Any replication interest ?
ATMEL Mega32.
I did not think it was fair not to show the transformer details.
Since I made this I have changed workstations and server twice. But I retrieved some pictures from the backup on how to wind the primary winding.
Insulate the primary from the secondary with 3 layers of SCOTCH 23.
The secondary ends opposite end of the primary ribbons. Be sure to embed the soldered connection to the HV cord in SCOTCH 23 tape.
Important, stretch the SCOTCH 23 tape approx. 50% and avoid trapped air. Trapped air will ionize and destroy the insulation. Less than the best can create internal shorts. Do not use low end normal insulation tape for this. On the picture you can see the yellow poly tape used for the ribbons. It is also an excellent insulator, but it is too thin, so the internal capacity gets high, and you get reduced power output.
Don't stretch the 23 tape much between the primary windings.
http://img380.imageshack.us/img380/6193/startxj3.jpg
http://img380.imageshack.us/img380/5041/endhc9.jpg
http://img146.imageshack.us/img146/3600/finishedbg0.jpg
By selecting 2 of the four core halves you can get the air gaps 0,5mm, 1,0mm, 1,5mm, 2,0 and 2,5mm. The magnetic energy is stored in the air gap, not the core. The wider the more power the core can handle,The cores are clipped to the coil former with clips bought together with the coil former.
The question is what to do now.
This is another beast than this thread is started with. The Radiant Oscillator is an easy to replicate item, while my supply is not.
As I have mentioned I have lurked around for more than half a year, trying my best to grasp this, to me, new world of alternative energy. I have seen several applications that is obvious to solve with a micro controller. The Lindemann motor being one example.
But for this statement to be true, you need some knowledge about uControllers.
I am a newbie in alternative energy, but I made my first micro controller instrument in the early 1980'ties. The last 5 years i have made 30 different PCB designs including SW.
My newest SMPS has no HW controller, all are made with sw in a Tiny45. This way I get exactly what I want.
I have seen and used a lot of different controllers and CPU's. For doing circuits the Tesla way I can recommend two easy to learn and use controllers. It is 8 bit controllers, who are members of a big family of processors, so you have a rich set to choose from.
Having learned to use one of the AVR's then you almost have leaned to use all of them.
I would focus on the 8 pin ATTiny45 (2$) and for more advanced use, the 24 pin AT90PWM3B (4$) with 3 independent PWM controllers on chip.
The top AVR family members are overshoot in most of our applications.
The SW tools are nice and free of charge, and the Dragon, a programming and debugging tool, costs less than 80$. Then you are up to full speed tool wise. Programming languages: assembler, C or C++.
Atmel Corporation - Industry Leader in the Design and Manufacture of Advanced Semiconductors
AVR Freaks
Avrfreaks.org is a big forum with lots of kind and helpful members, you often get help in half an hour. But don't mention alternative energy, they are with a few exceptions a bunch of skeptics.
The Tiny45 can sleep when no work has to be done consuming down to 0.1 uA, but still ready to wake up and do some work.
You can make self oscillating SS Bedinis with the 8 Pin Tiny45, automatically shifting batteries solid state, and power down when all is up, I have a nearly completed diagram for that. I have built a well functioning SS with a small PNP (TO-223, polarities mirrored) instead of a big NPN, so now the negative pole is pulsed. It has revived otherwise completely for years dead NiCd's to better than new capacity, so It works well and that's my base for the new automatic circuit not built yet.
So a lot of possibilities come to you if you climb the learning curve. If there is interest to go for it, I suggest we start a new thread for that purpose.
The avrfreaks forum gets you started, and I can assist giving tips here on how to use the uC for our applications. And I could fill the void controller space on the diagram.
Your choice !
Back to the HV supply:
Shortly spoken it is a normal flyback 24V supply, but with 11 high ripple current Chemicons in a cap bank, 11 * 680uF/50V, 3 winding full coil former width copper foil primary, sliced at the ends for a total of 10 terminals, and 48 windings of 0.63 mm magnet wire. Insulated with Scotch 23 HV insulation tape. Discharge path through the 3 windings -> 2 paralleled IGBT's a current sensing resistor 2.5 milliOhm and a total not directly magnetically coupled path to the core of approx. 120mm incl. IGBT pins.
The 100 x 160mm PCB is operated at 30 kHz by an Atmel Mega32 micro controller. In the original circuit it consumed approx. 400W drawing a knife arch up to 1.5mm gap and 180mm long/wide, operating at approx. 3-4 kV when started, It is capable of approx. 20kV unloaded for igniting the arch.
The overload circuit prevents loads of fried IGBT's. I have fried a total of 5 for development and use.
But the program must listen to the overload input so IGBT's are not stressed too much. The IGBT's has a hard job in this circuit, getting too hot starts an accelerating death spiral.
But with sw provisions for long term overload, no problem. Actually there is a uC, Tiny45 with temperature sensor on-chip, so if the processor is thermally coupled, reliability is no problem.
My supply has been in daily work for 2 years until obsoleted, I started with one IGBT, but had to use 2 to get it reliable. With one only, it lasted only a few months.
A good heat sink is necessary as it runs right now, size depending on how hard you want to push the IGBT's
My present program has intermittent operation 20% on time, That allowed me to raise power a bit more.
I can recommend Kicad for PCB layout, it works on both M$ and Linux.
Main Page - KiCad
AVR Freaks
Code::Blocks for SW development environment.
AVRStudio or avarice
The GCC compiler. WINAVR
The AVR Dragon programmer/ debugger.
Eric
Originally posted by **~Imhotep~**
View Post
I did not think it was fair not to show the transformer details.
Since I made this I have changed workstations and server twice. But I retrieved some pictures from the backup on how to wind the primary winding.
Insulate the primary from the secondary with 3 layers of SCOTCH 23.
The secondary ends opposite end of the primary ribbons. Be sure to embed the soldered connection to the HV cord in SCOTCH 23 tape.
Important, stretch the SCOTCH 23 tape approx. 50% and avoid trapped air. Trapped air will ionize and destroy the insulation. Less than the best can create internal shorts. Do not use low end normal insulation tape for this. On the picture you can see the yellow poly tape used for the ribbons. It is also an excellent insulator, but it is too thin, so the internal capacity gets high, and you get reduced power output.
Don't stretch the 23 tape much between the primary windings.
http://img380.imageshack.us/img380/6193/startxj3.jpg
http://img380.imageshack.us/img380/5041/endhc9.jpg
http://img146.imageshack.us/img146/3600/finishedbg0.jpg
By selecting 2 of the four core halves you can get the air gaps 0,5mm, 1,0mm, 1,5mm, 2,0 and 2,5mm. The magnetic energy is stored in the air gap, not the core. The wider the more power the core can handle,The cores are clipped to the coil former with clips bought together with the coil former.
The question is what to do now.
This is another beast than this thread is started with. The Radiant Oscillator is an easy to replicate item, while my supply is not.
As I have mentioned I have lurked around for more than half a year, trying my best to grasp this, to me, new world of alternative energy. I have seen several applications that is obvious to solve with a micro controller. The Lindemann motor being one example.
But for this statement to be true, you need some knowledge about uControllers.
I am a newbie in alternative energy, but I made my first micro controller instrument in the early 1980'ties. The last 5 years i have made 30 different PCB designs including SW.
My newest SMPS has no HW controller, all are made with sw in a Tiny45. This way I get exactly what I want.
I have seen and used a lot of different controllers and CPU's. For doing circuits the Tesla way I can recommend two easy to learn and use controllers. It is 8 bit controllers, who are members of a big family of processors, so you have a rich set to choose from.
Having learned to use one of the AVR's then you almost have leaned to use all of them.
I would focus on the 8 pin ATTiny45 (2$) and for more advanced use, the 24 pin AT90PWM3B (4$) with 3 independent PWM controllers on chip.
The top AVR family members are overshoot in most of our applications.
The SW tools are nice and free of charge, and the Dragon, a programming and debugging tool, costs less than 80$. Then you are up to full speed tool wise. Programming languages: assembler, C or C++.
Atmel Corporation - Industry Leader in the Design and Manufacture of Advanced Semiconductors
AVR Freaks
Avrfreaks.org is a big forum with lots of kind and helpful members, you often get help in half an hour. But don't mention alternative energy, they are with a few exceptions a bunch of skeptics.
The Tiny45 can sleep when no work has to be done consuming down to 0.1 uA, but still ready to wake up and do some work.
You can make self oscillating SS Bedinis with the 8 Pin Tiny45, automatically shifting batteries solid state, and power down when all is up, I have a nearly completed diagram for that. I have built a well functioning SS with a small PNP (TO-223, polarities mirrored) instead of a big NPN, so now the negative pole is pulsed. It has revived otherwise completely for years dead NiCd's to better than new capacity, so It works well and that's my base for the new automatic circuit not built yet.
So a lot of possibilities come to you if you climb the learning curve. If there is interest to go for it, I suggest we start a new thread for that purpose.
The avrfreaks forum gets you started, and I can assist giving tips here on how to use the uC for our applications. And I could fill the void controller space on the diagram.
Your choice !
Back to the HV supply:
Shortly spoken it is a normal flyback 24V supply, but with 11 high ripple current Chemicons in a cap bank, 11 * 680uF/50V, 3 winding full coil former width copper foil primary, sliced at the ends for a total of 10 terminals, and 48 windings of 0.63 mm magnet wire. Insulated with Scotch 23 HV insulation tape. Discharge path through the 3 windings -> 2 paralleled IGBT's a current sensing resistor 2.5 milliOhm and a total not directly magnetically coupled path to the core of approx. 120mm incl. IGBT pins.
The 100 x 160mm PCB is operated at 30 kHz by an Atmel Mega32 micro controller. In the original circuit it consumed approx. 400W drawing a knife arch up to 1.5mm gap and 180mm long/wide, operating at approx. 3-4 kV when started, It is capable of approx. 20kV unloaded for igniting the arch.
The overload circuit prevents loads of fried IGBT's. I have fried a total of 5 for development and use.
But the program must listen to the overload input so IGBT's are not stressed too much. The IGBT's has a hard job in this circuit, getting too hot starts an accelerating death spiral.
But with sw provisions for long term overload, no problem. Actually there is a uC, Tiny45 with temperature sensor on-chip, so if the processor is thermally coupled, reliability is no problem.
My supply has been in daily work for 2 years until obsoleted, I started with one IGBT, but had to use 2 to get it reliable. With one only, it lasted only a few months.
A good heat sink is necessary as it runs right now, size depending on how hard you want to push the IGBT's
My present program has intermittent operation 20% on time, That allowed me to raise power a bit more.
I can recommend Kicad for PCB layout, it works on both M$ and Linux.
Main Page - KiCad
AVR Freaks
Code::Blocks for SW development environment.
AVRStudio or avarice
The GCC compiler. WINAVR
The AVR Dragon programmer/ debugger.
Eric
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