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Re: an interesting mechanical engineering problem

Original poster: "Harold Weiss" <hweiss@xxxxxxxxxx>

Hi Dr. R,

What about using 12" ribbon instead of tubing? That way the connector plate could be a 12" x 12" x .125" flat plate and you could also build a tapping lug on the bottom. I'll send a pic offlist.

David E Weiss

Original poster: "D.C. Cox" <resonance@xxxxxxxxxxxx>

I'm presently in the process of designing the "world's largest portable Tesla transformer". It will be a 60 ft tall unit x 7 ft. dia sec coil, running as a DRSSTC, 160 kW continuous input, crowned with a 8 ft dia. toroid and above that, a 20 ft dia toroid. Our present design target, using 24 pcs of PowerEx 2400 Amp, 1700 Volt IGBTs, all carefully linked together in a low inductance configuration, with 3 inch wide x 1/4 inch thick copper plate (H-bridge with 6 of these massive IGBTs on each corner). Planned buss voltage is 800 VDC. Solid state control of the 440 Volt, 3 phase, 400 Amp inputs with very large SCRs --- similar to the smaller control system we are developing for our dual MOT coil with 7 - 7.5 ft long sparks running off a 120 VAC circuit.

Pri cap, with res. freq of 10 kHz, works out to 6 uF, 10 kV Maxwell pulse cap, with a 3.1 turn pri (thanks again to Bart's great JAVATC program).

The base will be 26 ft in dia. and can be disassembled for transport. The sec coil is going to have the winding, 31,000 ft of # 6 AWG wire, glassed inside after winding. This unit is 7 ft in dia and 44 ft long, but still transportable on a lowboy truck.

The primary is 3.1 turns, tapped, with a total of 3.5 turns. Our original design was to use 4 inch copper tubing to form the pri, but this is where the problem is coming into play. If we build a 26 ft dia coil, 3 turns, of 4 inch dia copper tubing, how do we disassemble the beast for transport.?

So far, a few ideas we are tossing around:

1) Use 1/4 turn sections of the copper tubing and link each 1/4 turn section together with massive copper blocks, 5 x 5 inches square x 6 inches long. Butt the primary 1/4 turn sections together and use a lot of brass setscrews to firmly capture the 1/4 turn sections in the brass blocks. I'm worried the resistance might become an issue with nearly 12 "copper connectors" joining the pieces together. I would like to use he large 4 inch copper tubing but it seems joining them together might be a problem, and trying to haul it assembled just will not work as the height would be too much for interstate bridges and city streets with cross-wires, etc.

2) It's not possible to use 2-3 inch dia. copper cable as the weight would be too high for assembly handling.

3) Perhaps use 1 inch dia copper cable and then wind 4 of these 1 inch dia. lengths in parallel to form the 3.5 turn primary. Handling 1 inch dia. copper cable should not be too much of a problem for a crew working with a small crane (which we will have onsite to erect the sec coil and attach the large toroids). With this idea, I probably would join the 4 cables together every 1/4 turn with some solid machined copper clamps to insure even current distribution in the primary.

I know there are some great thinkers on this list and a few good machinists, so ideas please!! We are open to consider every idea and try to adopt the one we think will work best.

Best regards,

Dr. Resonance
Resonance Research Corp.