Author Topic: Next Gen DRSSTC  (Read 77912 times)

Offline coilerer

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Re: Next Gen DRSSTC
« Reply #200 on: November 17, 2023, 01:40:08 PM »
First of all, Thank you, everyone, for your development of the UD3. I'm so excited to get mine integrated into my qcw coil.
On that note. I spoke to TMAX a while ago over email and confirmed that there is no buck ramp qcw mode currently available. Steve Ward mentioned he got "hacky" buck ramps to work on the early UD3. Is there any plan for developing buck ramp output as an alternative to phase shift? It would be great to get the arduino out of my build and just use the UD3.

Another question. Currently, I trigger my coil with an interrupter pin from the arduino. How would I go about telling the UD3 when the arudino is sending a ramp? This may become clearer to me as I mess with it, but I am still waiting on my programmer.

Thanks again for your hard work.

Daniel


Offline Hydron

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Re: Next Gen DRSSTC
« Reply #201 on: November 18, 2023, 10:19:52 PM »
You could probably do your own "hacky" ramp by fiddling with the PSoC code. Likely would just need tweaking the appropriate logic schematic to output pwm for the ramp instead of a variable phase shift, plus possibly a bit of SW tweaking, but the majority of the code can probably be left as is.

Offline Netzpfuscher

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Re: Next Gen DRSSTC
« Reply #202 on: November 24, 2023, 08:57:36 AM »
We have no DAC-Channels free. I can give you a PWM output of the ramp, should be no big change.

Offline coilerer

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Re: Next Gen DRSSTC
« Reply #203 on: November 25, 2023, 01:05:56 PM »
Quote
You could probably do your own "hacky" ramp by fiddling with the PSoC code. Likely would just need tweaking the appropriate logic schematic to output pwm for the ramp instead of a variable phase shift, plus possibly a bit of SW tweaking, but the majority of the code can probably be left as is.

That's a bit out of my short-term comfort zone, but maybe I can try in the future :). Thanks!

We have no DAC-Channels free. I can give you a PWM output of the ramp, should be no big change.

That would perfectly replace my Arduino. It would also mean I don't need a wifi connection (to my Arduino) to control my ramps!

Offline Jj

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Re: Next Gen DRSSTC
« Reply #204 on: January 05, 2024, 11:09:50 AM »

I'll be releasing that version as the UD3.1c once I verified the changes. The next batch of UD3's in my shop will be that version.

Hi Tmax do you have an idea of when your boards may be available again? I’m very keen to get a few to upgrade my old DRSSTCs.

Offline Mads Barnkob

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Re: Next Gen DRSSTC
« Reply #205 on: January 25, 2024, 01:01:36 PM »
I am gathering parts from around the lab and work shop, to get the driver running. When looking for the Ibus current sensor, I did not have a LEM 306-S in my collection, but I did have some Honeywell CSNS300-001 hall effect sensors.

So far so good. Looking at its datasheet, it also takes +/- 12V and delivers 150mA at 300A. Identical to the LEM 306-S. But checking the numbers, 150mA into 50R would give 7.5V, not 5V maximum of the Ibus input.


It is also listed to be a 1000:1 ratio CT (in schematic), but both are 1:2000


So there might be a few errors like wrongly stated turns ratio and shunt resistor should have been 33R instead of 50R?
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Offline flyingperson23

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Re: Next Gen DRSSTC
« Reply #206 on: January 26, 2024, 06:26:58 AM »
150 mA would indeed give 7.5 volts. My LEM LF 305-S seems to work fine. It's supplied +-5v, so can only output 100mA so is limited to measuring 200A. I put in 2000 as ct2_ratio and it works fine, although it appears to be a few hundred milliamps off. I know the current goes through a RMS filter, could that be causing the error? I need accurate current measurements to control a boost converter with the UD3.1; what would be the best way to get instantaneous/non-filtered readings?

Offline Netzpfuscher

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Re: Next Gen DRSSTC
« Reply #207 on: January 26, 2024, 05:19:18 PM »
@Mads

It's no problem to change the CT2 shunt to something different. It needs no change in the code. Simply solder whatever you like, then change the "ct2_burden" (Ohms) accordingly. It's better not to rely on the internal clamping diodes of the PSOC, so make the shunt
small enough not to fry the MCU input. (There is a 470 Ohms in series, but better safe than sorry). Then change the "ct2_ratio" to 2000 and you're fine.


@flyingperson23
The UD3 software is not designed to output every current sample. It uses DMA to collect 25 samples from the ADC before interrupting the CPU to calculate everything. I implemented this to decrease interrupt load. The current is sampled with 8 kHz the CPU is interrupted at a rate of 320 Hz so that's the rate you're getting 25 sampled at a time. Is that fast enough? Otherwise you need to decrease the
https://github.com/Netzpfuscher/UD3/blob/892b8c25da2784e880c0c2617d417b14c3421ecd/common/ud3core/config.h#L40

This is the line calculating RMS:
https://github.com/Netzpfuscher/UD3/blob/892b8c25da2784e880c0c2617d417b14c3421ecd/common/ud3core/tasks/tsk_analog.c#L261

Offline Kevindk9

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Re: Next Gen DRSSTC
« Reply #208 on: Today at 02:25:30 AM »
I have a few suggestions to help make this an actual 'universal driver'

-Manual controls
Ability to operate the driver without connecting with a computer. Just a way to use an on/off foot switch and potentiometer to control power. Like it only runs when a button is pushed.

Also, It would be nice to have buttons and hotkeys in Tesla Term also, that way you don't have to go through the drop down menu to do stuff. (the tesla coil messes with my track pad)



-Induction heater mode
Currently im using a slightly modified version of the UD3 code and I run my induction heater in QCW mode. I modified the max on time and minimum repeat time so a new QCW shot happens as soon as the old one ends. The problem is it starts the whole QCW routine each time (hard switching and tracking). I believe this killed my IGBTs once because it hard switches for 10s of cycles at a very high voltage.
Ideally the IH mode would only do the routine a single time and implement a debounce feature to make sure the tank has time to ring down incase you interrupt it.


-Transformer mode
Just a simple mode to run a ferrite transformer. Ability to set a fixed frequency. You could control it using a button press or run it from Tesla Term and use it to modulate the arc and play music.



Offline TMaxElectronics

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Re: Next Gen DRSSTC
« Reply #209 on: Today at 02:43:08 AM »
Interesting ideas, some of which I have actually at least played around with in the past.
I have a little ferrite core HV source that runs from a UD3 just using pulse width modulation. Pretty much just like you said: you could use the the pw slider in teslaterm to control the output power. I've also used the UD3 as a induction heater on a few occasions (once inadvertandly by having a hammer next to my big coil during testing... that then burned my hand :P).

The problem that I have with implementing that as a permanent feature is that there are some medium to large hardware changes required (especially for ferrite core mode) that aren't easy to do on the fly in the psoc. At least i don't know how :D Just placing different hardware next to the existing one and not enabling it until needed is unfortunately not an option as some types of the psoc hardware are already 100% used. I suppose the induction heater thing might work, but we'd really need to plan a proper mode switch in for that. Not just set the max. dutycycle to 100% :P

The idea of operation without a computer is nice and is actually partially implemented. The autostart option makes the coil behave exactly like a UD2.x or older coil with an interrupter input. But connecting anything to the UD3 directly (as in: without fiberoptic isolation) is not that good of an idea. We've already killed a few PSOCs just with crap coupled in through WS2812 LED strips ::)

But in the end it is an open source project: if somebody has an idea they can get the code and play around with it themselves, and if it works out well contribute back to the main codebase :)

Offline malte0811

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Re: Next Gen DRSSTC
« Reply #210 on: Today at 01:38:21 PM »
Quote
Also, It would be nice to have buttons and hotkeys in Tesla Term also, that way you don't have to go through the drop down menu to do stuff. (the tesla coil messes with my track pad)

This is something I have considered previously (mostly for the "kill" button), I just never got around to implementing it. I am currently in the middle of a larger refactor in TT (connecting to multiple coils with a single TT instance), once that is done I can look into hotkeys. Can you open an issue for it at https://github.com/malte0811/Teslaterm so I do not forget about it? In general hotkeys are going to be a "fallback" option though, with a mouse being the intended method of interaction. Have you tried using a "traditional" mouse rather than a touchpad? In my experience this is much more reliable around coils.

Since I'm already posting here: Currently Teslaterm has the option to run as a "headless" server (e.g. on an RPi installed in the coil), which the actual control computer then connects to using a standard browser. Is anyone actively using this mode ("node")? It complicates the code significantly in some places, so I would like to remove it if possible.

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Re: Next Gen DRSSTC
« Reply #210 on: Today at 01:38:21 PM »

 


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