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Registered Member #76
Joined: Thu Feb 09 2006, 10:04AM
Location: Hemer, Germany
Posts: 458
Okay, i call this monster the modular drsstc1 cause i want to build it very professional in different "sections". its the biggest drsstc i i´ll build,, nothing bigger. a few weeks ago i came across a bunch of 9 fuji igbt bricks with a current rating of 400/800A at 600volts. they are not the fastest but from some experiments i think i can use them for a huge fullbridge capable of 1600A pulse for a fres of around 50khz.
i nearly finished the bridge and 2 of the brick driver pcbs which fit exactly on a brick. for the heart of this beast i´ll use the drsstc controller from my drsstc6(primary current feedback,overcurrent protection etc). i want this drsstc to be reliable and therefore i´ll add some features such as: malfunction display of all supply voltages (for example, if everything is okay a green led will light for each supply voltage, if the voltage is lower or so a red led will light), overcurrent display in 16 steps from 100-1600A, overtemparature warning ,fan control etc.maybe a solid state variac
the other specs are not calculated at the moment but i want to use a big secondary , maybe 20x100cm wound with 0,3mm to give me a fres of around 45khz with a huge toroid (70cm diameter) for the tank cap i have no idea at the moment, maybe something around 500nf or more (yeah its expensive)
heres a pic of the almost finished bridge more to come soon
Registered Member #99
Joined: Thu Feb 09 2006, 06:10PM
Location: florida, usa
Posts: 637
Looking good... And Chris, when you blow an IGBT, you really blow them !Is that a crack I see in that IGBT?! I wonder if anyone has ever thought of putting the bridge into transformer oil?Like some transformers are done?Just get a bucket, and submerse the whole thing in the oil. Should supress much corona, no?
Registered Member #76
Joined: Thu Feb 09 2006, 10:04AM
Location: Hemer, Germany
Posts: 458
okay, some new infos.
yesterday i finished the 4 high side driver pcsb and they all work fine now after a bit fiddling. i build and tested a small switch mode powersupply for these driver pcbs but im not the biggest fan of smps so i decided to build a normal transformer to power the pcbs. yesterday i build these transformer with 75 watts and 4x10,6volts AC 0,5A and 4x28volt AC 0,5A which should be plenty of power to drive all pcbs. now i need to build a rectifier pcb with electrolytic caps and so to get the desired dc voltages. if im finished i can test my big bridge for the first time,
Registered Member #135
Joined: Sat Feb 11 2006, 12:06AM
Location: Anywhere is fine
Posts: 1735
I really like your layout with one exception. I'm not so trusting of PCB at the kind of power I'm thinking you intend to use.
Here's the situation:
You have two pieces of PCB overlapping in the bottom right corner IGBT. I'm not convinced that's really a great idea. You might have a surge and vaporize the copper, leaving part of the bridge disconnected. What I would suggest is getting some copper repair foil and soldering a strap from the overlapping PCB to the underlapping PCB. That way you know it has a physical connection.
Registered Member #76
Joined: Thu Feb 09 2006, 10:04AM
Location: Hemer, Germany
Posts: 458
i only use the double sided pcb as a base for the "real connections" the upper connections are made with 2mm thick brass sheets, the double sided pcb is connected too, this should be plenty for this powerlevel. for the decoupling caps i think 1 double sided pcb is enough
mhh, okay wait, now i understand what you mean, the second double sided pcb is connected over the brass sheet which has connection to the first double sided pcb, all screwed together,. i think its enough
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Modular DRSSTC 1
!Is that a crack I see in that IGBT?!
