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Ignition Coil High Voltage Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 1: Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
File Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 4: Overdriving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 6: Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
Step 1: Details
An ignition coil produces a high voltage output on its secondary when the current flowing in the primary winding is interrupted. The first step in generating a high voltage
from an ignition coil is to store energy in the inductance of the primary winding. That energy is then released, generating the high voltage output.
Energy is stored in the primary of the coil when current is flowing through it. This energy is provided by a DC power supply, usually the 12 volt battery of a vehicles
electrical system.
The primary circuit is driven by closing a switch to ground, which allows current to flow from the power supply through the primary. When the switch is initially closed, the
current in the coil remains zero, as the inductance of the primary does not allow the current to change instantaneously. The current in the primary then increases
exponentially until it reaches its steady state value.
The steady state current is the maximum value the current will have. It is determined by the voltage of the power supply and the total series resistance of the primary
circuit.
The steady state current in the primary is determined by:
I_steady_state = V_source/R_primary
Rprimary consists of the total resistance of the wire in the primary coil, as well as the resistance of the wires and other connections in the primary circuit.
The length of time needed for the current in the primary to reach its steady state value is determined by the time constant. The time constant is a parameter which is
equal to the primary inductance (in Henries) divided by the primary resistance (in ohms), and so it has the units of seconds. In equations it is commonly represented with
the Greek letter tau. A smaller time constant means that the current will increase more quickly.
The equation for the current in the inductor is:
i(t)=I_steady_state*(1-e^(-t/time_constant)
The graph shows how the current in the coil increases after the switch is closed. The graph expresses the current as the percentage of steady state value. Note that after
4 time constants have passed, the current is at about 98% of its steady state value, and the after 5 time constants, the current is at more than 99% of its steady state
value.
The relevant equations for the primary circuit are summarized in a chart below.
Energy in the Primary Winding
The energy stored in an inductor is a function of its inductance and the current flowing through it. The equation for the energy stored in an inductor is:
Energy= * L * I^2.
Refer again to the graph that shows the current and energy in the primary coil versus the time elapsed. Note that the longer the switch is closed, the less additional
energy is stored in the primary inductance. After the first time constant, the energy stored is 38% of the maximum. After two time constants have elapsed, the total energy
stored is 73%. After three time constants, the total energy stored is 90%. After four time constants, the total energy is 96%, and so on. After five time constants, the
energy stored is essentially at 100% of the maximum possible value for the power supply voltage and primary resistance in the circuit.
Once the primary current has reached its steady state value, no additional energy can be stored in the primary of the coil. If the switch remains closed after this point, the
energy from the source will simply be dissipated as heat in the resistance of the primary circuit. It therefore makes no sense to keep the switch closed longer than 4 or 5
time constants, as past that point the energy will simply be wasted.
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
Image Notes
1. - terminal. Connects to power supply directly, or through a resistor depending
on the coil.
2. - connection. Connects to ground through the switch. This connection is
common between the primary and secondary windings.
3. High Voltage output terminal. This connection is surrounded by a shroud to help
prevent arcing to the other terminals.
Image Notes
1. The HV connection is within the shroud.
2. Top view of coil, looking down into the HV terminal.
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
The inductance and resistance of the primary will vary between different coils, so the maximum on time of the switch will need some adjustment depending on the
characteristics of the coil you are using. Some coils are intended to operate with additional resistance in series with the primary coil, and this resistance will need to be
added to the other resistance in the primary circuit when calculating the steady state current and time constant.
Two different designs of the pulse generator are described in the next steps. One is based on a PIC microprocessor, and the other based on a 555 timer.
Pulse Generator Based on Microprocessor
A PIC microcontroller based pulse generator circuit is used to generate the signal used to turn the IGBT on and off. Using a microcontroller gives the flexibility to control
both the on time and the frequency independently. The software allows the spark repetition frequency to be set between 10Hz and 400Hz, and it allows the on time of the
pulse to be set between 0.5 and 2 milliseconds.
The maximum current can be limiting by adjustment of the on time. If the on time is set to less than about four time constants, then the current in the primary will never
reach its steady state.
The circuit uses two potentiometers, R3 and R7. One is used to set the on time, and the other to set the repetition frequency. The potentiometers are read by the
microprocessors A/D converter. R4 and C5 and R6 and C6 are used as low pass filters on these analog inputs. The software generates the output pulses based on the
on time and frequency readings.
One processor input is used to read an enable switch. When the switch is pressed, the input is brought low, and the microprocessor generates pulses on the output with
the on time and frequency as set by the potentiometers. When the switch is released R1 pulls the input high and the output is turned off.
The program flow chart diagram, *.asm source code file, and *.hex file for programming are included.
Alternate Pulse Generator Based on 555 Timer
This 555 timer circuit can also be used for the pulse generator, but it cant generally let you control the on time and frequency independently. Refer to the separate
schematic for the 555 timer version of the pulse generator.
The schematic shows a 555 timer circuit which uses diodes to create separate charge and discharge paths. The on time is determined by how long C1 takes to charge
through R1, potentiometer R2, and diode D1. The off time is determined by how long C1 takes to discharge through R3, potentiometer R4, and diode D2. By separating
the charge and discharge paths, the on and off times can be controlled independently, allowing the user to set the on time so that it is not so long that it results in wasted
energy. Note however that changes to either the on time or the off time will result in a change to the pulse repetition frequency, unlike the microprocessor based version
of the pulse generator.
The ON time, OFF time, and frequency of the output are determined as follows:
Ton = 0.693 * (R1 + R2) * C1
Toff = 0.693 * (R3 + R4) * C1
Frequency = 1/ (Ton + Toff) = 1.44 / [ C1 * (R1 + R2 + R3 + R4) ]
Pushbutton switch SW1 connects the reset line of the timer high, enabling the pulse generator output. The output goes low when SW1 is released, turning off the HV
output.
Switch
The switch used here to control the current in the primary is an International Rectifier IRGB14C40LPBF IGBT. This IGBT is specifically designed for automotive ignition
system applications.
When the switch in an ignition system opens to disrupt the current in the primary, the voltage across it rises up to hundreds of volts. This IGBT is rated to handle this
voltage. It also includes internal clamping diodes to protect against overvoltage. Refer to the internal diagram of the part shown below to see how the internal protection is
implemented.
Proper heatsinking is needed for your switch. This is especially true if you ever plan on overdriving your coil with a higher power supply voltage. Exact heatsinking needs
require some calculation of the actual power dissipated in your switch. To err on the side of caution mount to a piece of aluminum and also use some forced air, such as
from a small fan. In the system shown here, the heatsinking is provided by a large copper area of the PCB.
Circuit Protection
It is beneficial to provide protection to the driver circuit to avoid damage from transient overvoltage spikes. MOV1 is placed across the power supply input to clamp
voltage spikes. MOVs (metal oxide varistor) are protection devices which are designed to be off when the voltage across them is below their clamping voltage, but then
turn on and conduct once that voltage is exceeded. When it is conducting, the voltage drop across it is relatively constant. The MOV therefore clamps the voltage
across the power supply bus to a safe level, so that it does not rise high enough to damage the driver circuit.
The MOV must be selected with a clamping voltage that is greater than the power supply voltage; otherwise the MOV will be conducting all the time and it will overheat.
For example, the MOV I chose for use with a 14 volt power supply clamps at around 20 volts. Transient spikes greater than 20 volts will then be clamped so that the
power supply bus will not see a voltage greater than that.
It is also useful to have a larger of capacitor (C7) on the power supply input. A couple thousand microfarads worth of electrolytic capacitors works well. The capacitors
provide a low impedance path to high frequency spikes on the power supply. Make sure that the voltage ratings of the capacitors you use are greater than the supply
voltage and greater than the MOV clamping voltage.
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
Image Notes
1. Schematic showing the design detail of the complete system. This schematic
shows the microprocessor based pulse generator. Note the switch is a
protected IGBT. All the components inside the box labeled "SWITCH" are
internal to the part.
Image Notes
1. Alternative pulse generator circuit based on the 555 timer IC, for use if a
microprocessor is not desired. Note the diodes used to allow separate control of
the on and off times. See the instructions here and in the datasheet for the 555
timer to determine proper component values to provide the pulse timing needed
in your application.
Image Notes
1. This is the complete circuit internal to the IRGB14C40LPBF IGBT used in this
project. The extra components shown are for protection against transient
voltage spikes caused by the primary inductance being switched off.
File Downloads
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
12F683_IGN_DRVR.HEX (4 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to '12F683_IGN_DRVR.HEX']
Step 4: Overdriving
Ignition coils can be overdriven to increase the power output.
As mentioned earlier, the energy stored in the primary is related to the current flowing in the primary. Also recall that the length of time required for the current to increase
to a certain point is related by the time constant and the steady state current. The time constant is unchanged by a change in drive voltage, but the steady state current
does increase with a greater drive voltage. So, driving with a higher voltage allows the primary current to reach a given level of current in a shorter amount of time.
Overdriving therefore increases the output power by allowing more pulses of the same energy to be released in a given amount of time (a higher drive frequency)
compared to the case where a lower power supply voltage is used.
When overdriving the coil with a voltage greater than that of the electrical system it was designed for (usually 12 volts), it is possible to damage the primary if the switch is
left on too long. The current in the primary will increase to a level beyond what the coil was designed to carry in the automotive electrical system, and so excessive power
will be dissipated in the resistance of the primary winding. This must be taken into consideration when setting the maximum on time produced by the pulse generator
circuit. By properly limiting the on time of the switch, the coil can deliver more energy to the HV output without increasing the power dissipation in the primary winding or
the switch. This is possible because the power dissipated in the primary is determined by the RMS current in the primary. Using a higher power supply voltage and
properly limiting the ON time allows the RMS current in the primary to be kept the same while the energy throughput is increased.
Overdriving risks drastically increasing the power dissipated in the semiconductor switch if the on time is not limited. A switch that is adequate for 12 volt systems may
easily be destroyed when overdriving, if care is not taken. The on time of the switch will have a significant effect on the power that is dissipated in the switch. It becomes
even more important to use adequate heat sinking for the switch when overdriving. The image below shows the remains of an IGBT that burned out when overdriving a
coil. Keep the on time propely limited to avoid burning up your driver circuit!
If you are overdriving your coil, also keep in mind you will also have to make sure that the circuit protection (MOV and electrolytic capacitor) are rated for the higher
supply voltage.
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
Image Notes
1. This IGBT was destroyed by excessive power dissipation when overdriven with a power supply of about 35 volts DC.
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
Image Notes
1. Note the "scar" burned into the surface of the plastic shroud.
Step 6: Results
The pictures below show the complete ignition coil system mounted on a board. The pulse generator circuit and IGBT switch are on a small custom PCB. The input power
jacks, enable switch, and the on time and frequency controls are mounted on an aluminum angle bracket.
I'll repeat the safety warnings here.
Excecise caution and good sense when working with high voltage. Remove power from the system before making adjustements.
Don't touch the arcs. Be mindful that the potentials generated can jump a significant gap, and that insulation on tools like regular pliers may be inadequate to
prevent you from getting a shock.
Keep in mind that some parts of the system can get hot. The arcs can be hot enough to to ignite paper and plastic, so operate it in a safe location.
High voltage discharges generate Ozone gas, which can cause irritation if breathed in. High voltage discharges also generate some ultraviolet radiation, so
limit your exposure and don't stare directly at the arcs.
The first picture is a short time exposure showing the arcs from the high voltage output when used with a power supply of 14 volts. Note that they arcs are distinct blue
streams, as opposed to hotter arcs.
The arcs become much hotter when a greater power supply voltage is used along with a higher driver frequency. The subsequent pictures show operation using higher
power supply voltages. Notice that the arc is now a hot and yellow.
The video shows how the output arcs are affected by changes to the repetition frequency, switch on time, and power supply voltage.
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
Image Notes
1. Arcs achieved using 14V power supply.
Image Notes
1. Arcs achieved using 35V power supply.
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
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Comments
21 comments Add Comment
VadimS says:
Well designed circuit. I've seen a few designs that are best describes as shabby.
Noitoen says:
VadimS says:
I've built something similar for a tractor a few years ago. Made a vary noticeable difference in the idle and starting.
skowerr says:
LargeMouthBass says:
skowerr says:
LargeMouthBass says:
RickO5 says:
Fun idea, I may have to try that.
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
trewq7 says:
coll
HoldOnTight says:
stackerjack says:
static says:
Eurober says:
LargeMouthBass says:
Eurober says:
LargeMouthBass says:
Eurober says:
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/
Eurober says:
tunes says:
LargeMouthBass says:
tunes says:
Thanks so much for your comments and the files.
Dan
http://www.instructables.com/id/Ignition-Coil-High-Voltage-Display/