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« 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!
2
« 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
3
« 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?
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« 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.
5
« 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?)
7
« Last post by davekni on Today at 03:35:52 AM »
How do these gate waveforms look? Is the rise time too slow? I have no idea what rise time is because scope time/division is not listed. Oh, after noticing title saying 100kHz, I can then deduce scope is at 2us/div for first capture. Listing both volts/div and time/div for all traces would be helpful. Or amps/div for current. Rise time is probably fine. Some rise time is needed to provide dead-time between turn-off and turn-on. Also, do you know why I sometimes get the noise on the primary current waveform at the switching transitions but sometimes not? In this case it might be relevant to fix the noise because it lines up with some ringing/noise on gate turn off. Presuming UD2.7 or similar driver, phase lead does not function well at low current. Once current builds, phase lead works better. Phase lead makes switching at proper time slightly before zero current which reduces spikes.
8
« Last post by MRMILSTAR on April 17, 2024, 11:54:05 PM »
I just started researching this as you recommended. Is it possible to make one small enough for the lamp project? When I think of a Variac I think of a large Toroidal coil transformer with a large knob on it.
There are some very small variacs. I have one that is only about 3 inches in diameter. Consult E-Bay.
9
I'm building a small half bridge coil. How do these gate waveforms look? Is the rise time too slow? and what about the ringing on turn off? I've got 5.1 ohms gate resistors and 0.82 ohm turn off gate resistors. these values worked well for lower frequency coils but I might need to tweak them. I'm scoping the low side gate because if I scope the high side, I get the primary current distorting the gate waveform somewhat. I've also included shots of the bridge output with phase lead tuned as well as possible at 200A primary current. I'm planning to run it up to at least 600A But that was as high as I could get it with my isolation step down transformer at 40V AC in. Also, do you know why I sometimes get the noise on the primary current waveform at the switching transitions but sometimes not? In this case it might be relevant to fix the noise because it lines up with some ringing/noise on gate turn off. Thanks, Benjamin
10
« Last post by Michelle_ on April 17, 2024, 02:29:30 AM »
They are usually called "magnifiers" for some reason. People still occasionally build them but it seems that they are needlessly complex and take up more space than standard 2-coil designs. I haven't seen any evidence that they out-perform standard 2-coil designs.
Thanks for that key piece of info lol. Now that I have something to go off of I have found more information. I even found a thread you posted with an interesting paper about this, that nobody replied to sadly. The paper talks about people continually copying old ideas which really resonates with me no pun intended. I intend to do weird stuff with tesla coils, or maybe I'm not smart enough to know what's a bad idea. At least I'll probably try something nobody has seen before, maybe someone will be entertained by it. I will investigate this extra coil further and see if there's anything to it. Tesla himself had some interesting theories but of course it's hard to separate the fantastical from the practical; however I am inclined to wonder about things he insists upon based on his track record of innovation, even though a lot of his ideas were proven to be bunk. Thanks.
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