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Messages - Mads Barnkob
21
« 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?
22
« 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.
24
« 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.
26
« 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
29
« 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)
30
« 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.
31
« 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.
32
« 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.
33
« 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.
34
« on: February 24, 2024, 08:47:59 PM »
Hi Bart Very cool career you got going and quite a lot of papers from it I just read your two Tesla coil tech notes and if you have the time and want to, its some good stuff that deserve their own thread for further discussion or just to bring awareness to their existence.
35
« on: February 24, 2024, 07:25:48 PM »
Great work Max! I will soon check it out and I should properly make a video about upgrading the already running version, help spread the good word
36
« on: February 23, 2024, 06:59:58 PM »
Technical walk-through and demonstration of spark generation from my first dual resonant Tesla coil. I finished this dual 811A vacuum tube Tesla Coil back in late 2008, which dates this back 15 years by now! At the time I finished this coil, my best camera at the time, could only record in 640x480 with horrible noise in dark surroundings. This video is the walk-through and demonstration video I wanted to make 15 years ago, but got done now /> All pictures and construction details can be found at: https://kaizerpowerelectronics.dk/tesla-coils/kaizer-vttc-i/
37
« on: February 22, 2024, 01:06:19 PM »
I would not use tantalum in place of ceramic or film/foil/MKT/MKP capacitors.
Tantalum might work well enough for the decoupling capacitors at the ICs and reinforcement of supply rails, but not in parts of circuit for transient protection, timing circuits or filters.
38
« on: February 08, 2024, 06:47:35 PM »
I found a discarded welding machine in a scrap yard! It might be an older shielded metal arc welder, also known as SMAW or stick welder. But from what my father told me, these old ESAB machines are impossible to destroy. It got a good new home Features me being very bad at welding! /> All pictures and specifications can be found at: https://kaizerpowerelectronics.dk/teslacoils/esab-bantam-tbh-140-welder-restoration/BeforeAfter
39
« on: February 06, 2024, 07:29:29 PM »
That is some project! From the faucet style heat sink of the QFN package in dead bug style to a finished product with a web interface. Very nice, but take care and do get some sleep. Too much night-me sounds unhealthy I got a project myself, with a 10MHz reference, but its GPS based like what you came from. I have a Meinberg GPS170 sitting in a box, that really should get in a minirack and live on the bench.
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IKY150N65EH7, is it good for DRSSTC
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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ethanwu0131 April 12, 2024, 04:47:33 PM
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Re: UD 2.7 OCD LED stays on, no output during inital test
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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Admiral Aaron Ravensdale April 12, 2024, 11:43:36 AM
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Mosfet Buffer Stage Questions
[Beginners]
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Egg April 12, 2024, 12:49:02 AM
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Re: UD 2.7 OCD LED stays on, no output during inital test
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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davekni April 12, 2024, 12:41:16 AM
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Re: Plasma Torid - Class E Self Resonant Dual/Stereo - Plasma Torid Build
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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davekni April 12, 2024, 12:22:41 AM
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Re: Capacitor Blowout
[Sell / Buy / Trade]
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Michelle_ April 11, 2024, 10:45:53 PM
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Re: UD 2.7 OCD LED stays on, no output during inital test
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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Admiral Aaron Ravensdale April 11, 2024, 07:39:30 PM
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Re: UD 2.7 OCD LED stays on, no output during inital test
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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flyingperson23 April 11, 2024, 07:24:52 PM
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Re: Tesla coil safety questions, risk analysis quantified
[Beginners]
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sky-guided April 11, 2024, 06:09:30 PM
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UD 2.7 OCD LED stays on, no output during inital test
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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Admiral Aaron Ravensdale April 11, 2024, 12:55:16 PM
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Re: Plasma Torid - Class E Self Resonant Dual/Stereo - Plasma Torid Build
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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alan sailer April 11, 2024, 03:40:00 AM
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