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Diable Tonnere â€“ my latest project.

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Daniel Uhrenholt

Sat May 29 2010, 09:23AM

Registered Member #125 Joined: Fri Feb 10 2006, 01:52PM
Location: Aalborg, Denmark
Posts: 155

Hi all,

It's been a while since my last update, my girlfriend just moved in, so now I'm trying to have a life besides just doing fun projects:-)

First of all there is a battle of who will have first light between Finn and I, but I think it is Finn that gets the credit for that, because I have to move all of my stuff to another city before I can make sparks all day long:-) I live in a small apartment in Aalborg, and the coil takes half of the space in the bedroom...

Here are some pictures of the water cooling for the new H bridge, and the new bus for the capacitors. I wanted water cooling because of bad design from the beginning, as there wasn't enough space for the bridge I had in hand, and it is cool when I can make this kind of things myself:-)

I also had to make myself a new toroid for the coil, so I made a drawing of the rings I needed and went to the local metal college, and had some students make the rings for me. Then I welded the parts together at the University, and had to transport the toroid by bus to get it home:-)

And some pictures of the coil as it looks now:

Another larger project is the motor controllers that I am making for Finn and I. They are build on two Arduino platforms, communicating with ASCII over fiberoptics. The controller box will also have MIDI in it, but I am having some minor problems with the code for that, but I will have it done sometime next week when I get to the University again:-)

Now I will go to Hobro to visit Finn and make some stuff on Thumper:-)

Cheers, Daniel

Steve Conner

Sat May 29 2010, 10:16AM

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

This looks awesome

Just one word of warning: In your bus design, you have the current flowing through the bolts. If they're steel, they'll get extremely hot by induction heating.

Ideally the current path should be all copper and brass, but non-magnetic stainless steel will probably be OK.

Dalus

Sun May 30 2010, 09:09AM

Registered Member #639 Joined: Wed Apr 11 2007, 09:09PM
Location: The Netherlands, Herkenbosch
Posts: 512

Wow your picking up speed. Love the idea of directly cooling the IGBT's with water. Is it going to be a closed loop system? And how are you going to tackle corrosion due to the different metals?

Dr. H.

Sun May 30 2010, 02:59PM

Registered Member #931 Joined: Mon Jul 30 2007, 05:25PM
Location: Bulgaria
Posts: 486

Great job Daniel

and that is one CLEAN workshop you have there.

Cheers.

Daniel Uhrenholt

Sun May 30 2010, 09:06PM

Registered Member #125 Joined: Fri Feb 10 2006, 01:52PM
Location: Aalborg, Denmark
Posts: 155

Steve,

Thanks for the comment.

I don't use the bolts at connections between the bus bars, I have some distance pieces made out of brass hidden under the black plastic:-)

Linas,

I also like the idea of direct cooling of the IGBT`s, the idea came to me while I was working on a set-up for a company who makes the power electronics for windmills. I had a look inside the water cooling system on a 4MW windmill:-) They use direct cooling on their power stacks, and I was so lucky to see how it looked under the HUGE IGBT`s

I don't think that corrosion will be that big a deal, most of the parts is made out of brass, I think that I just have to change the water once a year...

I am still loking for radiators and pumps for it, so for first light it probably just the water hose from my parents garden:-)

Huben,

Thanks:-) It has to look clean when you have costumers running around all day there:-)

Cheers, Daniel

Dalus

Mon May 31 2010, 08:52AM

Registered Member #639 Joined: Wed Apr 11 2007, 09:09PM
Location: The Netherlands, Herkenbosch
Posts: 512

Pst I'm not Linas, if your worried about the corrosion you can use those watercooling liquids that are used in PC cooling systems. Those are designed to minimize any redox reactions between the different metals.

Daniel Uhrenholt

Mon May 31 2010, 09:06AM

Registered Member #125 Joined: Fri Feb 10 2006, 01:52PM
Location: Aalborg, Denmark
Posts: 155

Woops, Dalus i`m sorry about that:-)

I`m looking at some cooling systems for computers, that I would like to use for the coil. But the problem for now is the lack of $$ to use on coiling at the moment. This project has taken a lot of my time and money for some while, and I want some kind of vacation this summer with my girlfriend...

Dalus

Mon May 31 2010, 09:55AM

Registered Member #639 Joined: Wed Apr 11 2007, 09:09PM
Location: The Netherlands, Herkenbosch
Posts: 512

Understandable. I have exactly the same problem I do want to continue my coil but everything is going so slowly. A 20 year old student doesn't earn that much. I'll be glad if I can pay for the MMC this year :S

Finn Hammer

Mon May 31 2010, 09:28PM

Registered Member #205 Joined: Sat Feb 18 2006, 11:59AM
Location: SkÃ¸rping, Denmark
Posts: 741

Daniel Uhrenholt wrote ...

I had a look inside the water cooling system on a 4MW windmill:-) They use direct cooling on their power stacks, and I was so lucky to see how it looked under the HUGE IGBT`s

There is an article about the Danfoss way of cooling those very IGBT's in the current issue of Power Systems Design:

Cheers, Finn Hammer

Daniel Uhrenholt

Tue Jun 01 2010, 05:45AM

Registered Member #125 Joined: Fri Feb 10 2006, 01:52PM
Location: Aalborg, Denmark
Posts: 155

That fine piece of machined aluminum that we used for the system, is similar to the one seen in the second picture:-)

The university is making a intelligent system for fault detection in the cooling nozzles, this is all about big $$, as there is a lot of money to be saved if they can detect if the nozzles get stopped due to dirt in the system. Burnt IGBT`s in a sea windmill is NOT a cheap thing to replace:-)

Cheers, Daniel

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