Tesla coil - DR/SSTC / Projects / Forums

Forums

4hv.org :: Forums :: Projects

« Previous topic | Next topic »

Tesla coil - DR/SSTC

1 2 next

Move Thread

LAN_403

dmg

Wed Apr 14 2010, 03:39AM

Registered Member #2628 Joined: Fri Jan 15 2010, 12:23AM
Location:
Posts: 627

Ive been collecting parts and working on this project for a while, the goal here is to make a tesla coil that can be on a permanent platform, one that I will not be taking apart, or stealing parts from like my old coils, and aside from bieng my first "permanent" coil, It will be my biggest coil so far.
so hopefully Ill finish this before the end of summer.

Update1 june 6th 2010 - This is no longer an SGTC, but now a solid state coil (and if things go well, my first real DRSSTC)

Update2 July 13th, 2010 - Ive put this project on hold until further notice, I want to test out my controller and bridge on a smaller coil first, before I will look at this coil again, so I am constructing a smaller coil in the meantime, and Ill return to this project upon completion.

Update3 July 18th, 2010 - Nevermind everyone, I had a temporary lapse of judjment, this project is back on.

dmg

Sun Apr 18 2010, 12:42AM

Registered Member #2628 Joined: Fri Jan 15 2010, 12:23AM
Location:
Posts: 627

I managed to finish winding the secondary today, I am not realy a big fan of motor powered winders, I never liked them, so I wound this coil by hand. the secondary needs to be coated with polyurathane/epoxy and then I can put it into service.
also, the wire may seem gapped, but it is discoloration of the wire itself, hopefully it will be far less noticable once I apply all the coats to the secondary, and Ill need to cut off that little excess at the top

The secondary's resonant frequency is 130KHz without a topload, and with it drops to about 80KHz
Wire diameter: 0.51MM, 24AWG, wound with aspect ratio of 4.5:1
total lenth of wire used is 3512 feet.

the windings are 8'' by 36'', an extra inch makes up the secondary former due to the electrical tape.

anyone recomend a good spray sealant? Im kinda stuck between using spray enamel or spary polyurathane, this is just to hold the wire together, before I actually coat it with the liquid poly/epoxy.
so any suggestions are welcome
also, anyone know what is better to use? roller brushes or foam brushes?

Coronafix

Mon Apr 19 2010, 01:54AM

Registered Member #160 Joined: Mon Feb 13 2006, 02:07AM
Location: Melbourne, Australia
Posts: 938

Best thing to do is set it up on a motorized rotating form and paint it with polyurathane. The more coats the better it will be. Looking good so far.

dmg

Sat May 08 2010, 05:12AM

Registered Member #2628 Joined: Fri Jan 15 2010, 12:23AM
Location:
Posts: 627

Hello everyone,

okay.. progress is going on... slowly, but surely.

I started work on the controller, this will not only function as a TC controller, but will make a multipurpose supply that I can use for other stuff.. it will be a good ways from the tesla coil itself.
Ill have more explanation and progress posted later on.

also I made a quick video of the controller.. well.. running a basic program to simply test it out (sequence flasher yay!)
also note that the controller will not be used JUST for that purpose

EDIT: Sight update, ive desided to ditch the logic controller, and redesign my controller, most of the parts are still included, but the exeption of that logic board with the relay board.
(poor SMDs wont last long anyway)

dmg

Sat May 29 2010, 05:30AM

Registered Member #2628 Joined: Fri Jan 15 2010, 12:23AM
Location:
Posts: 627

Ive desided to ditch my original wood box that will house the controller, partly because it looked terrible, had lack of room, and was way too bulky,
this is a mock setup to see how I will place the components inside the box which is 9" X 4.5" X 11.5".
aside from the metal frame, there will be a raised portion on top to house the variac.
in short, there will be no more SMD parts, since I am worried about them dying, and Ive had better luck with even DIP packages, which seem to be fine.

I will later on add acrylic here and there, not only because it looks freaking awsome, but also due to the fact that It.... nah, its only because acrylic is awsome.

the new controller will be housed inside this metal frame, which I am still wondering whether to paint it black, or leave it gray.
I also got a chance to finish up the end caps of my secondary, which now, I will keep adding more coats, both inside and outside, and finish it with a clear epoxy coat.

...

Sat May 29 2010, 07:11AM

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

Thats looking very nice!

What is that polished piece of steel you have? New knob for the variac?

dmg

Sat May 29 2010, 01:07PM

Registered Member #2628 Joined: Fri Jan 15 2010, 12:23AM
Location:
Posts: 627

yes, that is a knob for the variac, the variac that ive gotten had a shaft, that any of the knobs that I had on hand would not fit, so I made one, having a few disks on hand (no 3 inch rod for lathe) ive desided to weld about 5 of them together and grind them down to make a knob.

dmg

Thu Jun 10 2010, 01:12AM

Registered Member #2628 Joined: Fri Jan 15 2010, 12:23AM
Location:
Posts: 627

the frame was started to be built a few days ago, and this is what I have up to now, there is still more work to be done on the frame, such as welding ends to the legs and rebar supports, and grinding down any rough welds, then after some more work, it should be ready for its very first coat of paint.

Ive also got around to doing a background light for the secondary coil (dont worry, its not inside it)
(sorry for blurrly pic, camera had a hard time in the dark, probably wrong mode?)

dmg

Thu Jun 17 2010, 12:07AM

Registered Member #2628 Joined: Fri Jan 15 2010, 12:23AM
Location:
Posts: 627

The coil has been starting to be pieced together, the secondary was cut a bit shorter, and the frame is almost complete, now Ive welded "X" shaped supports from rebar across the top section, that will have plates to screw into the primary base,

the primary base will have to get a paintjob, and I will get around to winding the primary this week or the next, with 6 turns of 3/8" copper tubing.

for now I am screwing around to see where I will bolt the bridge to and house the drive electronics, I will most likely put the bridge upside-down underneath the primary coil, and have all the drive electronics sitting in an enclosure on that middle square support on the bottom. and Ill need to get around to cutting copper buss for the bridge.
(Ill probably go wide busses, 1/16 thick, for the bridge itself and do 1/8 for the input and output leads)

Matt Edwards

Sat Jun 26 2010, 08:17PM

Registered Member #2838 Joined: Fri Apr 30 2010, 07:55PM
Location: tehachapi, CA
Posts: 333

Vary nice! If you have not coated it yet I used Minwax spray polyurethand (oil based). It seemed to work well.

1 2 next

Moderator(s): Chris Russell, Noelle, Alex, Tesladownunder, Dave Marshall, Dave Billington, Bjørn, Steve Conner, Wolfram, Kizmo, Mads Barnkob