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Messages - davekni

Pages: [1] 2 3 ... 143
1
Solid State Tesla Coils (SSTC) / Re: Problem with SSTC
« on: Today at 01:33:37 AM »
Quote
Everything worked correctly until I increased the discharge frequency, at which point it everything turned off and by checking the PCB I realized that the IGBT driver was broken, I replaced it but every time I increase the discharge frequency it burns again
What duty cycle were you testing that caused failure?  At high enough duty cycle the driver chip likely dissipates more power than it can handle.

Run at low duty cycle for testing.  Scope the driver chip inputs and outputs.  Verify that they start and stop cleanly at the beginning and end of each enable pulse, and that frequency is reasonably stable at your intended operating frequency.  (BTW, are you running ~200kHz as early scope traces suggest?)

2
Capacitor Banks / Re: Restoring a Rogowski coil calibrator
« on: July 11, 2024, 07:38:26 PM »
Quote
Any ideas how that could vary so much?
First thought would be ECB thickness.  Trace width would have some effect too.

3
Quote
Could that be a result of rolling shutter or something similar with a CMOS sensor?
Yes, I expect so.  I've seen the same effect in multiple frames of my QCW videos.

4
Beginners / Re: Tesla coil in FEMM
« on: July 08, 2024, 04:06:53 AM »
Quote
1) How to mirror axissymmetric in FEMM ( to get full view rather than just half view, I will attach some pictures) ?
2) Is it possible to test effect of primary coil on secondary coil (and possibly toroid also) ? Currently I'm testing only one coil at a time.
3) Is it possible to link it with LTSPICE (I know it sounds farfetched) to test primary coil with capacitor ?
4) Is it possible to test Tesla coil in FEMM with some frequency (currently I'm using 0 Hz) ?
1) No way I'm aware of within FEMM.  Perhaps I've missed an option.
2) Yes.  Make primary and secondary separate circuits.  Top load's effect on magnetic field is modeled too.  (Top load is a shorted turn.)  Resonance cannot be modeled in FEMM.  Transfer to LTSpice for that.  (FEE can model top load capacitance to provide input to LTSpice.)
3) Not directly.  Manually transfer inductances and coupling factor.
4) Yes.  Set problem to AC with specified frequency.
JavaTC is easier for most TC designing.  FEMM is useful for unusual geometries or other specific cases, induction heating, ...
If continuing with FEMM, read tutorial and manual.  FEMM user interface is somewhat awkward, but well documented.

5
Top load acts as a shorted turn, blocking magnetic field.  Most TC designs include some spacing between top of secondary winding and top load.

Not directly important that magnetic field lines cross all of secondary or not.  (A tiny bit if field is there.  Just not visible at the field density displayed.)  Key parameter is coupling factor between primary and secondary.  Most people use JavaTC for estimating TC parameters including coupling factor.  FEMM is more detailed and covers more geometry options, so I use that too.  Attaching a .txt file that can be changed to .lua, a FEMM script for calculating coupling factor.

* coupling_factor.txt

QCW coils work best with high coupling.  I've seen success cases here down to 0.35 (or perhaps even 0.3), but I'd aim for at least 0.4.  Your designs may already be that high.

6
Quote
Can hall effect sensors measure fast enough for drsstc feedback?
Good point.  LEM1005 would be marginal for most TCs.  There are combined Hall-effect/CT sensors, common for scope current probes.  Combining is actually quite simple as in the original Tektronix patent.

7
There's no way to know if this is a "good" core or not without knowing the rest of your buck design.  The most important factors are maximum ramp current (peak buck output current), buck switching frequency, and buck input voltage.  Inductor needs to handle maximum ramp current plus peak buck ripple current.  Ripple current depends on inductance, frequency, and voltage.

8
Quote
I bought this terrible expensive LEM1005 but it seems it dosen't work right.
Your LEM1005 is probably good.  It outputs current, so needs a burden resistor.  LEM1005 specification lists minimum and maximum allowed burden resistor values based on supply voltage used and operating temperature range.

Quote
Can someone verify that I do it right?
Your first scope capture looks better, with minimal spikes.  H-bridge output should switch slightly before zero current.
Best to do another final adjustment after H-bridge is running at full voltage.  IGBT timing changes with bus voltage.

9
Quote
Quote
With that I think I'm set. Is there anything I might wanna still test in the current setup before I try powering things up?
Have you already "powered things up" with a bench supply or other lower voltage supply for VBus (for H-bridge power)?  I'd suggest doing that before running at full line voltage.  Though not everyone does that - just the cautious sequence.

Either way (at low or full Vbus to H-bridge), initially test at low duty cycle (low repetition rate and short enable pulse width).  Minimizes chance of frying IGBTs if there is some issue.

Quote
Replacing the driver chip with a TC4426A seems to have solved all my previous issues. The ringing is no more and the driver correctly starts up with no feedback, which it previously could not. I also noticed that previosly the first gate pulse wasn't synchronized with the interrupter edge, but now it always is, which seems good.
Yes, all those previous issues are explained by wrong (non-inverting) driver chip.

10
Laboratories, Equipment and Tools / Re: Coulometric hourmeters
« on: July 02, 2024, 05:16:30 AM »
Quote
You got me wondering about the Hg oxidation state.   Turns out the +1 state (mercurous) tends to be a covalently bonded pair of Hg atoms with net charge of +2, a thing discovered in 19th century!.
When researching for my previous reply, found that Wikipedia and other sites all say that mercury compounds are mostly Hg++, and that Hg+ (usually Hg2++ as you said) is relatively rare.  I think it was also Wikipedia that mentioned somewhere that coulometric measurements using Hg were Hg++.  Can't find that again at the moment.

11
Laboratories, Equipment and Tools / Re: Coulometric hourmeters
« on: June 30, 2024, 06:49:45 AM »
Wouldn't be too expensive to buy some other models for potentially-destructive over-current testing.  A couple EBay listings:
    https://www.ebay.com/itm/334366585217
    https://www.ebay.com/itm/226021685783

Adding another thought:  If you measured R5 (mercury tube) resistance with a typical DMM, that was likely a brief run at ~100uA.

12
Capacitor Banks / Re: Restoring a Rogowski coil calibrator
« on: June 30, 2024, 03:57:13 AM »
Quote
It's a mystery why it works in my version of ltspicevii.
LTSpice has an option to automatically add a small parallel conductance to inductors to speed up simulation.  Perhaps other SPICE variants have options to automatically add small conductance to ground on floating nodes.

13
Laboratories, Equipment and Tools / Re: Coulometric hourmeters
« on: June 30, 2024, 12:46:04 AM »
Quote
I came here with a question for some applied physics expert, after looking up the number density of conduction electrons in mercury. Then figured it out while typing the question.  Here presented for review.
Quote
The values given for Al, Fe, Cu, Ag, and Hg are 3.00, 2.00, 1.00, 1.00, and 2.13 times the atom number densities I computed for the metals.
Using a value of 2.00 electrons per atom of mercury is likely accurate for this hour meter, but it has nothing directly to do with density of electrons in liquid mercury.  The value that matters is the oxidation state of mercury in the solution between mercury columns.  Most ionic mercury compounds are Hg2+ such as HgCl2.

Quote
Any guesses about why R4 is smaller & styled differently?   Selected to match a tube lot?  It's hard to believe the intended accuracy is enough for temperature coefficients to matter.
I'd guess it is for calibration.  ~50 years ago I'd purchased two mercury hour meters from a surplus store.  They had just the tube and scale, no internal resistors.  They were labeled with a specified current.  If I recall correctly, labeled currents for the two meters were not quite identical.  Unfortunately I didn't find them today in the box that has a couple similarly-old mechanical hour meters.
I also wonder why the more complex resistor network.  Perhaps designed to work in a humid environment where 4.5M resistors wouldn't be stable enough?  Or it was difficult to manufacture precision 4.5M resistors

Quote
Now we know it'll be easy to run this much faster than nominal, without bringing in high voltage.   Does anyone think it would be abusive to run it at double speed?  10x speed?  Is anyone familiar with the current densities or thickness rates in commercial electroplating processes?
10uA through tube would be 207 amps/m^2, in the typical range for electroplating.  However, I'd guess you could go quite a bit higher.  Normal electroplating is limited by at least two issues.  First is formation of dendrites on plating surface and required solution additives to minimize that.  No dendrite issue with liquid mercury.  Other issue is electrolysis of solution.  As long as voltage across tube is well under 1V, electrolysis shouldn't be an issue.
Another reason to guess that these can be ran fast:  Presuming calibration was done, wouldn't want to take 5k hours to calibrate.  Of course, it's possible that calibration was needed on only a couple tubes from each production batch of capillary tubes.  That would make speed less critical.

14
Capacitor Banks / Re: Restoring a Rogowski coil calibrator
« on: June 29, 2024, 11:40:56 PM »
Quote
I think it will open in LTSPICE if extension is changed from .txt back to .asc.  A report of success or failure would be welcome!  * rlc_disch2.txt
Yes, opens in LTSpice.  To simulate, needs a path to ground from one side or the other of L1.  Spice doesn't allow completely floating sets of nodes.  With that tweak, simulates fine.


15
Quote
I probed and measured the driver circuit componenets and got this schematic: https://imgur.com/FXMV1K2.
Measuring component values in circuit is difficult to do correctly.  Measurements are of all circuit paths from one lead of a component to the other, not just the component you are attempting to measure.

Quote
I tried simulating in LTSpice (https://drive.google.com/file/d/1WKS0CFihLaoG9BFmubod8igloCP1nHFK/view?usp=sharing) choosing mosfets that are similarish to the ones on the pcb but I couldn't get it to oscillate unless I removed C3. Even then it didn't oscillate at the ~4.6Mhz frequency I measured with an oscilloscope and the output voltage according to the simulation doesn't even reach 10V.
Simulation is a great way to understand circuits!  Back to above point, look at resonant capacitor and inductor values in the circuit you drew.  Calculate order-of-magnitude frequency for those components.  Not at all close to actual circuit frequency, indicating as above that circuit component values are way off from actual.

16
Quote
yes you are right this is my first time I use a Scope and it is possible I messed something up!
Looks like scope readout labels are swapped.  Cyan (light blue) trace lists 20A/div but looks like H-bridge output.  Yellow trace lists 10V/div.  Looks like perhaps output of current transformer missing a burden resistor.  Current transformers (CTs) output current and thus require a load resistor to convert that current to voltage.  BTW, for future posts, it would help to label scope traces in text just above or below image.

Good luck with debug.

17
Quote
Is this an error in the BOM or is there a way to use a non-inverting chip? I'm confused
Must be a BOM error.  There are a couple patch (modification) options for using non-inverting driver, but easier and safer to change driver chips.  Simplest patch is to add zener diodes across capacitors coupling driver chip outputs to PFETs.  That works only if 24V supply is stable and accurate and you happen to have ~16V zener diodes available.

Good work scoping signals carefully before full power runs!  Much cheaper to fix now than after IGBTs are fried.

18
Quote
I have a single GDT (since the THT version of UD2.7c only has one output) made of 9 turns of 4 twisted pairs from network cable. This is the core I got: https://www.tme.eu/en/details/b64290l0618x830/ferrite-cores/epcos/
GDT looks great.

Quote
My only concern right now is some ringing I'm seeing on the gates. After the drive disappears, there seems to be a consistent delay of about 30us and then some damped oscillations occur, which according to my scope can reach well above the IGBT's Uge threshold. It seems to be about 40kHz.
Normal damped oscillations are immediately after last gate pulse.  There is some issue with UD2.7c board, probably with driver chip or FET buffer between driver chip and GDT.  Are you using an inverting driver chip as is needed for UD2.7c?  A non-inverting driver chip could explain delayed ring.  But I'd also expect an issue with start of pulses, which look fine in your captures.  Scoping driver chip outputs would help, should both be high when disabled.  If those look good, then scope FET gates.

19
Looks like you are using LTSpice for drawing schematics.  Great start towards simulation.  Simulation will allow exploring topologies and seeing issues with some.

To start, simulate just the work coil and resonant parts (L4, cap above L4, C3, and C4).  Drive this network with a pulsed voltage source, simplest replacement for M1/M2 half-bridge.

Have fun learning!  Experimenting with simulation is much faster and less expensive than experimenting with actual electronics.  Then build something that works in simulation.

20
Your primary (L4 and C3) resonates at 130kHz.  Driving it at 125kHz makes simulation not switch at zero current.  With fixed frequency drive into a high Q load, small frequency changes make relatively large phase changes.  Probe primary current along with bridge voltage to see switching phase for your simulation.

Parallel resistance for interconnect inductance is tricky.  "Correct" value depends on inductance and frequency and a bit on physical geometry.  For 500nH at 250kHz, 2.5 ohms is likely low.  Probably 10-50ohms would be more realistic.

Yes, real power suffers when Vbus resonates at 2x coil frequency.  Average Vbus is constant, but Vbus is minimum when current is maximum.  Real power is lower.

Anders first three recommendations below are all good and ones I've used before.

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post Re: LabCoatz Staccato QCW No straight sparks
[Dual Resonant Solid State Tesla coils (DRSSTC)]
ZakW
July 02, 2024, 06:14:07 PM
post Is this a good pulse experiment capacitor?
[Capacitor Banks]
FPS
July 02, 2024, 06:02:38 PM
post Re: LabCoatz Staccato QCW No straight sparks
[Dual Resonant Solid State Tesla coils (DRSSTC)]
Admiral Aaron Ravensdale
July 02, 2024, 11:37:46 AM
post Re: Building my first DRSSTC
[Dual Resonant Solid State Tesla coils (DRSSTC)]
davekni
July 02, 2024, 05:22:10 AM
post Re: Coulometric hourmeters
[Laboratories, Equipment and Tools]
davekni
July 02, 2024, 05:16:30 AM
post Re: Building my first DRSSTC
[Dual Resonant Solid State Tesla coils (DRSSTC)]
drobotk
July 01, 2024, 11:50:12 PM
post Re: Restoring a Rogowski coil calibrator
[Capacitor Banks]
klugesmith
July 01, 2024, 08:48:53 PM
post Uses for Weston's Little Bee probe
[Laboratories, Equipment and Tools]
klugesmith
July 01, 2024, 08:40:59 AM
post Re: Coulometric hourmeters
[Laboratories, Equipment and Tools]
klugesmith
July 01, 2024, 08:09:42 AM
post Re: Coulometric hourmeters
[Laboratories, Equipment and Tools]
davekni
June 30, 2024, 06:49:45 AM
post Re: Restoring a Rogowski coil calibrator
[Capacitor Banks]
davekni
June 30, 2024, 03:57:13 AM
post Re: Coulometric hourmeters
[Laboratories, Equipment and Tools]
klugesmith
June 30, 2024, 03:19:40 AM

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