My take on a SuperD

[KingJL]

I am doing some experimentation with the Moodz alt2hbridge transmit circuit and wanted at the same time to experiment with the SuperD coil arrangement. The Moodz alt2hbridge TX seems to work best with low ohm TX coils, so my goals for the SuperD were: TX ~300uH @ ~0.5 ohm, RX ~300 uH each.

For the TX I wound 3 flat spiral coils with 28 turns of AWG 24 (wire diam w/insulation 1mm) formed as shown (actual inside dimensions were 258 mm x 136 mm). Each flat spiral coil was 329 uH (+/- 3 uh).

I then stacked the 3 flat spiral coils and connected them in parallel, resulting in a coil of 315 uh, 0.6 ohm, with a coil thickness of 3.7 mm.

Having a TX coils, I now needed some RX coils and a way to support the assembly and provide an easy way to adjust (null) the RX coils. I decided on an assembly consisting of 4 layers of 3mm expanded PVC rigid foam: 3mm bottom plate, 3 mm RX coil layer, 3mm TX layer, and 3 mm top plate. The RX coils would slide in and out with a pinned slot to maintain alignment. The parts/formers for the 3 layers were produced on a 3018 CNC router. The RX coils were wound with AWG 30 enameled copper magnet wire and ended up being 303 uH.

The followin series shows the machined parts and assembly progress:






The assembly allows me to test on the bench, then "fix" the assembly, after adjusted and nulled. I will work on method of encapsulation and mounting on a rod later... for now it is a test coil assembly.

So far, I am satisfied with the result!

[moodz]

Very nice work .... I have been 3D printing mine ... had to fine tune the process to get the ABS version to print OK without warping.

moodz.

[MartinB]

Very nice work .... I have been 3D printing mine ... had to fine tune the process to get the ABS version to print OK without warping.

moodz.[ATTACH]57919[/ATTACH]
[ATTACH]57920[/ATTACH]

Nice printer you have there. How did you stop ABS from warping?

[MartinB]

I am doing some experimentation with the Moodz alt2hbridge transmit circuit and wanted at the same time to experiment with the SuperD coil arrangement. The Moodz alt2hbridge TX seems to work best with low ohm TX coils, so my goals for the SuperD were: TX ~300uH @ ~0.5 ohm, RX ~300 uH each.

For the TX I wound 3 flat spiral coils with 28 turns of AWG 24 (wire diam w/insulation 1mm) formed as shown (actual inside dimensions were 258 mm x 136 mm). Each flat spiral coil was 329 uH (+/- 3 uh).
[ATTACH]57910[/ATTACH]
I then stacked the 3 flat spiral coils and connected them in parallel, resulting in a coil of 315 uh, 0.6 ohm, with a coil thickness of 3.7 mm.
[ATTACH]57911[/ATTACH]
Having a TX coils, I now needed some RX coils and a way to support the assembly and provide an easy way to adjust (null) the RX coils. I decided on an assembly consisting of 4 layers of 3mm expanded PVC rigid foam: 3mm bottom plate, 3 mm RX coil layer, 3mm TX layer, and 3 mm top plate. The RX coils would slide in and out with a pinned slot to maintain alignment. The parts/formers for the 3 layers were produced on a 3018 CNC router. The RX coils were wound with AWG 30 enameled copper magnet wire and ended up being 303 uH.
[ATTACH]57912[/ATTACH]
The followin series shows the machined parts and assembly progress:
[ATTACH]57914[/ATTACH]
[ATTACH]57915[/ATTACH]
[ATTACH]57916[/ATTACH]
[ATTACH]57917[/ATTACH]
[ATTACH]57918[/ATTACH]
[ATTACH]57913[/ATTACH]
The assembly allows me to test on the bench, then "fix" the assembly, after adjusted and nulled. I will work on method of encapsulation and mounting on a rod later... for now it is a test coil assembly.

So far, I am satisfied with the result!

Really nice job. This is my next project so please keep us informed on progress. What are the dimensions of your coils?

[KingJL]

Really nice job. This is my next project so please keep us informed on progress. What are the dimensions of your coils?

TX as shown in first picture: 258 mm x 136 mm (inner dimension), 416 mm x 194 mm (outer dimension) flat spiral wound with 28 turns, equivalent circle inner diameter is 219.56 mm.

RX coils:

Form dimension is:
213.775 mm x 88.516 mm with a 3mm deep slot 1.2 mm wide cut into the perimeter to accommodate winding, resulting in an equivalent circle diam 158.579 mm (wound with 25T AWG 30).

[MartinB]

TX as shown in first picture: 258 mm x 136 mm (inner dimension), 416 mm x 194 mm (outer dimension) flat spiral wound with 28 turns, equivalent circle inner diameter is 219.56 mm.

RX coils:
[ATTACH]57921[/ATTACH]
Form dimension is:
213.775 mm x 88.516 mm with a 3mm deep slot 1.2 mm wide cut into the perimeter to accommodate winding, resulting in an equivalent circle diam 158.579 mm (wound with 25T AWG 30).

.

Great thank you. I will give it a try.

[moodz]

Nice printer you have there. How did you stop ABS from warping?

...set buildplate to 110 Celsius and extrusion temp to 250 celsius with 0.4mm extrusion ( prints a 22 cm dia housing in just under 2 hours ).

[MartinB]

...set buildplate to 110 Celsius and extrusion temp to 250 celsius with 0.4mm extrusion ( prints a 22 cm dia housing in just under 2 hours ).

Thank you. I will give it a try.

[KingJL]

TX as shown in first picture: 258 mm x 136 mm (inner dimension), 416 mm x 194 mm (outer dimension) flat spiral wound with 28 turns, equivalent circle inner diameter is 219.56 mm.

RX coils:
[ATTACH]57921[/ATTACH]
Form dimension is:
213.775 mm x 88.516 mm with a 3mm deep slot 1.2 mm wide cut into the perimeter to accommodate winding, resulting in an equivalent circle diam 158.579 mm (wound with 25T AWG 30).

Correction on TX outer dimensions: 316 mm x 194 mm... my bad!

[MartinB]

Correction on TX outer dimensions: 316 mm x 194 mm... my bad!

Thanks for the update. I can just about get that on to my vacuum former

[KingJL]

Thanks for the update. I can just about get that on to my vacuum former

I can post a step of the final shape/dimensions of the final assembly... in fact if you are into Fusion 360, I can supply the design archive.

Step file of final assembly in the zip file:
SD_assembly.zip

[MartinB]

I can post a step of the final shape/dimensions of the final assembly... in fact if you are into Fusion 360, I can supply the design archive.

Step file of final assembly in the zip file:
[ATTACH]57925[/ATTACH]

Thank you. I do have Fusion 360 but do not use it enough as I prefer 123 Design. I think this project will give the kick I need to change my habits

[KingJL]

Assembly step file and exploded view

I have finally created a step file of the final assembly created from the individual parts:
SD_Assy v6 v3.zip

Also a drawing showing the 'exploded' view of the assembly:
Assembly View.pdf

[MartinB]

I have finally created a step file of the final assembly created from the individual parts:
[ATTACH]57935[/ATTACH]

Also a drawing showing the 'exploded' view of the assembly:
[ATTACH]57936[/ATTACH]

Great work. Thank you

[MartinB]

...set buildplate to 110 Celsius and extrusion temp to 250 celsius with 0.4mm extrusion ( prints a 22 cm dia housing in just under 2 hours ).

Tried those settings but still get significant warping. Do you use an enclosure on your printer? What do you use as an adhesive on your print bed? I am printing onto plain glass