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« Last post by Michelle_ on Today at 06:03:57 PM »
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« Last post by Michelle_ on Today at 05:26:13 PM »
Hello, Here is my thinking.
First, At the common ZVS oscillator circuit, there're usually two resistors with bigger package that have around hunderds of resistance. They, and the two of fast diodes and the resonant tank are the MOSFETs gate driving circuit. On the other hand, the two smaller ~10k resistors as the pull-down resistors, parallel to the zenor diodes (usually 12V).
So, if you increase the input voltage. This two driver resistors can pass more current for some of the more current pass through Zenor (guess 1) And the MOSFETs gate signal is like 0V/12V (by zenor) ~square wave so the more voltage can constantly shift up Vin-12V the voltage across this two driver resistor (guess 2) Then, I don't know for this kind of resonant circuit, if the Miller effect still plays a big part when the input power been increase (guess 3)
For your sample post SGTC. I was Lucky~ I only use a simple LCR meter to measure the L and C of primary coil, secondary coil, and primary resonant capacitors to approach the resonant frequency.
I think it is a more detailed sample way~
(1) Think of the shape of your secondary coil (it make you have to consider about the coupling), for a SGTC I think you need a longer secondary compares to DRSSTC for avoid the arc flash from the high voltage in the primary to secondary (SGTC tens of kV compares to DRSSTC hundreds V to kv).
(2) Assume the coupling factor like typical 0.1~0.3 and simulte them in SPICE to check how much inductance the primary need (The leakage inductance and capacitance make the resonant freq.)
Then make your circuit and tune them. For the resonant capacitor. I use MS15000V film-capacitor from EACO. I think CDE or WIMA or KEMET or other manufacturer are common on the market.
The current or the voltage as the leader in the primary resonant tank (Same resonant frequency, big L small C or big C small L). I don't know the actual different of their behavior to a SGTC.
By the way, https://www.youtube.com/watch?v=__IYgKmSxGM this was my goal.
Thanks for sharing your thoughts. Right now for my primary I have a pancake designed in javaTC. The diameter of the bottom of my secondary is 3" and the ID of the primary is 5". I will probably make a short wall in between them for good measure. The primary OD is set to 7-8" depending on if I have 1/8" tubing or 1/4" tubing selected (I bought both). It ends up being around 7-8 feet of wire but I have more than that and will tap in. It's saying something like .8-1" between coils on the primary but I will also 3d print recesses/walls to help isolate the windings from one another but leave enough room for the tap. My coupling coefficient is .15, I figured I can raise the secondary relative to the primary to lower it if needed? For 5 turns (Seems like either size tubing) I am getting a .02uf primary capacitor, and for 4 turns a .03 uf primary capacitor. I figured I will go shopping and look for something in that range and adjust the turns of the primary to match what I can get. Based on what I can see if I have capacitors in that range I can tap the primary and get directly in the range of the secondary's resonant frequency and have quite a bit of room for adjustment either way. ALSO: I am reading that you're not supposed to run the ZVS/flyback with no load which could be why it was overheating? That would be good news because it would mean it is otherwise working correctly and the output voltage is high.
3
« Last post by NyaaX_X on Today at 04:03:38 PM »
Hello, Here is my thinking. First, At the common ZVS oscillator circuit, there're usually two resistors with bigger package that have around hunderds of resistance. They, and the two of fast diodes and the resonant tank are the MOSFETs gate driving circuit. On the other hand, the two smaller ~10k resistors as the pull-down resistors, parallel to the zenor diodes (usually 12V). So, if you increase the input voltage. This two driver resistors can pass more current for some of the more current pass through Zenor (guess 1) And the MOSFETs gate signal is like 0V/12V (by zenor) ~square wave so the more voltage can constantly shift up Vin-12V the voltage across this two driver resistor (guess 2) Then, I don't know for this kind of resonant circuit, if the Miller effect still plays a big part when the input power been increase (guess 3) For your sample post SGTC. I was Lucky~ I only use a simple LCR meter to measure the L and C of primary coil, secondary coil, and primary resonant capacitors to approach the resonant frequency. I think it is a more detailed sample way~ (1) Think of the shape of your secondary coil (it make you have to consider about the coupling), for a SGTC I think you need a longer secondary compares to DRSSTC for avoid the arc flash from the high voltage in the primary to secondary (SGTC tens of kV compares to DRSSTC hundreds V to kv). (2) Assume the coupling factor like typical 0.1~0.3 and simulte them in SPICE to check how much inductance the primary need (The leakage inductance and capacitance make the resonant freq.) Then make your circuit and tune them. For the resonant capacitor. I use MS15000V film-capacitor from EACO. I think CDE or WIMA or KEMET or other manufacturer are common on the market. The current or the voltage as the leader in the primary resonant tank (Same resonant frequency, big L small C or big C small L). I don't know the actual different of their behavior to a SGTC.By the way, https://www.youtube.com/watch?v=__IYgKmSxGM this was my goal.
4
« Last post by Michelle_ on Today at 02:56:40 PM »
So, the two big resistors near the three output terminals start creeping over 60 degrees if I’m putting in more than 16v, (no fan yet obviously) does that seem wrong to anyone? The rest of the setup looks much cooler from my thermal camera. At 24v in the resistors kept heating up into the high 60s before I turned power off.
5
« Last post by Benbmw on Today at 06:17:15 AM »
I had the chance to fire up my ANSYS simulation and thought you would enjoy some examples of what it can do. Attached is an animation and plot of a nominal induction launcher design with the following parameters. Note that this is a time harmonic solution (not transient) with 10 identical coils and an armature that is longer than the "barrel". A case which would be great for efficiency, since all of the coils are running at the same frequency and all doing work on the armature. So a bit of a simplified launcher.
Armature diameter: 25mm Armature wall thickness: 3mm Armature material: Aluminum Armature weight: 200g
Coil number: 10 Coil cross section: 20mm x 15mm Coil wire gauge: 10 AWG Coil turns: 45 Coil drive current: 1kA
With this model I can sweep all sorts of variables like armature-coil gap spacing (one I knew you were keen on), drive phase number, drive frequency, etc. etc.
The animation shows the product of the azimuthal current density J and the radial magnetic field density B which has units N/m^3 (if you do a volume integral you get total force on the armature). The plot shows the total armature force vs drive frequency for gap spacing of 1, 2, and 3mm. As you can see, a smaller gap is better, but the gains aren't astronomical, more on the order of 10 or 15%, at least for this design.
I would be happy to plug in your numbers and run a similar simulation sweeping whatever variables you are interested in. Just let me know!
6
« Last post by Michelle_ on Today at 05:46:07 AM »
That looks like within about 10% of prediction which is pretty good. Certainly close enough for initial tuning. Did you account for the tolerance of your capacitors?
I don't have any capacitors yet, I wanted to measure the output voltage of my power supply at 24v first (tomorrow) and then I think I will have enough information to specify them, as far as I understand it what I was going to do was: 1.) measure the actual secondary frequency 2.) Measure the actual output voltage 3.) Model a primary coil in javaTC and get a suggested capacitor 4.) Find a real one that's close to or slightly higher than the suggested value 5.) Re calculate the primary and tapping point, check coupling coefficient 6.) Buy capacitors and make primary capacitor with 10Mohm resistors to drain 7.) 3D print form for building pancake primary and wind primary EDIT: Fly back voltage = 10,000 at 10v in 24,000 at 24v in Unloaded of course.
7
« Last post by MRMILSTAR on Today at 05:18:31 AM »
That looks like within about 10% of prediction which is pretty good. Certainly close enough for initial tuning. Did you account for the tolerance of your capacitors?
8
« Last post by davekni on Today at 04:34:52 AM »
I'd agree, IKY150N65EH7 looks like a very nice part based on data sheet. 4-lead package (Kelvin emitter connection) helps keep switching speed fast even with package lead inductance. Presuming you use full IKY150N65EH7 capability, 600A or higher OCD, minimizing internal Vce switching spikes will be key, along with keeping sufficient margin between Vbus and 650Vce rating. My testing of a different part in similar package might be useful: https://highvoltageforum.net/index.php?topic=2498.msg18348#msg18348Construct a low-parasitic-inductance H-Bridge. May also be necessary to add resistors in series with gate diodes to slow turn-off a bit. (IGBT turn-off will be much faster than data sheet lists when using bipolar Vge from GDT secondary. Data sheet is for 0-15Vge and 10ohms in series for both turn-on and turn-off.) Tune phase lead well.
9
« Last post by klugesmith on Today at 04:11:53 AM »
Have you seen this video, about what's inside a similar AC sync indicator? It includes current measurement, and a demonstration of fixed 12:00 and 6:00 as I'd suggested. />
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« Last post by Michelle_ on Today at 04:02:44 AM »
RESULTS
This is interesting. I didn't actually count the number of windings but,
Depending on if my javaTC numbers are more nominal or based on what can be measured:
JavaTC estimated resonant frequency: 430-494KHZ (with top load) JavaTC estimated resistance: 106-122ohm
Measured (with signal generator and oscilloscope) resonant frequency: 472.5KHZ (with top load) Measured resistance: 107ohm
That seems pretty good right? I'm not sure how exact other people's results are but I feel better that things match fairly closely (it seems close to me?)
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[Electronic Circuits]
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markus April 09, 2024, 06:08:53 PM
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