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Registered Member #1232
Joined: Wed Jan 16 2008, 10:53PM
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Posts: 881
Whatever method you choose, it's always going to include a large dollop of trial and error, because the losses in the corona are hard to predict.
You first take a guess (or educated guess based on previous experience) at some of the Class E component values, coupling coefficient, primary turns etc. Then you tentatively power up the circuit at low voltage and try to get a look at the drain waveform. You then make some changes to the component values, and maybe the tuning or coupling to get closer to the ideal Class-E waveform and power up again. These changes might be very effective and get you close to the ideal waveform. Hooray! Only the problem is that it's still only at low supply voltage and low power. Small sparks suck Soooo...
You turn up the supply voltage, and this is where things start to get funky. The corona volume gets larger as more RF power is fed in, but this means the corona losses increase and the resistive base impedance of the resonator changes. As the discharge gets bigger this also tends to add capacitance to the top of the coil lowering the resonant frequency. Both of these effects disturb the drain voltage waveform away from the ideal waveform with a soft-landing at turn-on for efficient Class-E amplifier operation. The MOSFET's own intrinsic drain-source capacitance also falls as the drain-source voltage increases, further muddying the waters.
So, in general the design process and particularly the "gradual increasing of power" part is very much an iterative process with frequent tweaks to the tuning, coupling and drain-source shunt capacitor being required. The ultimate goal being Class-E operation with 99% efficiency (hence cool MOSFETs) whilst simultaneously exhibiting a roaring high-power plasma discharge at the top of the resonator. To achieve this you have to sacrifice the nice looking idealised Class-E drain waveform at low-power, and remember that efficiency at low-power isn't as important as at full power because voltages and currents are lower. You'll also run it at full power anyway because that's what looks most impressive!
RF engineers designing high-power Class-E broadcast transmitters have got it easy with their nicely specified purely resistive 50 ohm loads. And for these cases the conventional Class-E design equations, or Excel spreadsheets work very well. Although the variation of MOSFET device capacitances with voltage can cause some minor headaches as the power is modulated.
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