, so the peaks in the voltage should not actually be filtered out? So I've used a total of 20 uF snubber capacitors. How would you assess the situation? I'm scared to go up to 560V with the bus voltage because I do not want to kill the IGBTs. On the other hand, I can (despite the bad switching time) do not measure dangerous voltage peaks.
I would be very grateful for any advice / hints.
Thank you and kind regards from Germany,
Michael

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