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Messages - Mads Barnkob
2
« on: March 22, 2024, 10:20:35 PM »
I found a old and discarded smoke cannon at a scrap yard! It looked in rough shape, but still had some oil in its container. With a bit experimentation and at last forcefully feeding it oil, it gave off its smoke! As a bonus, I got most of my workshop lubricated from half-burned oil smoke raining down droplets everywhere! />
4
« on: March 20, 2024, 08:03:41 PM »
Flyback transformers are special in having an air gapped core, which is utilized by the driving method Flyback converter topology. So a flyback transformer is just a air gapped transformer. It is the driving method where energy is stored in the core in the first half cycle, switch turns off and energy is transferred to the secondary winding in the second half cycle. The term flyback comes from Cathode ray tubes (old TVs and monitors) where the abrubt saw tooth like output, got the beam in the cannon to flyback to draw the next line on the monitor. In high voltage world, we abuse the shit out of them with all other kinds of drive modes than flyback We feed them with ZVS, single switch, half-bridge or full-bridge inverters to get the highest possible voltage output, often leading to a premature death of the transformer. To drive it continuesly, the air gap should be removed, as the half cycle energy storage is no longer being used. On the other side, core saturation will happen much faster.
5
« on: March 20, 2024, 07:51:57 PM »
Being a inverter, rather than a big lump of iron, a microwave inverter is not as sturdy and can stand up to abuse.
Look up the load impedance of a magnetron and you got an idea of how much you load the output. They are most likely only rated for full power for a 5-10 minutes, with forced air cooling.
All that being said, it is a nice small 2300 VAC inverter, on/off controlled, maybe something like power supply for a marx generator.
6
« on: March 20, 2024, 10:39:47 AM »
Thanks Mads, I thought that a 100A rectifier would be ok for a coil running off a 50A breaker? I have a single phase 240V supply so the bus voltage should be 680V with no load.
There is some derating graphs in the datasheet. Here both sine wave and rectangular are mentioned, where the rectangular causes higher dissipation etc.
7
« on: March 19, 2024, 05:01:41 PM »
As always, it is great to see more people join the HVF community! Young, old, experienced, new learners and great to see the eager to build and share Thanks for taking the time to give an introduction of yourselves
8
« on: March 19, 2024, 04:31:02 PM »
Beautiful work on that bridge, I love to see some nice handmade items I never tried split MMC, so looking forward to hear more about your experience in that field. I think your poor little half-bridge rectifier SKKD 100/12, is going to suffer a bit, you might need a bigger one. Surge overload current capabilities is however helped with a much lower Vrrm voltage, as you are properly at 500-600VDC?
9
« on: March 19, 2024, 03:59:54 PM »
I have decided to make some small changes to my coil design. I've decided to use 10mm copper pipe for the secondary with 8mm spacing between turns. This should allow the primary to keep cooler during longer runs without the need of water-cooling the primary. Recalculating with java TC i get a coupling coefficient from 0.14 to 0.17 depending on how high the primary is. Which brings me to my first question. What's the optimal coupling coefficient for DRSSTCs of this size and power? And how high coupling coefficient is too high for a DRSSTC? Looking at other builds on this forum ive seen coils with a range of coupling coefficient from around 0.1 to even i think 0.2. From what I've read the higher the coupling coefficient is the more power can be transferred from primary to secondary but at the risk of having racing sparks. That's why I'm wondering about the optimal coupling to get the max spark length without increasing the risk of racing sparks too much.
Second question i have is about my secondary coil. Originally i planned to use 0.355mm wire and have the winding length of around 730mm with 2000 turns, Calculating this gives me spacing between turns of 0.01mm. How realistic is it to wind it that tight? And would it be better to get 0.315mm copper wire instead of 0.355mm in order to achieve the 2000 turns and having close to 730mm of winding?
Last but not least ive started to plan out the laminated bus design for my coil. I plan to make it from 2mm alu sheet with 2mm of fiberglass material as the insulating layer.
How does the current layout look in terms of good design practices and keeping the inductance low? Is there anything i should improve in the layout or the overall DRSSTC design?
1) 0.15 to 0.2 is normal for coupling of a DRSSTC, is does not have the same high voltage primary as a SGTC, which JavaTC is designed for, so suggested coupling should be a bit higher for DRSSTC. 2) Enamel thickness on a thin wire is roughly adding around 10% to diameter, so what I input to my helical coil calculator ( https://kaizerpowerelectronics.dk/calculators/helical-coil-calculator/ ) to get winding length for JavaTC with a wire size of 0.355 mm would be 0.0355 mm between turns (1 layer from each wire). You could also check out the manufacturers specification of enamel thickness, I got a table of thickness depending on the wire classes here: https://kaizerpowerelectronics.dk/tesla-coils/drsstc-design-guide/secondary-coil/3) Your laminated bus is about as low inductance as you can get. Only thing would be to move rectifier to the side, so have shorter path from +/- to the capacitors, instead of going over one of the IGBTs, placing it in the middle would make it even for everybody. Properly a totally neglectable detail.
11
« on: March 14, 2024, 09:32:27 PM »
Yes you can do it this way. Just make sure to properly rate the resistor for the voltage and power (I recommend highly overrate it). Because in case the resistor fails short circuit (which might be rare but it's possible), then the resistor will blow your bridge.
Luckily it is rare that a large ceramic power resistor fails short. The currents that IGBTs can withstand for 1ms is quite insane, with a bit of luck, the DC bus charge is enough to blow it into piece and not maintain a short circuit for very long.
13
« on: March 08, 2024, 08:22:34 PM »
Also id like some feedback on the MMC capacitor connections. Mainly what would be the optimal way to connect the 3 series strings in parallel and connecting main leads to them. And what would be the best way to cool such a heatsink? I was thinking of getting some 80mm fans and blowing air trough the end of it.
Be careful with tightening the interconnect screw between two capacitors, by twisting them hard, this risks ripping the bonding of the foil from the terminal. It is actually prohibited all virtually all threaded terminal capacitor datasheets. Usually I recommend mounting them on a plate of busbar (which doubles as heat sink to dissipate capacitor losses), but with only two in series, you have enough cooling from the end busbars. Which leads to next question. Next question, which is about leads. Connect the three string in parallel with two even length busbar, something like 5-10mm thick and maybe 20-30 mm wide would make a nice heat sink and solid current path. Connect leads in opposite sides, so that current path from lead, through any string of 2 capacitors and to other lead, its exactly the same length. Even the slightest moving air does a huge difference, form no moving air, when it comes to heat sinks. So you do not need to ram air through the heat sink, just make sure its adequate flowing without giving you too much noise. But then again, fan noise is not exactly a priority to limit, in a DRSSTC
16
« on: March 04, 2024, 11:42:25 AM »
The capacitor directly on the bus is a 560uF electronicon dc link capacitor. I'd hoped it would take most of the resonant current, but I'll probably switch the red wires to 2x 4awg twisted together for less inductance. Less inductance is good. I'd agree that 560uF will handle resonant current. 2x wires are likely unnecessary.
Current distribution in parallel capacitors is split on capacity ratios, please tell me if I'm wrong So let's say you pull 100A from the DC bus and you have 560uF and 12000uF, the 560uF will supply 4.5A and the 12000uF 95.5A (so the largest current part is still hindered by the "long thin" wires)
17
« on: March 04, 2024, 11:33:29 AM »
I am trying to clean out my workshop, so this will only be a link to my listings on a danish website for selling used technical stuff: https://ham.brugtgrej.dk/itemlist.php?mode=useritems&userid=2620International shipping is in the range of 20-40€ for a 5-15kg package. So it's pretty fair for shipping large stuff. Reply to this topic or send PM for € prices and shipping.
18
« on: March 03, 2024, 08:16:34 PM »
Nice big coil in works there! I had to google MITERS, I thought you mean "meters" as in a coil that could make sparks longer than a meter and here, was the forum, so got a little puzzled. I like the idea of a simple boost converter, can you share more details on how its controlled? I think you will get problems with your DC bus wiring, those long red wires are going to add an unwanted amount of inductance. Might even limit your peak current ability and will melt with those planned on-times. What is the capacity of the MKP cap sitting directly on IGBTs? Your safety feature with disconnecting GDT, before discharging DC bus seems like a lottery. You leave your IGBT gates in a uncertain state with possible current flowing and a full DC bus on it. I foresee a race condition problem with blown up silicon as the result.
19
« on: March 03, 2024, 08:02:48 PM »
Not a bad project to restart, good parts all around and not a huge rat nest Water reservoir is however too small, even with a radiator, a good old floor bucket can sustain some run times of like 15 minutes and its up to bathing temperatures. Reuse of cooling water is then possible in the shower There certainly is something "off" with the high capacity. I think you are looking at some unfavorable Q factors. That MMC will also burn to the ground. You do mention that you need to cool it better, but I call for a total reconstruction. You should have space between each individual capacitor, in both directions. Best way to achieve a MMC that can be cooled is to use small cuts of copper or brass plate/band to solder them together with. Film capacitors get rid of their heat from 2/3 through the leads and 1/3 through the package. The small copper/brass plates will work as heat sinks and with space between all caps, forced air cooling can flow between them. I would also not trust that distance between the high voltage side (between L and C in resonant circuit), even worse if you go up in current with a small capacitance MMC.
20
« on: March 03, 2024, 07:45:29 PM »
That is a beautiful little coil! The large table top version, which is a size that very few build. I think this is why about the SKM150 modules, it falls in between the realms of small coils that can run on TO-247 devices and the somewhat larger floor models on wheels that goes up into 200-300A range IGBT bricks. Your 3D printer has also been on a lot of work for this one, so does that work easily from SolidWorks and pick a part directly to 3D printer? There is one concern, which might not be a problem at 375A OCD setting. Your MMC is NOT designed for heat dissipation. It is more designed for destruction and meltdown of the middle. You should have space between each individual capacitor, in both directions. Best way to achieve a MMC that can be cooled is to use small cuts of copper or brass plate/band to solder them together with. Film capacitors get rid of their heat from 2/3 through the leads and 1/3 through the package. The small copper/brass plates will work as heat sinks and with space between all caps, forced air cooling can flow between them. Tried to visualize that suggested small plates, add distance between the caps in your head, paint.exe was not good enough to illustrate that Red circle is where a capacitor will fail first, due to over heating. It cannot radiate heat from the side and leads are almost gone and only connects to another warm capacitor.
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Re: DRSSTC Questions
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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flyingperson23 March 17, 2024, 12:33:06 AM
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