Author Topic: 160mm DRSSTC II project | Questions  (Read 1129 times)

Offline Late

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160mm DRSSTC II project | Questions
« on: December 29, 2023, 10:15:26 PM »
Hello everyone,

After finishing my DRSSTC and playing around with it for a while I noticed some bad designs practices that I had used when making it so I decided to make a second bigger DRSSTC but this time with a way better design which should allow it to run more reliably.


Recently I started planning the DRSSTC II project and the current specs that I'm going for are as follows:

Secondary coil: 160mm x 730mm with ~2000 turns of 0.355mm enameled copper wire

Top load: 170mm x 810mm toroid constructed from aluminum air duct

Primary coil: 200mm x 500mm flat spiral coil with 8 turns of 8mm copper pipe with possibility to water-cool the primary in the future

Coupling: ~0.15 with possibility to adjust it

Primary capacitor: MMC made from 6 220nF 6000VDC dawncaps in 2s3p configuration

Bus: 3 phase input for ~565VDC on the bus

Bus capacitor: 2s2p from some nice 6800uF 350V Itelcond electrolytics with 15kΩ 15W resistor across each parallel bank of caps to act as both discharging and loading resistor.

Inverter: Full-bridge from 2 CM300DU-24NFH half-bridge bricks with a 10kΩ loading resistor across the output and with 2 3uF 1kV snubber capacitors across the IGBT terminals

Driver: My own modified version of the UD2.9 pulse skip drive

Here's the inverter schematic and JavaTC inputs and outputs:




The frame for the whole construction I'm planning to make out of some 30x30 aluminum profile. Whole frame will be around 520mm x 520mm x 300mm. With the primary coil platform being 150mm higher than the whole construction to avoid the heating of the frame. Here's a crude drawing of the frame:



For the build I have already acquired the IGBT's and the BUS capacitors which I got a pretty good deal on. For the case the plan is to cover the openings in the 3030 alu frame profile with some clear acrylic or polycarbonate and to maybe add some LEDs inside to illuminate the whole construction. For the bus itself I plan to go with a laminated bus made from some 3mm alu sheet with fiberglass and resin as the insulating layer to keep the bus stray inductance as low as possible.

Id love to hear any input about my coils plans and to see if there's anything I should improve or fix when making it. And also is there anything I should pay more attention to when assembling/building the coil?
Hi, my name is Patriks and I'm from Latvia. I'm interesting electronics, especially power electronics and high voltage. I also make content on YouTube showing my journey in the awesome world of High Voltage.

YouTube: LateNightProjects

Offline davekni

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Re: 160mm DRSSTC II project | Questions
« Reply #1 on: December 30, 2023, 12:02:59 AM »
Quote
With the primary coil platform being 150mm higher than the whole construction to avoid the heating of the frame.
Perhaps a bit close for a 500mm diameter primary to metal frame.  Hope you get other opinions too.  I've tried to keep one primary radius gap to other sizable metal objects, but I don't know if that's actually needed.  A FEMM simulation could predict effects.  Perhaps there are simpler tools to estimate coupling between primary and metal frame.

Quote
Here's the inverter schematic
Presume the 5R6 gate pull-down resistor values are place-holders.

Looks like a good design in general.
David Knierim

Offline Benjamin Lockhart

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Re: 160mm DRSSTC II project | Questions
« Reply #2 on: December 30, 2023, 04:15:42 AM »
I would reduce your primary turn to turn spacing to something like 6mm.
Making the coil smaller is always nice, and that should actually increase your coupling slightly as well.
If you play around with the primary outside diameter in javatc you will find there is a sweet spot with the highest coupling.
« Last Edit: December 30, 2023, 04:18:05 AM by Benjamin Lockhart »

Offline Late

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Re: 160mm DRSSTC II project | Questions
« Reply #3 on: December 30, 2023, 02:34:41 PM »
Presume the 5R6 gate pull-down resistor values are place-holders.

Yes the 5R6 resistors are just the placeholders. When ill have everything assembled ill be adjusting both of them for each gate to get the fastest rise and fall times without having big spikes.
Hi, my name is Patriks and I'm from Latvia. I'm interesting electronics, especially power electronics and high voltage. I also make content on YouTube showing my journey in the awesome world of High Voltage.

YouTube: LateNightProjects

Offline Late

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Re: 160mm DRSSTC II project | Questions
« Reply #4 on: December 30, 2023, 02:38:23 PM »
I would reduce your primary turn to turn spacing to something like 6mm.
Making the coil smaller is always nice, and that should actually increase your coupling slightly as well.
If you play around with the primary outside diameter in javatc you will find there is a sweet spot with the highest coupling.

I put the turn to turn spacing to roughly 10mm to be able to easily connect the primary tap clamp without risking any shorts to adjacent turns. And the 0.15 coupling seemed like a good value but yea sure ill be playing around a bit with javaTC to find the optimal spacing.
Hi, my name is Patriks and I'm from Latvia. I'm interesting electronics, especially power electronics and high voltage. I also make content on YouTube showing my journey in the awesome world of High Voltage.

YouTube: LateNightProjects

Offline Benjamin Lockhart

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Re: 160mm DRSSTC II project | Questions
« Reply #5 on: December 30, 2023, 09:50:05 PM »
The turn spacing on my big coil is 4.8mm with 6mm tubing and I'm using fuseholders for the tap connection and there's lots of space.
6mm tube was too small for 1000A though and demands water cooling.
« Last Edit: December 30, 2023, 09:51:41 PM by Benjamin Lockhart »

Offline Mads Barnkob

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Re: 160mm DRSSTC II project | Questions
« Reply #6 on: December 31, 2023, 12:07:42 AM »
99% of the time, a Tesla coil is in storage, so think a lot about storage, modularity, transportation etc. The coil you are building here, will take up about 1½-2 cubic meters of space, Tesla coils always seem smaller on paper :)

Your design does look pretty sound and follows best-practises. Maybe ditch the connection between DC bus capacitors and give them individual resistors instead, to balance them better.
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Offline Late

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Re: 160mm DRSSTC II project | Questions
« Reply #7 on: January 01, 2024, 10:59:29 PM »
The turn spacing on my big coil is 4.8mm with 6mm tubing and I'm using fuseholders for the tap connection and there's lots of space.
6mm tube was too small for 1000A though and demands water cooling.

Yea on my other DR I'm also using 6mm pipe and at 1kA it gets pretty toasty fast. Hoping that on this coil using 8mm pipe should prevent it getting too toasty. Might need to even use 10mm pipe though not sure. For the tap connection I'm planning to make a custom connector from some copper like I did for my current DR.




For this DR ill make something very similar to that but with 2 16mm2 cables going to it. And will reduce the turn spacing to around 6-8mm as suggested. Though with that small of a distance wont that cause issues with the outer turns induction heating the inner turns?
Hi, my name is Patriks and I'm from Latvia. I'm interesting electronics, especially power electronics and high voltage. I also make content on YouTube showing my journey in the awesome world of High Voltage.

YouTube: LateNightProjects

Offline Late

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Re: 160mm DRSSTC II project | Questions
« Reply #8 on: January 01, 2024, 11:08:17 PM »
99% of the time, a Tesla coil is in storage, so think a lot about storage, modularity, transportation etc. The coil you are building here, will take up about 1½-2 cubic meters of space, Tesla coils always seem smaller on paper :)
For easy transport i plan to add some wheels on the bottom of it so it can easily be wheeled in and out of my workshop. And I'm planning to make each part of the DRSSTC easily swappable or upgradable if in future ill want to do anything like that. Size wise i made it smaller than the largest size i could easily fit in the bottom shelf of a commercial shelving unit i have against the wall in my workshop. I will try to make a 3d model of everything in fusion or solidworks to see how much free space is left over and based on that ill see by how much i can decrease the whole size as smaller ofc means lighter so easier for me to move, store and set it up alone.

Quote
Your design does look pretty sound and follows best-practises. Maybe ditch the connection between DC bus capacitors and give them individual resistors instead, to balance them better.
Glad to hear that. I spend quite a lot of time researching and looking at other DRSSTC builds to make my coil the best design i can.


Hi, my name is Patriks and I'm from Latvia. I'm interesting electronics, especially power electronics and high voltage. I also make content on YouTube showing my journey in the awesome world of High Voltage.

YouTube: LateNightProjects

Offline Late

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Re: 160mm DRSSTC II project | Questions
« Reply #9 on: January 01, 2024, 11:34:30 PM »
I have acquired both the bus capacitors and the IGBTs. The bus capacitors are bit bigger than i thought but they will work wonderfully for this build and the red color of them will stand out.




I'm thinking of arranging them something like this in the build with the capacitors being held together by a plastic plate and on the other side connector to the laminated bus.


I have ran into one issue though, I cant seem to find suitable heatsink for cheap anywhere locally. Does anyone know where i should look for heatsinks or where i could get one for not too expensive? I'm located in Europe, Latvia and I'm looking for a heatsink that's around 280-500mmx150-300mmx50-120mm
« Last Edit: January 01, 2024, 11:37:35 PM by Late »
Hi, my name is Patriks and I'm from Latvia. I'm interesting electronics, especially power electronics and high voltage. I also make content on YouTube showing my journey in the awesome world of High Voltage.

YouTube: LateNightProjects

Offline thedoc298

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Re: 160mm DRSSTC II project | Questions
« Reply #10 on: January 02, 2024, 10:33:56 PM »
Really nice build and you gave me an idea for the variable primary tap, I like yours and will be making some for my other coils. Be nice to see it fire.

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Re: 160mm DRSSTC II project | Questions
« Reply #10 on: January 02, 2024, 10:33:56 PM »

 


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