Hi, I had some conversations with Bob.
I like to share them with you:
This part is about inductors.
All 3 inductors are of the toroidal variety in the trucker system. I know there will be those that may not like to hear it, but the best results were observed with silver plated, stranded, teflon insulated wire. This can be purchased from surplus outlets. The stranded version of this wire does not work on the large 3 phase toroid itself, yet works great on the chokes used to prevent that energy from leaking out of those 3 phase toroidal systems. Heavy guage stranded and solid copper house wire, and solid magnet wire were tried, and did not have the same results. This is not to say that they may not be made to work, just that they did not work in the configurations tested.
In the trucker system, the common + connected toroid is wound full fill with AWG 4, and both of the - connected toroids are wound full fill with AWG 8. I tried different sizes of toroids, and compared the results. There was not much noticed increase from using larger toroids, other than it lowered the required frequency to be applied. The Q is low, so the peak is broad, and tuning is not super-critical. All pulsing used in the commercial application was below 250 Hz in this particular application.
Exact toroid specs are pretty much useless here, as the characteristics of the cell(s) this is connected to will dictate what works best. However it may be useful to note that the toroid cores used were MicroMetals 45 mix, the same as that used for the more recent chokes recommended for the large 3 phase toroidal systems. The smallest toroid cores tested were T157-45, and the largest were T400-45. I did try one of the large T650-52 as used in the 3 phase toroidal power system, but the result was just not worth the much higher cost and the space required.
Hope this helps
Bob Boyce
Second part is on how that toroid of him should work:
Bobs system part2:
Pulsing dc into toroid on 3 primary's
Chokes must prevent electron leakage when powerpuls is off.
secondairy coil is hooked between dc and wfc. Voltage on the secondairy is must not exceed level that starts electrolysis. A Bias like voltage. Never let voltage drop towards 0 volts.
The 3 primairy's must provide a signal waveform that provides enough power to start electrolysis in some way..?? BOB?
3 frequencys are capable of creating a stepup ramp. When freq 1 is pulsing you have a low step. When 2 frequency's hit the same time, the pulse on the secondairy will be twice as high then a single puls.
And when all 3 pulses hit the toroid at the same time, the pulse on the secondairy will be 3 times as high then a single puls.
The pulse it self is square. Play with Mark and space and with voltage levels to get optimum result.
If i miss something, please join in, Bob!
His answer:
Sorry, I have been extremely busy providing customer support for those customers and dealers that have been left "out in the cold" so to speak by the manufacturer. I solved the problems by reflashing the controllers back to the original firmware that I had proven was working properly prior to me leaving. This removed all of the manufacturers malware that they had been updated with, and I corrected the calibration values back to original specs. The original units out there are now working as designed again.
The simplified pulsing system does not use the same multi-phase drive as the larger toroidal system. Though the description you gave does describe that larger toroidal system very well. The steps in pulsing levels are very effective in that system.
The simplified system also uses a choke on the power bus side to prevent EMI leakage through to the vehicles power system. How it differs is that each cell unit has a single choke in series with it that uses the pulses provided by the control devices (FETs or DC SSRs). The programming is such that pulses of the same repetition rate are provided at all times that the system is on. Pulse width is adjusted between 0% (full off) and 99% (full on) in 1% steps to control current. On any feedback type control system, the shunt must also be isolated from any EMI produced in order to function properly.
Bob Boyce
