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X-Drive, and a new singing Teslacoil

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LAN_403

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Thu Sept 25 2008, 09:08AM

Registered Member #76 Joined: Thu Feb 09 2006, 10:04AM
Location: Hemer, Germany
Posts: 458

Since my work became very popular here in germany within the last few months, i got some orders for building such musical drsstcs for theatres and so on. i want to share my work with others here and want to show you my latest drsstc work to inspire and to make people think about their own circuits and how to make it better.

The so called "X-Drive" driver is based on my older designs which are very reliable. one drsstc with this driver i build for a big company here in germany is lasting some 200hours of service with no problems. cause im not out for long discharges but reliability i tried to improve the overcurrent protection circuits etc.

cause i wanted to share my work with drsstc beginners too, i started thinking about the layout of such a driver and how to make it "bulletproof" and easy to build and adjust.

basically you have a "main board" with all components on it like on every other drsstc driver. and then you have 3 component plugs to install the components you want. the driver itself works without this components installed except the feedback board. so anyone can decide if he needs a overcurrent protection at all etc..

the driver is really straight forward

and here are the components
Overcurrent protection and bargraph for a maximum current you can adjust. with the jumpers on the board you can adjust the max current you want from 50 to 500A in my case-

Primary feedback component
Feedback and overcurrent CT and rectifier for the ocd ct on one board. just plug it in you primary circuit and youve done.

and because every new drsstc, especially one build for a client, needs a control unit, i started to build one.

This control unit has everything you want. special thanks here to steve conner and his solid state variac. sorry steve, but i changed your circuit to something i can call reliable. did last forever to adjust and find some bugs...

with this unit you can control the voltage of the little beast and everything else. my new so called "digidmod4.2" modulator is build in which makes the drsstc an allrounder. you can control the drsstc with single instruments like a keyboard or an e-guitar. a new feature can make you control the drsstc by voice. the amplitude of the incoming audio signal controls the on time. as the amplitude increases, the on time increases too. every signal higher than 1khz is divided by 2 to stay below the 1khz at any time. a pwm regulation controls the incoming frequency and the adjusted on time in realtime. if the frequency is getting higher, the on time decreases to prevent the fuse or the bridge from blowing up by to much current. the inbuild "normal" modulator can help by adjusting the coil and is activated by a switch.
basically these modulator is conceived to control the drsstc with an ipod, but of course you can use every other analog audio source like a laptop or a cell phone or whatever you want.
basically you drive the modulator with sinusodial signals, but you can even use square or triangle or sawtooth or mixed signals. the build in adjustable lowpass filter can help you by sorting out some "parts" of an audiosource you dont want to be modulated at all.

the control unit is connected via 2 cables to the drsstc. the optical toslink connection is to guarantee the highest possible safety for the user. the second cable is the power chord where you can control the driver and the voltage on the bridge etc.

More to come soon.

Steve Conner

Thu Sept 25 2008, 10:14AM

Registered Member #30 Joined: Fri Feb 03 2006, 10:52AM
Location: Glasgow, Scotland
Posts: 6706

Cool

Which solid-state variac circuit was it, and OMGplz can we see the improved version?

The bugs I'm aware of are: Both circuits lacked a soft-start, and the second one would sometimes get confused and pop the breaker at start-up, even if you did remember to turn the knob down to zero. I think it was due to phase shift caused by inrush in the control transformer (that provides the phase reference as well as powering the circuit) and I fixed it by connecting a capacitor in series with the primary.

The only reason I made the second one was that it can be remote controlled by a DC voltage. The first one is controlled by a variable resistance.

MRacerxdl

Thu Sept 25 2008, 01:03PM

Registered Member #989 Joined: Sat Sept 08 2007, 02:15AM
Location: SÃ£o Paulo, Brazil
Posts: 476

That is a great work reaching!
My DRSSTC was based in your smallest coil schematic, but since I was increasing the power, I was need to change it a bit.
But very good work!
Keep working good!

aonomus

Thu Sept 25 2008, 02:00PM

Registered Member #1497 Joined: Thu May 22 2008, 05:24AM
Location: Toronto, Ontario, Canada
Posts: 801

Very nice and clean build there, no wonder people are ordering musical DRSSTCs -.-

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Thu Sept 25 2008, 07:49PM

Registered Member #76 Joined: Thu Feb 09 2006, 10:04AM
Location: Hemer, Germany
Posts: 458

@ Steve
i didnt change much.. i used your second design which is voltage controlled. i left out the voltage gain pot of 100k which is shown in your shematic. i just used a 10k pot with 10k current limit resistor to regulate from 0 to 15 volt. that is my "Volt_F" as known in your shematic. to prevent the fuse from blowing up even if the pot is half or full power, i added a simple rc time constant. i changed the value of the rfi filter cap from 10n to 100Âµ, so even if the pot is set up full, the cap needs some seconds to get the full voltage. youll get a soft increase of voltage and so on a soft increase of voltage on the output too.,

i changed the value of the unknown primary L to 250ÂµH and lowered the capacitance of the 100nF cap to 33n.

thats it.

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Thu Oct 02 2008, 07:27PM

Registered Member #76 Joined: Thu Feb 09 2006, 10:04AM
Location: Hemer, Germany
Posts: 458

Finally some more pics. i want to get the whole coil finished within a few days. theres not much to do left. primary coil, secondary and finally the toroid and some wiring left.
i think the coil is ready in some days.

heres a small picture galery i made.

...

Thu Oct 02 2008, 08:44PM

Registered Member #56 Joined: Thu Feb 09 2006, 05:02AM
Location: Southern Califorina, USA
Posts: 2445

Pretty slick!

Can't wait to see it in action...

one thing I might comment on, when you put galleries together its works 100x better to put actual thumbnail sized pictures in for the thumbnails instead of the full several MB picture that and a resize tag.

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Sat Oct 04 2008, 09:33AM

Registered Member #76 Joined: Thu Feb 09 2006, 10:04AM
Location: Hemer, Germany
Posts: 458

Finished the primary coil today and the whole coil is coming out nicely. i cant wait to get the secondary finished and to prepare for the first tests. hopefully tommorow

Alexandre

Sat Oct 04 2008, 03:16PM

Registered Member #1228 Joined: Tue Jan 15 2008, 01:08AM
Location: Curitiba, Brazil
Posts: 162

This DRSSTC is really very impressive, especially the Primary, was very good and very well done ...

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Tue Oct 07 2008, 07:02PM

Registered Member #76 Joined: Thu Feb 09 2006, 10:04AM
Location: Hemer, Germany
Posts: 458

Finished the Coil today and did first tests.

Cause this coil have to be reliable rather than anything else, the output might be a little pitty for someone, but for a coupling lower than .12 , primary current of around 300 to 350A and 230v dc with less than 3,5Amps the output is enough to impress someone.

For sure this test was done with my new control box including steves solid state variac and my new digidmodV4.2 universal modulator. for the first light i thought it would be better to test with the inbuild standard interrupter, but for sure i will post some new vids with music...

Ps

Added the vid to youtube.

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