Measurements v0.1
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33
Hardware_development/Measurements/v01/Audio_1.txt
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33
Hardware_development/Measurements/v01/Audio_1.txt
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freq - frequency in Hz
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7.40 - excitation from two batteries in series (7.40V)
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15.00 - excitation from from batteris in series (hypotetical, power supply is used)
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Audio amplifier TDK2040 is tested.
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Single cascade is used with 30 capacitors and 60 (30x two-in-series) diodes 1N4007.
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Power supplied by RIGOL DP832 at frequency for max output DC voltage is measured, too.
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Sinusoidal excitation so that audio goes into saturation.
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ETD49 core with 4 isolated layers as secondary, no gaps and 3-turn primary
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freq 7.40 15.00
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------------------
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1k 1.94 3.37
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2k 3.67 7.17
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3k 4.73 9.51
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4k 5.55 10.93
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5k 6.07 11.85
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6k 6.38 12.55
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7k 6.55 13.03
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8k 6.63 13.44
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9k 6.64 13.73
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10k 6.62 14.00
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15k 6.31 14.51
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20k 5.92 14.53
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25k 5.58 14.38
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30k 5.24 13.93
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35k 4.85 13.11
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Max power @9kHz / 7.4V = 0.64W
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Max power @10kHz /15.0V = 2.01W
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56
Hardware_development/Measurements/v01/Audio_2.txt
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56
Hardware_development/Measurements/v01/Audio_2.txt
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freq - frequency in Hz
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Vcc - power supply voltage, professional power supply is used.
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Audio amplifier TDK2040 is tested.
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Double cascade is used with 8 diodes BY6 and 8 capacitors, per side (16 diodes and 16 capacitors are used in the total).
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ETD49 core with 12 isolated layers as secondary, 300um gap and 4-turn primary.
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Vcc = 12V
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f[kHz] | V[kV]
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--------|--------
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1 | 3.8
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2 | 4.5
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3 | 4.5
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4 | 5.1
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5 | 4.4
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6 | 4.4
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7 | 5.0
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8 | 6.0
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9 | 7.9
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10 | 10.6
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11 | 13.8
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12 | 17.1
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13 | 20.2
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14 | 22.0
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15 | 20.2
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16 | 17.7
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17 | 13.3
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18 | 11.0
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19 | 9.7
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20 | 8.9
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Vcc = 15V
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f[kHz] | V[kV]
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--------|--------
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1 | 4.4
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2 | 4.6
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3 | 4.7
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4 | 5.0
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5 | 4.4
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6 | 4.4
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7 | 5.0
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8 | 6.1
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9 | 7.6
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10 | 10.6
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11 | 13.7
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12 | 16.8
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13 | 19.1
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14 | 23.0
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15 | 22.1
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16 | 18.4
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17 | 14.5
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18 | 11.3
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19 | 10.3
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20 | 9.2
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Having in mind the O-ESD project aims the following design decisions are made.
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(1) Two rechargeable batteries in form factor 18650 will be used, followed by two separate DC/DC converters as the power supply.
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(2) LCD with 4x20 characters with additional tasters and one rotary encoder will be used as the user interface.
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(3) Arduino Nano will be used as microcontroller (it could be replaced with Arduino Every or other microcontrollers with the same board size and number/raster of pins).
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(4) Flyback topology will be used in high-voltage generator. Trafos that are custom made using ETD29 or ETD49 cores will be used. Trafo secondary will be connected to the input of a single cascade, while the polarity of the output voltage will be controllable.
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(5) Shaper #1 topology is first in line to be used.
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(6) Reed relay with 5 V turn-on voltage will be used as high-voltage switch with additional transistor for providing current for relay control side.
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(7) Acrylic plastic will be used as mechanical support, while all PCBs will be made of FR4 with standard thickness of 1.57 mm.
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83
Hardware_development/Measurements/v01/Flyback_1.txt
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83
Hardware_development/Measurements/v01/Flyback_1.txt
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freq - frequency in Hz
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3.70 - excitation from one battery (3.7V)
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7.40 - excitation from two batteries in series (7.40V)
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In no case the current from excitation is allowed to go above 2A. In no experiment the current is observed to be above 1.5A.
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The results in tables are output voltages measured at 1000:1 HV probe, hence the output voltage is given in kV.
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Flyback configuration with TIP122 NPN transistor with 330 Ohms resitor in base is used.
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Single cascade is used with 30 capacitors and 60 (30x two-in-series) diodes 1N4007.
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ETD49 core with 4 isolated layers as secondary, no gaps and 3-turn primary
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freq 3.70 7.40
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------------------
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1k 4.52 8.42
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2k 6.67 12.47
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3k 7.76 14.78
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4k 8.80 16.75
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5k 9.35 17.23
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6k 9.60 18.31
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7k 9.85 18.82
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8k 9.71 18.87
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9k 9.53 18.75
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10k 9.49 18.75
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15k 9.01 18.40
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20k 8.68 18.11
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25k 8.13 17.38
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30k 7.50 16.44
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35k 6.77 15.35
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ETD49 core with one layer as secondary, no gaps and 3 turn primary
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freq 3.70 7.40
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------------------
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1k 1.08 4.11
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2k 1.57 5.79
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3k 1.86 7.35
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4k 2.15 8.25
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5k 2.25 8.87
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6k 2.37 9.38
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7k 2.50 9.55
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8k 2.07 9.49
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9k 4.43 12.20
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10k 4.41 12.36
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15k 8.13 12.31
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20k 7.70 14.44
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25k 7.19 13.45
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30k 6.67 12.51
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35k 6.46 12.45
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Trafo #2 (Git repository > Hardware development > 4-HV > Trafos)
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freq 3.70 7.40
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------------------
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1k 0.61 1.61
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2k 0.87 2.22
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3k 0.93 2.35
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4k 1.12 2.43
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5k 1.07 3.47
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6k 1.88 3.48
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7k 1.37 3.28
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8k 1.22 3.16
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9k 1.27 3.63
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10k 1.18 4.41
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15k 2.10 4.27
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20k 5.13 6.52
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25k 3.49 9.03
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30k 2.21 6.10
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35k 1.47 3.97
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Trafo #2 with just one primary used (Git repository > Hardware development > 4-HV > Trafos)
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freq 3.70 7.40
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------------------
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1k 4.55 11.21
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2k 6.84 15.02
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3k 7.93 17.17
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4k 9.02 18.50
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5k 9.63 19.21
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6k 10.01 19.75
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7k 10.14 20.03
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8k 9.94 20.05
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9k 11.10 21.15
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10k 9.86 22.19
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15k 8.97 20.67
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20k 8.81 20.98
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25k 7.44 18.47
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30k 7.60 16.05
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35k 8.90 17.44
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179
Hardware_development/Measurements/v01/Flyback_2.txt
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179
Hardware_development/Measurements/v01/Flyback_2.txt
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freq - frequency in Hz
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3.70 - excitation from one battery (3.7V)
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7.40 - excitation from two batteries in series (7.40V)
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In no case the current from excitation is allowed to go above 2A. In no experiment the current is observed to be above 1.5A.
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The results in tables are output voltages measured at 1000:1 HV probe, hence the output voltage is given in kV.
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Flyback configuration with TIP122 NPN transistor with 330 Ohms resitor in base is used.
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Single cascade is used with 30 capacitors and 60 (30x two-in-series) diodes 1N4007.
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Power supplied by RIGOL DP832 at frequency for max output DC voltage is measured, too.
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ETD49 core with 4 isolated layers as secondary, no gaps and 3-turn primary
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freq 3.70 7.40
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------------------
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1k 4.52 8.42
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2k 6.67 12.47
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3k 7.76 14.78
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4k 8.80 16.75
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5k 9.35 17.23
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6k 9.60 18.31
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7k 9.85 18.82
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8k 9.71 18.87
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9k 9.53 18.75
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10k 9.49 18.75
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15k 9.01 18.40
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20k 8.68 18.11
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25k 8.13 17.38
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30k 7.50 16.44
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35k 6.77 15.35
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Max power @7kHz / 3.7V = 1.01W
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Max power @7kHz / 7.4V = 4.08W
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ETD49 core with 4 isolated layers as secondary, no gaps and 1-turn primary
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freq 3.70 7.40
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------------------
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1k 1.32 3.83
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2k 1.90 4.90
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3k 1.87 5.31
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4k 2.91 7.67
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5k 2.46 6.33
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6k 2.17 6.45
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7k 1.87 6.36
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8k 2.18 7.38
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9k 2.99 9.84
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10k 4.36 13.49
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12k 9.04 18.61
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15k 6.71 14.17
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20k 2.69 7.21
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25k 1.39 3.97
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30k 0.85 2.36
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35k 0.55 1.34
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Max power @13kHz / 3.7V = 1.84W
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Max power @12kHz / 7.4V = 8.07W
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ETD49 with 4 isolated layers as secondary, 100um gaps and 3-turn primary
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freq 3.70 7.40
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------------------
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1k 3.10 7.08
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2k 4.19 9.53
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3k 4.88 11.13
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4k 5.38 12.29
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5k 5.68 13.05
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6k 6.09 13.92
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7k 6.90 15.44
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8k 6.91 15.39
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9k 6.62 14.84
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10k 6.84 15.33
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15k 7.88 17.61
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20k 9.07 19.35
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24k 8.88 18.59
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25k 8.83 18.19
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30k 7.67 15.57
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35k 6.08 11.83
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Max power @20kHz / 3.7V = 0.88W
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Max power @20kHz / 7.4V = 4.11W
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ETD49 core with 4 isolated layers as secondary, 100um gaps and 1-turn primary
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freq 3.70 7.40
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------------------
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1k 0.71 2.22
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2k 1.11 2.78
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3k 1.10 3.01
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4k 1.06 3.22
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5k 1.39 4.11
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6k 1.05 3.68
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7k 2.10 4.72
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8k 3.56 8.13
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9k 1.44 4.37
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10k 1.44 4.20
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15k 1.41 4.19
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20k 4.41 9.17
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24k 11.01 19.46
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25k 9.25 16.53
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30k 2.32 4.81
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35k 1.12 1.84
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Max power @20kHz / 3.7V = 1.80W
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Max power @20kHz / 7.4V = 8.17W
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ETD49 core with one layer secondary, no gaps and 1-turn primary)
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freq 3.70 7.40
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------------------
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1k 1.08 4.11
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2k 1.57 5.79
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3k 1.86 7.35
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4k 2.15 8.25
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5k 2.25 8.87
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6k 2.37 9.38
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7k 2.50 9.55
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8k 2.07 9.49
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9k 4.43 12.20
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10k 4.41 12.36
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15k 8.13 12.31
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20k 7.70 14.44
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25k 7.19 13.45
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30k 6.67 12.51
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35k 6.46 12.45
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Trafo #2 (Git repository > Hardware development > 4-HV > Trafos)
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freq 3.70 7.40
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------------------
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1k 0.61 1.61
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2k 0.87 2.22
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3k 0.93 2.35
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4k 1.12 2.43
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5k 1.07 3.47
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6k 1.88 3.48
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7k 1.37 3.28
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8k 1.22 3.16
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9k 1.27 3.63
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10k 1.18 4.41
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15k 2.10 4.27
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20k 5.13 6.52
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25k 3.49 9.03
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30k 2.21 6.10
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35k 1.47 3.97
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Trafo #3 (Git repository > Hardware development > 4-HV > Trafos)
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freq 3.70 7.40
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------------------
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1k 4.55 11.21
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2k 6.84 15.02
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3k 7.93 17.17
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4k 9.02 18.50
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5k 9.63 19.21
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6k 10.01 19.75
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7k 10.14 20.03
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8k 9.94 20.05
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9k 11.10 21.15
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10k 9.86 22.19
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15k 8.97 20.67
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20k 8.81 20.98
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25k 7.44 18.47
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30k 7.60 16.05
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35k 8.90 17.44
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Max power @11kHz / 3.7V = 1.10W
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Max power @12kHz / 7.4V = 4.41W
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Trafo #1 (Git repository > Hardware development > 4-HV > Trafos)
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!During the testing (above 7kV at the output of the cascade) the trafo experiences interalbreakdowns that can be heard!
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freq 3.70 7.40
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------------------
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1k 2.33 4.06
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2k 3.18 5.49
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3k 3.53 6.02
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4k 3.81 6.63
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5k 4.54 7.67
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6k 4.90 8.91
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7k 4.38 8.07
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8k 4.43 6.92
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9k 4.75 7.53
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10k 5.33 8.63
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15k 6.73 12.86
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20k 8.59 14.52
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25k 7.40 12.37
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30k 5.51 8.83
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35k 4.19 5.90
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BIN
Hardware_development/Measurements/v01/Flyback_3.pdf
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BIN
Hardware_development/Measurements/v01/Flyback_3.pdf
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Hardware_development/Measurements/v01/Flyback_4.pdf
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Hardware_development/Measurements/v01/Flyback_4.pdf
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Hardware_development/Measurements/v01/Flyback_4.png
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Hardware_development/Measurements/v01/Flyback_4.png
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After Width: | Height: | Size: 60 KiB |
74
Hardware_development/Measurements/v01/Push_pull_1.txt
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74
Hardware_development/Measurements/v01/Push_pull_1.txt
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@ -0,0 +1,74 @@
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freq - frequency in Hz
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3.70 - excitation from one battery (3.7V)
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7.40 - excitation from two batteries in series (7.40V)
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In no case the current from excitation is allowed to go above 2A. In no experiment the current is observed to be above 1.5A.
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The results in tables are output voltages measured at 1000:1 HV probe, hence the output voltage is given in kV.
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Push-pull configuration with two TIP122 NPN transistor with 330 Ohms resitor in base is used.
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Single cascade is used with 30 capacitors and 60 (30x two-in-series) diodes 1N4007.
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Power supplied by RIGOL DP832 at frequency for max output DC voltage is measured, too.
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ETD49 core with 4 isolated layers as secondary, no gaps and 2x3-turn primary
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freq 3.70 7.40
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------------------
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1k 5.28 9.09
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2k 7.33 13.00
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3k 8.72 16.59
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4k 9.96 18.43
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5k 10.79 19.75
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6k 11.22 20.74
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7k 11.46 21.47
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8k 11.57 21.99
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9k 11.60 22.42
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10k 11.42 22.48
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15k 10.93 22.02
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20k 10.52 21.77
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25k 10.21 21.56
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30k 9.86 21.07
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35k 9.40 18.52
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Max power @ 9kHz / 3.7V = 1.71W
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Max power @10kHz / 7.4V = 7.30W
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ETD49 with one isolated layer as secondary, no gaps, 2x2-turn primary
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freq 3.70 7.40
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------------------
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1k 3.16 4.91
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2k 4.25 6.78
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3k 5.11 8.41
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4k 5.70 9.73
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5k 6.14 10.91
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6k 6.47 12.03
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7k 6.80 13.05
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8k 7.07 13.99
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9k 7.28 14.91
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10k 7.45 15.44
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15k 7.96 16.33
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20k 8.08 16.61
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25k 8.05 16.45
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30k 7.93 16.25
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35k 7.81 16.05
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Max power @20kHz / 3.7V = 2.72W
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Max power @20kHz / 7.4V =11.44W
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Trafo #3 (Git repository > Hardware development > 4-HV > Trafos)
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freq 3.70 7.40
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------------------
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1k 6.16 12.87
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2k 8.34 15.55
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3k 9.60 17.33
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4k 10.32 18.42
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5k 10.98 19.48
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6k 11.22 19.85
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7k 11.20 20.37
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8k 10.66 21.07
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9k 11.94 21.82
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10k 11.19 22.12
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15k 9.65 22.17
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20k 9.35 21.68
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25k 7.64 21.23
|
||||
30k 7.56 17.17
|
||||
35k 8.86 18.22
|
||||
|
||||
Max power @ 9kHz / 3.7V =1.06W
|
||||
Max power @15kHz / 7.4V =4.10W
|
||||
58
Hardware_development/Measurements/v01/Push_pull_2.txt
Normal file
58
Hardware_development/Measurements/v01/Push_pull_2.txt
Normal file
|
|
@ -0,0 +1,58 @@
|
|||
freq - frequency in Hz
|
||||
3.70 - excitation from one battery (3.7V)
|
||||
7.40 - excitation from two batteries in series (7.40V)
|
||||
In no case the current from excitation is allowed to go above 2A. In no experiment the current is observed to be above 1.5A.
|
||||
The results in tables are output voltages measured at 1000:1 HV probe, hence the output voltage is given in kV.
|
||||
Push-pull configuration with two TIP122 NPN transistor with 330 Ohms resitor in base is used.
|
||||
Double cascade is used with 16 capacitors and 16 BY6 diodes (8 of each per side).
|
||||
Power supplied by RIGOL DP832 at frequency for max output DC voltage is measured, too.
|
||||
|
||||
ETD49 core with 4 isolated layers as secondary, no gaps, 2x3-turn primary
|
||||
freq 3.70 7.40
|
||||
------------------
|
||||
1k 2.51 3.89
|
||||
2k 3.62 6.09
|
||||
3k 4.23 7.95
|
||||
4k 4.65 9.18
|
||||
5k 4.91 9.77
|
||||
6k 5.08 10.16
|
||||
7k 5.19 10.35
|
||||
8k 5.24 10.47
|
||||
9k 5.28 10.56
|
||||
10k 5.29 10.61
|
||||
15k 5.09 10.46
|
||||
20k 4.70 10.02
|
||||
25k 4.38 9.58
|
||||
30k 4.16 9.20
|
||||
35k 4.09 9.13
|
||||
|
||||
Max power @10kHz / 3.7V = 2.00W
|
||||
Max power @10kHz / 7.4V = 7.39W
|
||||
|
||||
Trafo #3 (Git repository > Hardware development > 4-HV > Trafos)
|
||||
freq 3.70 7.40
|
||||
------------------
|
||||
1k 4.46 8.60
|
||||
2k 5.51 11.88
|
||||
3k 6.12 15.20
|
||||
4k 6.31 17.60
|
||||
5k 6.43 18.15
|
||||
6k 7.11 19.82
|
||||
7k 6.60 21.93
|
||||
8k 6.26 22.05
|
||||
9k 6.81 22.74
|
||||
10k 7.67 14.76
|
||||
15k 5.50 11.95
|
||||
20k 5.70 13.29
|
||||
25k 6.58 15.33
|
||||
30k 7.68 17.28
|
||||
35k 9.08 18.78
|
||||
40k 10.23 18.05
|
||||
45k 11.35 17.15
|
||||
50k 11.38 16.33
|
||||
55k 9.73 14.77
|
||||
60k 6.97 12.40
|
||||
|
||||
|
||||
Max power @45kHz / 3.7V =2.68W
|
||||
Max power @ 9kHz / 7.4V =W
|
||||
26
Hardware_development/Measurements/v01/Readme.txt
Normal file
26
Hardware_development/Measurements/v01/Readme.txt
Normal file
|
|
@ -0,0 +1,26 @@
|
|||
This folder contains measurement results for prototypes v0.1 of high-voltage generator based on all considered topologies.
|
||||
|
||||
We mix-and-match topologies previous termed as (1) flyback, (2) push-pull and (3) audio, with various trafos, cascades (single or double) and different power supplies in order to achieve as high as possible output voltage. While there are many combinations that were tested, documented ones are only those that have significant impact to the design decisions.
|
||||
|
||||
The results in tables are output voltages measured using 1000:1 high-voltage probe connected to DC voltmeter, hence the output voltage is given in kV. The frequency of switching flyback/push-pull or the input signal to the audio amplifier is varied. Hence, all the results are given as a function of frequency.
|
||||
|
||||
(1) The results for flyback configuration can be found in
|
||||
Flyback_1.txt
|
||||
Flyback_2.txt
|
||||
Flyback_3.pdf
|
||||
Flyback_4.pdf and
|
||||
Flyback_4.png (a plot of data in Flyback_4.pdf).
|
||||
|
||||
(2) The results for push-pull configuration can be found in
|
||||
Push_pull_1.txt and
|
||||
Push_pull_2.txt.
|
||||
|
||||
(3) The results for audio configuration can be found in
|
||||
Audio_1.txt and
|
||||
Audio_2.txt.
|
||||
|
||||
A document with measured results for shapers can be found in ./Shapers/shapers.pdf. Since both shapers needed redesign, the new designs are at
|
||||
O-ESD > Hardware development > 5-Shapers > Shaper1_v1 and
|
||||
O-ESD > Hardware development > 5-Shapers > Shaper7_v2.
|
||||
|
||||
Finally, the decisions are made taking into the account all the gathered information and are summarized in Design_decisions.txt file.
|
||||
Loading…
Reference in a new issue