Author Topic: Phoenix's QCWDRSSTC  (Read 429 times)

Offline Phoenix

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Phoenix's QCWDRSSTC
« on: September 05, 2020, 06:20:09 PM »
Hello  :)

Since my study program got interrupted a bit by Corona i decided to build a QCW during the Quarantine. It was quite a big task to build the whole setup but it is definetly worth the effort. I also want to thank Steve Ward for explaining to me how to properly tune phaselead and loneoceans for uploading his buck controller schematic which I modified to fit my setup.

Here are the specifications of the QCW:

125x246mm secondary coil with 560 turns of 0.4mm wire
75x300mm toroid as topload
0.4 coupling coefficient
16.5nF MMC consisting of 110 Wima FKP1 capacitors with 15nF and 2000V each. The MMC is built in a modular way so I can add and remove strings to change the capacitance
Upper pole starts up at 400kHz and drops to 350kHz during sparkloading
30000µF 350V buck capacitor bank (but this will get upgraded soon to 450V 24300µF)
Buck converter using an FF400 IGBT Module
Fullbridge consisting of IXXN110N65C4H1 Minibricks
Maximum primary current up to 200A

Here are some pictures:







So far I am pretty happy with the performance. I have seen sparks that reach up to 210cm length.


Here is the primary current (magenta) and the bridge output voltage (yellow) during this spark. The primary current goes up to about 180A and the peak ramp voltage is 310V.


The sparks are already nice and straight but I think that there is still a bit of room for improvement. That is why I will upgrade the ramp voltage to 420V. In order to keep the primary current rise lower i am also going to implement a startup oscillator to start the coil at the upper pole while the primary is tuned below fres secondary (with sparkloading). This leads to better energy transfer while the secondary is getting pulled lower by sparkloading. Better energy transfer = lower primary current since less reactive power stays in the primary. 
« Last Edit: September 05, 2020, 06:26:04 PM by Phoenix »

Offline Mads Barnkob

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Re: Phoenix's QCWDRSSTC
« Reply #1 on: September 07, 2020, 09:30:27 PM »
That is a very clean build quality, nicely done and good performance! 8½ times secondary winding length is worth being proud of :)

The huge fan might even be more noisy than the sparks, does it however do a decent job of keeping the IGBTs cool now that you do not use water cooling?

You have a pretty serious amount of DC bus capacitance, I can see that you are going to lower it a bit with the added voltage rating, but surely not even 25000 uF is going to see much voltage ripple?
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Offline Phoenix

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Re: Phoenix's QCWDRSSTC
« Reply #2 on: September 07, 2020, 09:51:24 PM »
Hi Mads

Thank you for your nice words  :)

Yes the big 300W radial fan is really noisy it sounds like a jet engine. But so far there was no need to actually turn the fan on during operation. At 1BPS there is basically no heating of the bridge, I measured around 0.2 degrees after 2 minutes. I also tried 10BPS but only at medium power and I got about 2 degrees above ambient on the bridge after 10s with the fan still off.

With the current 30mF charged to 325V i am seeing around 25V of ripple. I roughly calculated that the ripple with the new 450V caps will be around 30-40V. I should definetly also add an OCD circuit to the buck converter since failures at these energy levels get very violent. There is more than enough time to disable the gatedrive of the buck igbt after a bridge fail since the current rises slowly until the large inductor saturates.


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Re: Phoenix's QCWDRSSTC
« Reply #2 on: September 07, 2020, 09:51:24 PM »

 


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