Plasmasonic prototype in action (5 sec exposure and color corrected)

What is the Plasmasonic

The Plasmasonic(R) is an advanced solid state Tesla Coil that produces artificial lightning at lengths up to five (5) feet.  When operated with its handheld controller, it can create a variety of different lightning and sound effects including polyphonic music reproduction using its builts-in MIDI interface.  In otherwords, the user has the ability to create music through the output arcs of the Plasmasonic from any MIDI source, including a keyboard, guitar, laptop, or other compatible MIDI instrument, and reproduce up to two tones simultaneously.

Tesla Coils by their nature, are incredibly awesome devices.  Ever since Nikola Tesla demonstrated the first Tesla Coil in the late 1900's, the ability to create artificial lightning has never ceased to amaze people watching them in action.  With the Plasmasonic, you can impress your friends by making music with the plasma, or simply impress them by creating a spectacular show demonstrating the awesomeness of artificial lightning!  You can also light up fluorescent and neon tubes and demonstrate the principal of wireless energy transfer.

The Plasmasonic is available as a high-level kit, meaning that all of the subassemblies are pre-built and tested prior to delivery to the end user.  All which is required by the end user at delivery is to assemble  the mechanical portion of the coil using the included hardware and to connect all the subassemblies together with the provided pre-fabricated wire harnesses, and finally to test and tune the assembled system using the provided instruction manual.  Fully constructed and tested Plasmasonic Tesla Coils are also available at an additional charge.

Background

The idea for the Plasmasonic was first conceived in early 2012.  At that time, Eastern Voltage Research, which was founded by my wife Lenka and I in 2010, had already been producing educational Tesla Coil and other high voltage kits for the amateur market.  Our kits were extremely popular and we felt that the next direction we needed to move into was to offer complete Tesla Coil systems as a product, especially ones that would be designed and targeted for commercial and educational use.  We recognized that many individuals, especially those associated with commercial and educational institutions, do not have the electrical background or the skills necessary to design a complex solid state Tesla Coil from scratch, or even possess the skills to construct one from a kit containing hundreds of parts purchased over the internet.  With that in mind, we began the design of the Plasmasonic, making sure we would adhere to a basic set of requirements:

• Lightweight and easily transportable - Able to be fit in compact car
• Operate from standard 115VAC 50/60Hz line power
• Highly reliable and easily repairable
• Product output arcs of at least 4 feet in length
• Be completely modular - all main components to be dedicated subassemblies and interconnect by connectorized subassemblies
• Require no soldering by end user, or construction of custom magnetics
• Attractively priced so that it would remain within reach of amateur enthusiasts

Technical Specifications

Plasmasonic Prototype 1 - Stands 3 feet tall and produces 5 feet of output arc

The following technical specifications are based on two prototype systems that were constructed this past year.  As the electrical design of the prototype reflects the end item configuration of the Plasmasonic, we do not anticipate any changes in the technical specifications as they are listed here:

• Primary Coil:  0.25" DIA copper tubing
• Secondary Coil:  36 AWG magnet wire on phenolic coliform (prototype)
• Primary Capacitor:  0.28uF @ 8kV (prototype)
• Topload:  18" x 4.5" seamless aluminum toroid
• Power Section:  CM300 IGBT half-bridge module
• Maximum recorded arc length (170VAC input):  6 feet (prototype) (updated)
• Maximum recorded arc length (140VAC input):  5 feet (prototype) (updated)
• Maximum recorded arc length (115VAC input):  4 feet (prototype) (updated)
• Cooling:  Two (2) 115VAC muffin fans
• Input voltage:  115VAC, 50/60Hz
• Input Current:  10A max @ 115VAC (updated)
• Max. Input Power:  1150W @ 115VAC (updated)
• Dimensions:  15" x 15" x 36"
• Weight:  45 lbs (updated)

Whats Included?

For those purchasing the top tier perks - the complete Plasmasonic Tesla Coil, you will receive the following:

• 18" x 4.5" seamless aluminum spun toroid
• Secondary coil assembly (pre-wound and varnished)
• Polycarbonate enclosure
• Primary coil (0.25" Cu) and strike rail (0.375" Cu)
• Advanced Tesla Coil controller module
• Power distribution module
• Handheld MIDI controller
• Primary MMC assembly
• DC power supply / IGBT half-bridge assembly
• AC cooling fans (2)
• RGB LED illumination system
• 1000:1 pre-built current transformers (2) (connectorized)
• Pre-built gate transformer (connectorized)
• IGBT gate drive assembly
• Power cord, oil resistance, 115VAC
• Fiber optic cable (for handheld controller)
• Detailed instruction manual (PDF format)
• Cable harnesses for all subassemblies

It is important to note, that all the subassemblies above will be pre-built and tested.  The end user will not be required to solder and construct Printed Circuit Boards (PCBs).  They will also be pre-assembled into their dedicated subassemblies and pre-tested prior to delivery to the user.

Where we are in development

Schematics / Parts List / PCB Artwork - Typical documentation per subassembly

In the past year, we have constructed two (2) identical working prototype systems.  Both system have worked as designed, and have been extensively tested to ensure safe, reliable operation.  As we now have working prototypes, we are now focused on the following near term tasks:

• Finalizing the engineer design and documentation for each subassembly.  This includes updating Printed Circuit Board (PCB) designs, creating detailed parts lists, other documentation including assembly drawings and schematics.

• Working and communicating with vendors to ensure a smooth transition into production once funding is completed.  This step is specifically for all Printed Circuit Board (PCB) designs, custom magnetics, the secondary coil, and the aluminum toroid.

• Finalizing the mechanical drawings for each subassembly.   This includes the design of the polycarbonate enclosure and mounting provisions for all subassemblies as well as the custom enclosures which are being fabricated for the handheld controller and Advanced Tesla Coil Controller.

These above tasks are nearly finished and we estimate 100% completion by mid-September which will allow us to be ready to enter final production.

Why we need your support

Eastern Voltage Research Plasmasonic (front) / GOT VOLTS? (rear) T-Shirt

We have been working tirelessly in the past year to develop the Plasmasonic and we've come a long way.  But now we need your help.  Your support and contributions will allow us to take our final designs into manufacturing so that we can bring you and potentially thousands of other amateur high voltage enthusiasts around the world, including commercial and educational entities, a spectacular Tesla Coil that can provide years of safe, reliable operation.

In particular, we require your support to be able to have enough funds to take our final Printed Circuit Board (PCB) designs through the fabrication and assembly process, as well as purchase the high dollar components required for a high power Tesla Coil, namely the high power IGBT modules and energy storage capacitors.  These items are required to be purchased upfront and in bulk, so that we may offer an attractively priced system that is affordable to all those interested.

Production Schedule

Camaster Stinger CNC Router with vacuum table

To support production needs, we recently invested in a Camaster Stinger CNC Router system with vacuum hold down table.  This will allow us to fabricate all of our polycarbonate enclosure pieces at low cost, while also allowing us the flexibility to make changes on the fly, if required, without having to worry about dealing with an outside machine shop.  We also have a fully equipped machine shop with a lathe as well as an additional milling machine to assist the fabrication of custom parts.

 Our present production schedule is as follows:

• August 2013 - Complete electrical / mechanical updates
• September 2013 - Update drawings and create production files (i.e. gerbers)
• August-September 2013 - Indiegogo funding period
• October 2013 - Procurement of all parts
• October 2013 - Fabricate and Assemble Printed Circuit Boards (PCB)
• October 2013 - Fabricate polycarbonate enclosure / brackets
• November 2013 - Build subassemblies and wire harnesses
• December 2013 - Build subassemblies and wire harnesses
• January 2013 - Begin shipping Plasmasonic Kits
• January 2013 - Build and Test Top Perk Completed Plasmasonic
• February 2013 - Begin shipping Top Perk Completed Plasmasonic

Manufacturing Plan

As soon as funding is completed, our procurement cycle will begin.  This will kick-off the purchasing of all components and materials necessary to build the Plasmasonic systems.  We are already in discussions with our vendors and with the exception of the CM300 IGBT module and energy storage capacitors, there have not been any potentially long lead items identified. 

 Supplier Base

• Printed Circuit Boards (PCBs) - All printed circuit boards will be fabricated and assembled locally in NJ.  We made this decision as it will allow us to meet one-on-one with the assembly house in the event there is an issue and also allows us to work face-to-face with the technicians there to ensure we are doing everything properly to ensure a smooth delivery of assembled PCBs.

• Toroids - Our aluminum toroids are being spun by a reputable manufacturer who has been fabricating this particular sized toroid for many decades.

• Electronic Components - All electronic components are being purchased through either Digikey or Newark Electronics.  All components used in our assemblies are off-the-shelf components that are readily stocked at these suppliers.

• CM300 IGBT Modules - These modules are purchased through Newark Electronics direct from Powerex. 

• Polycabonate Enclosure / Brackets - Machining of the polycarbonate enclosure pieces will be done in-house using a Camaster CNC machine that we invested in earlier this year to support this effort.  We also have a lathe and milling machine which will be used to assist the fabrication of various components as required.  In the event of a problem, there are several local machine shops which can step in to take over the production of the enclosure pieces, albeit at higher cost.

Assembly

Building of subassemblies and wire harnesses will be relatively easy and consume very little time.  The subassemblies themselves are of very little complexity requiring only a handful of screws and nuts for assembly and testing required is minimal with the exception of the Advanced Tesla Coil Controller and Handheld MIDI Controller, which will have their own dedicated test fixture for testing.

Risks and Challenges

Manufacturing
Eastern Voltage Research has produced and sold thousands of Tesla Coil related products over the past several years.  We have a thorough understanding of the costs and challenges involved at procuring and producing electronic components and subassemblies at the quantities involved.  However, even through we have contingencies in place, we do recognize that we can be affected by delays in manufacturing outside of our control.  To mitigate this risk, we have limited the number of perks being offered - namely the full Plasmasonic kits - to ensure that the number of products we are responsible for delivering remains manageable. 

Long Lead Items
Two components have been identified has potentially long lead items.  These are the Powerex CM300 IGBT modules and the 36DX energy storage capacitors which are used in the half-bridge assembly.  To mitigate this risk, we have already placed orders for these in advance, to ensure that they meet our end item delivery date requirements.  Manufacturer specified lead time on these items is approx. 100 days which still keeps us within our delivery timeframe.

Procurement
Electronic components utilized in the design of various subassemblies have been chosen specifically to be common, non-specialized components which are readily available.  We see very low risk in procuring the components necessary to build the quantities of product that we anticipate.  Both the toroids and secondary coils are being manufactured by vendors with extensive experience in both these areas and we have already received sample product from both. 

User Interface / Difficulty of Assembly
Finally, we have tried to make these Tesla Coils as user friendly as possible, especially when assembly is required by the end user.  All the subassemblies are pre-built, pre-tested, and stand-alone.  They all interconnect with each other by color-coded and/or labeled connectorized wire harnesses.  A highly detailed instruction manual with diagrams and step-by-step instructions including photos, will be provided at the time of assembly.  The manual will provide a thorough explanation of Tesla Coil operation, step-by-step assembly procedures, safety information and procedures, and many photos.

Technical Risks
Our two (2) prototype systems that we have been testing are for the most part form, fit, and function.  The only major difference between the prototype system and the end item system will be that the boards will be populated by machine, rather than hand soldered as was the prototype.  Therefore, we see very little technical risk in going from the prototype to the end item configuration.

Complete Technical Descriptions

Prototype Plasmasonic system

For those interested in the full technical details of the Plasmasonic system, here are some in depth descriptions of each of the subassemblies used in this Tesla Coil:

Advanced Tesla Coil Controller (end item)

Advanced Tesla Coil Controller
This controller provides the smarts necessary to drive the high power IGBT based half-bridge circuit as well as the fault processing circuitry necessary to ensure safe, reliable operation of the system.  It includes a peak current limiting circuit, a gate drive voltage UVLO (under voltage lock-out) circuit, as well as sequencing circuitry which works with the Power Distribution module to limit inrush current on application of power to the DC Power Supply / Half-Bridge Assembly.  it also provides communication with the Power Distribution module and during certain fault conditions will remove power from the DC Power Supply and also initiate a crowbar shutdown during major fault conditions.  This fault processing is employed to maintain high reliability of the system.  It also provides an optically isolated communications link to the power distribution board to control sequencing, inrush, and fault handling.

Handheld MIDI Controller (end item)

Handheld MIDI Controller
The handheld controller provides the drive signal to the Advanced Tesla Coil Controller necessary to operate the Plasmasonic.  It is connected via fiber optic cable which is necessary for high voltage isolation.  The handheld controller includes both a polyphonic MIDI interface which can converter MIDI signals from either a keyboard, guitar, computer, or other compatible instrument, and can create up to a two-note polyphonic playback of music with the Tesla Coil.  There is also a standard interrupter mode which allows the user to vary both pulsewidth and pulse repetition frequency (PRF) during operation.  The controller can be customized by the end user, and also provides a number of hardware implemented fault protection schemes including pulsewidth limiting.

RGB LED Illumination Board (end item)
RGB LED Illumination Board - Various color modes

RGB LED Illumination Board
This board contains eight (8) high power RGB LEDs which are controlled via an onboard microcontroller to produce a variety of different lighting modes including steady, flash, pulsating, and strobe functions.  Modes are manually cycled using an onboard pushbutton, but provisions for an externally mounted pushbutton are also provided.  This board mounts directly underneath the polycarbonate enclosure. It is important to note that the photos of this board in action do not serve it justice.  This thing is BLINDINGLY bright in person! 

DC Power Supply / Half-Bridge Assembly (prototype)

DC Power Supply / Half-Bridge Assembly
This assembly is comprised both of a voltage-doubler rectifier power supply and a half-bridge switching circuit using a CM300 1200V, 300A IGBT module.  This circuit takes the incoming 115VAC and creates a bus voltage of nearly 350VDC which is used by the IGBT based half-bridge to provide the high current switching necessary to drive the primary circuit of the Tesla Coil and generate the high voltages necessary to produce the output arcs one sees.  Not shown on the prototype, there will be safety bleeders / balancing resistors placed across each capacitor, and the capacitor bank will also be placed in parallel which a much lower resistance bleeder, controlled via a relay, which will discharge the capacitors in the event of a fault or when power is removed from the system.  The prototype photo above shows CM300,1200V IGBT modules, however, in the end item assembly, CM300, 600V IGBT modules will be used.  A 0.124" thick laminated bus bar utilizing 6 oz. copper connects the capacitors to the CM300 IGBT module.

Primary MMC Capacitor Assembly (prototype)

Primary MMC Capacitor Assembly
This board contains the MMC capacitors which are part of the primary resonant circuit of the Tesla Coil.  The prototype utilizes (8) 0.56uF, 2kV capacitors in a series / parallel arrangement which creates an effective capacitance of 0.28uF @ 8kV.  The capacitors are mounted to a 0.124" thick Printed Circuit Board (PCB) which is comprised of 6 oz. copper for maximum current carrying capacity.  A high power muffin fan is also mounted to the assembly to provide cooling for the capacitors. 

IGBT Gate Driver Board
This board contains gate drive circuitry which connects directly to the gate terminals of the IGBTs.  It is designed using FASTON tab connectors, so that it will simply plug onto the tab terminals of the IGBT.  This facilitates easy removal without the need to solder components and wires directly to the IGBT itself.

Power Distribution Module
This board provides power distribution and fuse protection for the entire system as well as inrush current limiting circuitry which is sequenced by the Advanced Tesla Coil controller.  There is also a crowbar circuit which is designed to quickly discharge the energy in the DC Power Supply capacitors in the event of a fault condition. 

Primary Coil
The primary coil is approximately 6 turns of 0.25" copper tubing which is mounted directly on polycarbonate supports on the base enclosure of the Tesla Coil.  This primary couples directly with the secondary coil to provide the energy transfer between the primary circuit and secondary circuits.

Secondary Coil
The prototype secondary coil, comprised of 36 AWG (prototype), is positioned in the middle of the primary coil and along with its top mounted toroid, gives the Tesla Coil its distinctive look.  The secondary coils are pre-wound, varnished, and also connectorized to facilitate easy installation with the rest of the Plasmasonic system.

Toroid
The toroid is the top load of the Tesla Coil which is mounted atop of the secondary coil.  The Plasmasonic uses an 18" x 4.5" seamless aluminum spun toroid (not pressed) and interfaces the secondary by sitting on a custom machined copper plate which is attached to the top of the secondary coil.

 Frequency Asked Questions (FAQ)

1.  What level of experience is required to build and operate the Plasmasonic?

There are basically two versions that the Plasmasonic will be offered as outlined below.  Each version lists what is required by the end user to achieve a fully functional Plasmasonic system:

Plasmasonic Tesla Coil Kit

• Polycarbonate enclosure must be assembled using hardware provided
• Subassemblies must be installed into enclosure using supplied hardware
• Subassemblies must be connected by supplied wire harnesses
• System must be tuned per instructions using oscilloscope using basic test procedures
• End user should have some level of electronics or electrical background and familiarity with taking voltage measurements and using an oscilloscope
• Minor soldering may be required to install a ring lug or two.

Complete Plasmasonic Tesla Coil

• Shipped in three pieces (base assembly, secondary assembly, and toroid)
• User required to connect these three pieces per instructions
• Base assembly is fully assembled, fully tuned, and ready for operation.

2.  Can anyone purchase a Plasmasonic?

The Plasmasonic is targeted specifically for educational and commercial use, and not for the general consumer market.  With that said, we do offer the Plasmasonic to individuals we feel are knowledgeable and capable enough to build and operate one safely.  It is designed specifically for professional applications and is designed to be used in safe, controlled environments.  The purchaser of a Plasmasonic system must recognize all the hazards and dangers of operating a high voltage power system, and be able to operate the system safely with a complete understanding of the safety risks involved.  Eastern Voltage Research reserves the right to offer these systems to only those individuals it determines to be qualified to safely build and operate one.  We recommend that any individual interested in making a pledge for a complete system contact us beforehand.

3.  Will the Plasmasonic run for hours at a time? (submitted by contributor)

The Plasmasonic system is designed for light demonstration use which includes classroom and commercial use, musuem installations, and general demonstration use.  It is not designed or intended to be used for performance or event use where the Tesla Coil would be operated continously for long periods of time such as on a stage or musical venue.  Recognize that most museum Tesla Coil installations only run their coils for seconds at a time periodically through the day and in class room / auditorium settings, coils maybe only run for a couple minutes maximum.  Therefore, to be on the conservative side, we recommend max. run times of 2-5 minutes with the same amount of time for cool down between runs. Note that this is for continuous interrupter mode.  With MIDI, there is a lot of space between notes, so runtimes can be much longer as the overall duty cycle of the system is lower (assuming notes are not playing in continous fashion)

4.  What equipment is required to build and test the Plasmasonic once it is delivered?

Assembly of the Plasmasonic system will only require basic hand tools such as screw drivers, sockets, allen wrenches, and similar.  Testing of the Plasmasonic coil will require a multimeter (digital preferred) and an oscilloscope with at least two (2) probes.

5.  What exactly is included in the kit that will be delivered to me?

With both the kit version and the completed version of the Plasmasonic, everything (materials) that is required to build and operate a fully functional Tesla Coil is included.

6.  What type of MIDI device is compatible with the Plasmasonic?

7.  What are the power requirements of the Plasmasonic Tesla Coil?

The Plasmasonic operates from standard 115VAC 50/60Hz.  It is compatible with 15A and 20A electrical circuits and max. current draw is approximately 10A.