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Messages - oneKone

Pages: [1] 2 3 ... 17
1
Transformer (Ferrite Core) / Re: A big-ish diy xformer
« on: August 09, 2022, 07:30:29 AM »
@abstruse1

I was having problems with the winding not starting at the very bottom of the new segment, it's just a simple (but wasteful) transition. As for the litz wire, I did try some standard car audio power cable, it it quickly melted. I think it was also slightly larger diameter (conductor) than the litz wire I wound.

2
General Chat / Successful flyback/xformer driver above 3kw
« on: July 30, 2022, 04:55:51 AM »
Just thought I'd put this out there;

How many members here have built a successful flyback/xformer driver that can operate above 3kw (let's say 3-6kw range) without failures. Judging from what I've seen there's not many out there due to the common igbt brick failure (myself is included in this failure scenario)

3
Hey Finn.

I've been burned by cheaper (smaller package) Mosfets and igbts from AliExpress and eBay. Sometimes they work, just a small gamble with time mostly.

I have a packet of 5 here from rs components if you want them (I have a feeling I might have some AliExpress ones as well, but not entirely sure). A farcry from the 20 you need, bit at least they'll be genuine.

4
Transformer (Ferrite Core) / Re: A big-ish diy xformer
« on: July 28, 2022, 03:04:48 AM »
I’m pretty jealous of you guys with access/skills for machining…This thing would make an excellent base for a fusor power supply.

-Matt

These bobbins would be something easily made on a small Chinese lathe, but there's also the upfront cost of a lathe and tooling, sometimes it's also the luck of knowing a machinist 😂. I had thought about selling bobbins, but shipping from Australia is just too expensive for what it is.

5
Transformer (Ferrite Core) / Re: A big-ish diy xformer
« on: July 28, 2022, 03:00:59 AM »
Very nice project, good looking final enclosure as well! Not just that regular oil filled IKEA container from the kitchen department :)

Which tapping are you running it at on the primary coil? Since you say it can pop bricks and limited to 180A?

Your driver reset, driving down to 10% duty cycle is fine, but power cycling to reset, why not just do something like in the DRSSTC drivers, that it just resets on the next interrupter pulse? (could just be a 555 timer giving 100 BPS reset pulses, as there is no interrupter here)

Your inverter box needs some safer terminals :D

Cheers,
Originally I had made a fibreglass enclosure, but I wasn't completely happy with the outcome (more fibreglass practice is needed 😅)

For the video it's running on 8 primary turns. Atm for the OCD, series inductor and enclosure. I'm treating it all as the first revision. I do plan on making a more robustly housed driver that's also somewhat safer from wandering fingers.

6
Transformer (Ferrite Core) / Re: A big-ish diy xformer
« on: July 26, 2022, 05:51:33 AM »
We have the equipment at work for the manual mill, but the setup time would be a killer to get it done before work/lunch break. Or could even be someill looking into on the CNC router at home 🤔

7
Transformer (Ferrite Core) / A big-ish diy xformer
« on: July 26, 2022, 04:10:58 AM »
For a while now I've been absent from the forum, the ease of FB has driven my lazyness not to post (most importantly to share).

I've been working on creating a reliable secondary for a while now. I pursued 3d printed bobbins for the longest of times, but unfortunately they're not reliable enough as there was always a failure mode of the secondary arcing through the print. To beat this I started to make the bobbins from acetal with almost flawless results (so far).

Some specs;
Core: UF86A

Primary: 6+2+2+2 turns of litz wire made from 35 strands 0.4mm wire, finally wrapped in Teflon tape,

Secondary: the bobbin is machined from acetal/delrin, OD: 70mm, ID: 31.7mm, length 60mm, segment depth is 9.5mm/2mm wide with I think* 2.5mm walls. Each wound segment has 500 turns of 0.14mm wire. The "free" segments are simply for the wire to transition from the top of one layer to be perfectly ath the bottom of the next. 

The enclosure is made from PVC pipe with an acrylic top plate, brass M6 studs/nuts, 3d printed core support and PVC electrodes with acrylic caps/press fit brass terminals.





/>
The driver itself has been another can of worms... The occasional brick failure is annoying, but solving the problem is a not so bad challenge. Atm it's running a standard TL494 with 35% duty cycle, A3120 gate drives (each with an isolated 18v supply) driving a skm200gb. I've recently added over current set to 180a primary current, in an over current event it draws the driver down to 10% duty cycle and needs a power cycle to reset. I'm currently working on a new series inductor and a OCD that doesn't need to be power cycled.

After I get the driver sorted I'll be starting on a few other sizes high voltage transformers, just to see what I can come up with.

Cheers






8
Cheers @AstRii.

So far I haven't had any problems with excessive primary heating, although my run times are only a few minutes.

9
I've had awesome success with buying semikron bricks from AliExpress (bizon tech is a good seller). I run skm200gb125d half bridge modules in one of my full bridge drsstc. I think* it's currently running at 140khz, upto 1.4ms on time, bps I've never looked, 600apk, RMS draw is 4.6kw. I'm confident an skm200 will.suit your needs perfectly.

10
Cheers for the reply Netzpfuscher it compiled/programmed perfectly. @hydron I completely forgot about that 🤦‍♂️. I remember finding that setting while trying to figure out the problem, but didn't even think to select it.

Now the next step for me is looking into a form of communication. I found a link on github that allows serial connection over wifi using an esp32. To me this seems like a simpler solution than a fiber link, assuming the connection stays stable during use.

11
I got the psoc Dev kit and ud3 boards this past week, I'm hoping to order the components during the week to get this project officially going.



I also tried to program the cy8-kit to familiarise myself with the psoc creator. Unfortunately I ran into two errors. one of which I think I solved correctly, the other I'm still stumped on.
My process was:
• opening the ud3 master/ UD31.cywrk and setting the ud3-qfn as active
• setting the target device to the cy8-kit I have and trying to program it. These are where the two first errors came from

• I clicked the search function on the errors and changed the "bootable" module bootloader location. (common\binary\UARTldr)
• after trying to program again I finally get these warnings with the last two errors. I'm confident it's the methodology I've used in fixing the first two set of errors, I'm just unsure of where to go from here.




12
@Netzpfuscher @acobaugh thankyou both for the clarification and help, my saying thankyou for the files and the support so far is a massive understatement.

I'll order the boards later this afternoon, in the mean time I'll look over Netzpfuscher "next gen drsstc" thread about what fiber links have been used.

If I'm honest I've been a big fan of tht for a very long time, but simply the appeal of this project is more than enough for me to switch to SMT.

13
Cheers for the reply.

The only reason I was going to make my own board was because I was unaware there's a public available board/schematic, maybe I'm not looking hard enough.
My intention was to use the same pinout as labelled in the psoc creator, at least in the early stages it would give me a greater understanding as to how a ud3 board works (I'm more of a hands on learner).

As for fiber signalling, honestly I haven't got upto that yet. When I get upto that stage I think I'd look.i to the ifd-95 or something along those lines.

14
Dual Resonant Solid State Tesla coils (DRSSTC) / Psoc ud3 a noobs journey
« on: September 02, 2021, 03:05:01 AM »
After looking @laci thread about his drsstc using a psoc Dev board and @Netzpfuscher ud3 project I thought I'd finally have a go at the project. I'm still very green when it comes to microcontrollers, my only experience is modifying some simple Arduino sketches...


My understanding atm is that I load the ud3_qfn into the psoc creator program, build and flash the psoc cy8ckit-059, I'm not sure if it's as simple as that? *I should add that I'm still waiting for my dev board in the mail*

For the circuit/hardware side of things I'm planning to use @profdc9 schematic as a reference to make my own board, it will more than likely be a mix of tht/SMT.

By the end of the project I'm hoping to gain a greater understanding as this really does seem like the future for drsstc.

Cheers
 

15
I'd say it's your primary being so detuned. 8 primary turns @ 150nf is about 82khz, I'd guess your secondary is about 200-250khz unloaded (really really rough guess).

16
Transformer (Ferrite Core) / Re: Skm flyback destroyer 🤗
« on: July 26, 2021, 12:37:52 PM »
I made some progress on the build this past weekend, unfortunately I didn't get any build pics ... Juggling house renovations and hobbies is challenging!

For the most part I got everything setup and ready to go. I just have to make an engraved panel for the frequency pot and get some aluminium mesh bent for the sides. Unfortunately my oscilloscope transformer failed so I'm now without a scope, it may be upto a month before I order a new one so I'm trying to decide to run it (having previously run the system) or simply wait. I guess I could just use a multimeter on a ct and take note of the primary current.

Here's some pics is the progress.






17
Transformer (Ferrite Core) / Re: Skm flyback destroyer 🤗
« on: July 21, 2021, 01:50:19 AM »
Will you have inrush current problems with those caps ?

For me it won't be a problem as this will only ever be used with a variac. But now you mention it maybe I should add a softstart just incase the bus ever gets powered wrong.

18
Electronic Circuits / Re: Counterfit Parts
« on: July 08, 2021, 12:00:16 AM »
Unfortunately TO-247 are imo the most faked components in this hobby. I think I've ordered from 20+ vendors in hoping to find one that actually works. Eventually I gave up and started ordering bricks/igbt modules, I have seen fakes but they're obvious with the lower price attached to them.

19
Transformer (Ferrite Core) / Re: Skm flyback destroyer 🤗
« on: July 07, 2021, 01:36:27 PM »
Cheers for the info @davekni, I'll have to look into making my own supplies. It'll be handy for future projects.

@TMaxElectronics I'm just using a tl494, straight up copied from mads website.

I ended up finishing the bridge last night, I'll hopefully go I to detail on how I make my bus bars in a seperate thread. Overall I'm happy with how it turned out. The switch is an skm400gb126d, mdq100 rectifier, two epcos 10,000uf 400v bus caps. I thought about trying to make it more compact but it would have sacrificed the ease of working on the bridge.



20
Transformer (Ferrite Core) / Skm flyback destroyer 🤗
« on: July 06, 2021, 03:17:36 AM »
A while ago I started messing around with driving skm bricks to drive my diy flybacks. I had varying success with using a gdt and 40-50% duty cycle. After speaking to "Steve arcs" I decided to try what he used, a3120 gate drive IC and lower duty cycle in favour for longer dead times.

This project is something that's been kicking about for a few months now, recently I thought I'd make it into a proper project vs letting it slip onto the back shelf and letting it be forgotten.

The first thing I stated working on was the gate drive side of things. I had (have?) No real experience with opto gate drives ic so my approach is minimalist. The boards simply have bus capacitors, gate resistor/dt diode and gate protection diodes.



My next plan was to use 24v 1a smps and modify them for the gate drive power supplies. In the end I had two floating supplies with an adjustable voltage range of 15-30v DC. At 17v (gate drive) when pulling an arc the a3120 would hit uvlo, a sign to me that peak current even for a short time was enough to pull the smps voltage down. As a short term fix I adjusted the voltage upto 19v. I've since ended up ordering 18v 2a smps, I'm simply hoping this will be enough (just a pure blind guess).


I'm currently finishing up the bridge side of things. The plan is to make an enclosure this weekend from plywood. Originally I was thinking of making an aluminium enclosure but added complexity was something I wasn't keen to take on.

Cheers

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