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Comparison of Tesla Coil Driver Topologies: Rotary Spark Gap Versus Double Resonant Solid State

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Comparison of Tesla Coil Driver Topologies: Rotary Spark Gap Versus Double Resonant Solid State THE PENNSYLVANIA STATE UNIVERSITY THE GRADUATE SCHOOL SCHOOL OF SCIENCE, ENGINEERING, & TECHNOLOGY COMPARISON OF TESLA COIL DRIVER TOPOLOGIES: ROTARY SPARK GAP VERSUS DOUBLE RESONANT SOLID STATE A Master of Engineering Paper by Eric B. Wasatonic Submitted in Partial Fulfillment of the Requirements for the Degree of Master of Engineering in Electrical Engineering July 11, 2013 The paper of Eric B. Wasatonic was reviewed and approved by the following: Dr. Seth Wolpert Associate Professor of Electrical Engineering Paper Advisor Dr. Peter B. Idowu Associate Professor of Electrical Engineering Paper Reader Dr. Sedig S. Agili Associate Professor of Electrical Engineering Paper Reader i Abstract Tesla coils were first invented in the 19th century, and have been the focus of development ever since. In all that time, certain aspects of their design have progressed with improvements in electronic technology. It is the focus of this project to investigate the impacts of those improvements. Compared to a spark gap topology, the improved, electronically driven Tesla coil was found to be more controllable, more efficient, less noisy, and possess distinctly different output discharge qualities despite claims to the contrary. Also, the project yielded innovations in the process of designing and building the experimental setup, and novel methods of taking certain measurements. Improvements were given to inductance formulas, coil winding technique, and measurements of differential voltage and output discharge current. Both the experimental process and its results stand to inform the coiler community about criteria that may affect design choices. ii Acknowledgements This research was made possible by my many years of education and guidance from the electrical engineering faculty at Penn State Harrisburg, especially Dr. Sedig Agili, Prof. Cheryl Ebel, Dr. Peter Idowu, Dr. Aldo Morales, and Dr. Seth Wolpert. I am grateful to Dr. Jerry Shoup for inviting me to work as Electrical Lab Supervisor, thus providing me with most of the parts, raw materials, tools, and lab space needed to build and operate my Tesla coil. I am especially thankful to my parents and my girlfriend for their support and motivation for me to work through this project. I would also like to thank Daniel McCauley, for granting me permission to include in this paper, figures and schematics copied from his book on the design and construction of double resonant solid state Tesla coils. iii Table of Contents 1 Chapter 1: Introduction ............................................................................................................ 1 1.1 Nikola Tesla and His Legacy ........................................................................................... 1 1.2 General Characteristics of a Tesla Coil ............................................................................ 2 1.3 Basic Understanding of Different Tesla Coil Technologies ............................................ 5 1.4 Modern-Day Prevalence of Tesla Coils ........................................................................... 9 1.5 Definitions of Terms ...................................................................................................... 14 1.6 Literature ........................................................................................................................ 15 2 Chapter 2: Objectives ............................................................................................................ 17 2.1 Spark Length Efficacy .................................................................................................... 17 2.2 Analysis of Resonator Voltages and Currents................................................................ 17 2.3 Arc-to-Ground Current Measurement ............................................................................ 18 2.4 Output Discharge Visual Appearance ............................................................................ 18 2.5 Acoustic Sound Level Output ........................................................................................ 19 3 Chapter 3: Experimental Method .......................................................................................... 20 3.1 Overview ........................................................................................................................ 20 3.2 Parameters Held Constant .............................................................................................. 20 3.3 Design and Construction of the Tesla Resonator ........................................................... 22 3.3.1 The Secondary Coil................................................................................................. 22 3.3.2 The Topload and Secondary Circuit Tuning ........................................................... 27 3.3.3 The Primary Coil..................................................................................................... 32 3.3.4 Primary Capacitor ................................................................................................... 38 3.3.5 Coupling Coefficient ............................................................................................... 41 3.4 Design and Construction of Rotary Spark Gap Driver .................................................. 43 3.5 Design and Construction of Double Resonant Solid State Driver ................................. 46 3.5.1 DRSSTC Fundamentals .......................................................................................... 46 3.5.2 Components of the DRSSTC Driver....................................................................... 49 3.6 Power, Control, and Measurement Setup ....................................................................... 55 3.6.1 Control Console ...................................................................................................... 55 3.6.2 Voltage Probes and Current Transformers ............................................................. 59 3.6.3 Effective Shielding and Measuring Topload Ground-Arc Current......................... 70 3.6.4 Measuring Topload Currents with Observations of Light Bulb Intensity .............. 72 3.6.5 Observing Height of Brush Discharge .................................................................... 75 4 Chapter 4: Data and Analysis ................................................................................................ 76 4.1 RMS Measurements ....................................................................................................... 76 4.2 Clarification of Arc and Brush Discharge Height Data ................................................. 79 iv 4.3 Spark Length Efficacy .................................................................................................... 79 4.4 Analysis of Resonator Voltages and Currents................................................................ 87 4.5 Arc-to-Ground Current Measurement ............................................................................ 99 4.6 Output Discharge Visual Appearance .......................................................................... 104 4.6.1 Brush Discharge .................................................................................................... 104 4.6.2 Arc Discharge ....................................................................................................... 105 4.7 Acoustic Sound Level Output ...................................................................................... 109 5 Chapter 5: Conclusion ......................................................................................................... 114 5.1 Original Innovations in Tesla Coil Design and Construction ...................................... 114 5.1.1 Method of Driver Selection .................................................................................. 114 5.1.2 Construction and Resonant Tuning of Secondary Coil ......................................... 114 5.1.3 Design of Primary Coil ......................................................................................... 115 5.2 Original Innovations in Tesla Coil Measurement Techniques ..................................... 116 5.2.1 RMS Measurements in General ............................................................................ 116 5.2.2 Secondary Coil First-Turn Voltage Measurement ................................................ 116 5.2.3 Differential Voltage Probe Modification .............................................................. 117 5.2.4 Adjusting Height of Ground Electrode for Arc Current Measurements ............... 118 5.2.5 Light Bulb Intensity Method of Measuring Topload Output Current ................... 118 5.3 Significant Revelations Revealed by Data ................................................................... 120 5.4 Potential Improvements for Further Science ................................................................ 126 5.4.1 More Data ............................................................................................................. 126 5.4.2 Better Data ............................................................................................................ 126 5.4.3 Safer Driver Selection Switch ............................................................................... 127 5.4.4 Better Oscilloscope ............................................................................................... 127 6 References ..........................................................................................................................
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