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CHAPTER 5

DESIGN OF 500 - kJ PULSED POWER SUPPLY USING


COMPUTER SIMULATION

5.1 INTRODUCTION

The electromagnetic rail guns require compact pulsed power


supplies that are to be installed in combat vehicles. The components with high
degrees of energy and power density as well as complex system designs need
to be realized in such vehicle in order to meet the requirement for the
integration of pulsed power supply (Wisken et al 2003). The pulsed power
supply is related to choice of energy storage system. An energy storage device
that has an acceptably small weight and volume yet can provide appropriately
conditioned power is an essential component for the successful
implementation of a portable electrical energy system (Gully 1991). Today
the energy storage systems which feed the rail launcher are still large.
Extensive work and research are being conducted all over the world to
minimize the volume occupied by the power supply and its weight. Capacitor
based systems are the most familiar type of pulsed power supplies system
used in a rail gun research for the past several years. They consist of a number
of individual capacitors grouped together called a module and these modules
can be grouped together called segments. The capacitors in a module are
discharged simultaneously and then the segments are discharged sequentially.
The purpose of modules and segments is to give a more constant current pulse
to the rail gun load. It is possible to maintain a near constant output current,
over a substantial part of the current pulse by varying the inductance and
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capacitance values of segments and then sequentially discharging the


segments (Dwight warnock 2003). The design of 500-kJ capacitor module
pulsed power system to be applied for the electromagnetic rail gun is
currently under investigation by the Government of India. The Anna
University, Chennai has initiated a program to develop 500-kJ pulsed power
supply using computer simulation techniques. In order to design a 500-kJ
pulsed power supply using computer simulation in this thesis, the basic
electric requirements of electromagnetic guns to be fulfilled by the
appropriate PPS systems are studied. From these requirements, design criteria
for high energy discharge modules and their auxiliary systems are derived.
Finally, an attempt is made to design a 500-kJ PPS using computer simulation
to accelerate the projectile with a velocity of 1 to 1.5 km/s. In order to achieve
this task in this work, computer simulation packages called PSPICE software
and MATLAB software are used. In PSPICE simulation, trade off study is
made to find the optimum number of capacitor stages to get desired current
pulse shape and rail parameters. MATLAB is used to obtain the optimum
value of rail parameters such as muzzle velocity, current at exit, and effective
barrel length. By applying a systematic approach to optimizing the power
supply this study has shown that by distributing the capacitance into five
equal sized banks, the 75 grams of projectile can be accelerated with a
velocity of 1.25km/s. The design is achieved by trial and error methods by
changing rail parameter and pulsed power supply parameter. Finally, this
work gives some basic considerations on volume and weight requirements of
500-kJ capacitive PPS systems to be applied for rapid fire of electromagnetic
rail guns.

5.2 INTRODUCTION TO PULSE FORMING NETWORK

Pulsed power supply (PPS) system is important to an


electromagnetic gun system( Yongxia Han 2009). Usually, the PPS is made
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up of modules called pulse forming unit (PFUs), which are capacitor based
and switched by semiconductors. These PFUs are grouped into several
segments and then the modules in the same segment are switched
simultaneously as shown in Figure 5.1.

CAPACITOR BANK

RACK -1

MODULE 1
PULSE
MODULE 2 SHAPING
INDUCTOR

MODULE 3
CROWBAR
SWITCH

RACK -2

MODULE 1
PULSE RAIL GUN
SHAPING
MODULE 2
INDUCTOR

MODULE 3
CROWBAR PROJECTILE
SWITCH

RACK -3

MODULE 1
PULSE
SHAPING
MODULE 2
INDUCTOR

MODULE 3
CROWBAR
SWITCH

Figure 5.1 Simple schematic diagram of capacitor based PPS (Tatake


et al 1994)
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For the past several years, a lot of work has been done on research
and development of PPS based on a pulse forming network. Many researchers
have reported their work on simulation model and real model previously.
Lehmann et al (1995) have presented an overview of what can be done to
enhance the efficiency of a rail launcher fed by capacitor banks by adjusting
the rail design in view to accelerate payloads of several kilograms up to
velocities of few km/s with minimum of charged electrical energy. Wey et al
(1995) have developed the capacitor bank, consisting of two stages is used for
experiments with a 50mm round bore rail gun at a maximum current of 2MA.
The rail gun is fed at two different points in order to test distributed energy
storage system rail gun concept. Deadrick et al (1982) have developed and
validated simulation code at the Lawrence Livermore National Laboratory
(LLNL) to predict the performance of a rail gun. The code is called
MAGRAC (MAGnetic Rail gun ACCcelerator ), models the performance of a
rail gun, driven by a magnetic flux compression current generator
(MFCG).The MAGRAC code employs a time-step solution of the non-linear
time varying element rail gun circuit to determine rail currents. Emelin et al
(1995) have described the pulse formation of a programmable multi-stage
pulsed power supply for electric rail guns. This power supply allows optimal
operation of the rail gun by maintaining a near constant acceleration force
over the launch period. A 450-kJ pulsed-power supply (PPS) for
electromagnetic launcher has been built up and tested with a short-circuit load
and a rail gun load (Yi Liu 2010). Tatake et al (1994) have developed
simulation code using Pascal language to predict the performance of the rail
gun. Timothy et al (2004) have described the preliminary design assessments
associated with the 200 MJ Naval PoC Facilities. The circuit model was
created using MicroCap™ software to validate the PFN performance at each
of the installation increments. Hildenbrand (1993) has described the simulator
developed for the Army Research, Development and Engineering Center in
1993. The code was in FORTRAN. Jack Bernardes et al (2003) have
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proposed a generic design for the capacitor based PPS. They simulated the
PPS and rail gun model using Micro-Cap VI, which is an electrical circuit
analysis software package. From the above literature survey, it is found that
worldwide research is on to develop the PPS, with respect to their
requirements, in order to predetermine the performance of rail using various
simulation techniques. In this work, the PSPICE and MATLAB simulation
packages have been used to predict the performance of PPS system.

5.3 KEY COMPONENTS OF PULSED POWER SUPPLY SYSTEM

The block diagram in Figure 5.2 shows the key components


necessary to design a capacitor based PPS system for an electromagnetic rail
gun pulsed power system in a combat vehicle.

HV - charger

Charge Dump
Panel Load
(Rail gun)
Resistor network
protection diode PPS-Module

Crowbar Pulse forming


power diode inductor

Energy Power
Storage Switch

Figure 5.2 Key components of pulsed power supply system

The PPS module is connected with charging device through charge


dump resistors and relays. The discharging process of the capacitor inside the
PPS module will be initiated by a high power switch which should have a
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blocking voltage of several kilovolts and a current capability of several kilo


amps. During the discharge, the energy stored in a capacitor is transferred to
rail gun load through a pulse shaping inductor. During the crow bar operation
the inductor is charged and stores the energy.

5.3.1 Capacitor

Capacitors are used as an energy storage device to store the energy


and then to discharge the energy over time. The accumulated charges on the
electrodes of a capacitor induce charges in the dielectric. These induced
charges determine the permittivity of the dielectric medium. Every dielectric
material has its own value of permittivity. Permittivity introduces another
term called dielectric constant “K” of the dielectric medium. The dielectric
constant K is defined as the ratio of the permittivity of the dielectric to the
permittivity of free space or a vacuum (Cletus Kaiser 1998). In general the
stored energy density (MJ/m3) of a capacitor can be calculated using
(MacDonald et al 2009)

D 4.4 10 6 PF .K.E 2 (5.1)

where K , is the dielectric constant, E is breakdown strength of the dielectric


medium and PF is packing fraction (fraction of total volume which stores
energy). So the energy density of a dielectric material is proportional to its
dielectric constant ( K ) and square of its dielectric breakdown strength ( E )
values. Therefore, high K and E values are significant to achieve high
energy density in capacitors. Most capacitors used in pulsed power
applications are oil-filled, film and/or paper dielectric. Most polymers used in
capacitors have dielectric constant between 2 and 4; impregnated paper has a
dielectric constant between 3 and 6, and the polar polymer polyvinylidene
fluoride has a dielectric constant of 11 ( Ennis et al 1990). Typical values for
electric field in pulsed power capacitors ranges from 500 V/µm – 800 V/µm.
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The electric field is limited by the breakdown strength of the polymer


dielectric, which is the maximum field that can be applied before a
breakdown event short-circuits the electrode. There have been many
improvements over the last 10 to 20 years in energy storage capacitor
fabrication and the energy densities of 1.5 to 3.0 J/cm3 are now available
(MacDonald et al 2009).

5.3.2 Switches

One of the most critical components in pulsed power systems is the


main output switch due to the electrical and operational safety requirements.
The switching device has to pass high currents and withstand high voltages
and with this it should be reliable, durable and provide high technology
efficiency. Requirements to switching devices depend also on the type of
energy storage system. In capacitor based PPS, a switching device should
switch on the capacitor bank to the load quickly and reliably and provide
multiple passing currents up to several hundreds of kilo amperes with
duration from several microseconds to several milliseconds (Dmitrii Alferov
et al 1999). On one hand, it has to block the charging voltage of the capacitive
storage, without any pre-triggering or pre-firing, on the other hand it has to
perform reliable switching when triggered with a minimum of self impedance
due to the switching losses to be avoided ( Wisken et al 2004).

The switching devices are mainly classified as

1. Non solid state switches


2. Solid State Switches

Non solid state switches are

1. Spark gap
2. Triggered vacuum switch
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Solid State Switches

Solid state power devices consist of a gate, cathode, and anode. The
gate is used to trigger the device by closing the connection between the anode
and cathode. The device can only be turned off, once all the current has been
dumped to zero. The solid state devices are limited by its break over voltage
and di/dt ratings. The solid state devices will fail if either of these two
parameters are exceeded .The different types of solid state switches are given
below

1. Silicon controlled rectifies


2. Silicon carbide thyristors.
3. Gate turn off SCR.
4. MOS Controlled thyristors.
5. Light activated thyristors.

Singh et al (1995) have made a comparison between the above


switching devices for their ability to conduct high peak current at high
coulomb levels while operating in a mobile tactical system having severe
volumetric constraints. He has concluded that for series-parallel arrangement
of silicon controlled rectifiers was considered to offer the best approach for
the tactical system.

5.3.3 Diode

In pulsed power supply systems, the crowbar diodes conveniently


perform important functions. They automatically close upon when the
capacitor charges in reverse direction. The diode string will be placed parallel
with the capacitor bank, as the voltage on the bank attempts to reverse the
parallel diodes will be forward biased. Thus the crow bar diode, preventing
voltage reversal on capacitors and trapping energy in pulse shaping coils. The
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advantages of crow bar operation are: it increases the life of the energy
storage capacitors, increases energy transfer efficiency, and additional options
for pulse shaping (Rolf Dethlefsen 1993). The diode will immediately begin
to conduct at the peak bank current, therefore it must be rated at the same
standard as the bank switches.

5.3.4 Cable

The cables for the rail gun system must be capable of handling
large currents with minimum power loss. The cable will be self-supporting, co
axial cable as far as electromechanical force is concerned, so conductor
bracing will be eliminated. Another great advantage of the coaxial bus is there
is minimal leakage of coaxial cable (Jiannian Dong et al 2005).This will be
very helpful in minimizing interaction with the data acquisition and control
system.

5.4 COMPONENTS USED IN DESIGN OF 500-kJ PULSED


POWER SUPPLY

The requirement of pulsed power system given by the Government


of India as follows:

Energy rating = 500 kJ/shot and 8 rounds/minute (Total of 4MJ)


Muzzle velocity = 1 to 1.5km/s,
Pulse width= 4 - 5ms and
Volume occupied by pulsed power supply and its weight.

According to the electric requirements of the pulse power supply,


the key components of PPS have to be chosen. In order to carry out this work,
the required components that are essential to build 500-kJ power supply
design are chosen from the manufacture data. There are many other smaller
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circuits and parts such as timing and control circuits for the bank isolation
switches, to protect the capacitors that will be required, in order to make the
overall system fully operational. These items are essential to the design and
its safe operation, but will not be considered in this work, as they are not the
main focus of this thesis.

5.4.1 Capacitor

The capacitors used in the 500- kJ PPS system are self healing
metalized electrode capable of storing 50-kJ of energy, designed and
manufactured by General Atomics Electronic Systems Inc. The pulse power
supply (PPS) has to store 500-kJ of energy, hence totally 10 capacitors have
been chosen to design a pulsed power supply using computer simulation.
These capacitors are divided into 5 independently triggerable capacitor bank
modules and each module has two capacitors and they are connected in
parallel. The energy density of capacitor used in the PPS is about 3MJ/m3. The
life duration of capacitor reaches up to 1000 times. The technical data of
3MJ/m3 capacitor is given in Table 5.1.

Table 5.1 Technical data of the capacitor (www.gaep.com)

Capacitance 23685µF
Voltage 6.6kV
Stored energy 50kJ
Pulse discharge current 30kA
Size 112 362 417mm
Internal inductance <500nH
Weight 30kg

All the five banks are identically configured therefore the current
pulse from each bank will also be identical. Each bank consists of total of two
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capacitors and connected in parallel, resulting in a peak current per capacitor


of 30 kA. So the predicted maximum peak discharge current from each
capacitor bank is 60kA.

5.4.2 Inductor

As the volume of the capacitors and the switching assemblies are


reduced, the volume of the pulse shaping inductor begins to dominate system
size. This is particularly true for conventional solenoid inductors, where their
external magnetic field must be taken into account. In some cases, other
system components must be kept in a low field region, effectively expanding
the volume of the inductor. In general, it is necessary to keep other
components approximately one radius and one half-length away from the
inductor. The effective volume of the inductor is thus four to eight times the
volume of the inductor itself. The pulse-forming inductance is decreased on
selected modules in an effort to generate an increase in peak launcher current
and launch velocity. The inductor used in this pulsed power supply has toroid
design to reduce the external magnetic field during the discharge. This is
necessary to prevent electromagnetic inference to other electronic equipment.

5.4.3 Fuse

Fuses are used to enable the capacitor to handle large amount of


current while providing isolation in the event of short circuit at high voltages
(Miguel Del Güercio 2003). Fuses are designed and manufactured by GEAP.
Each Maxwell high voltage fuse is rated at 6 kA and 22 kV. Five fuses are
connected in parallel and placed in series with the output of each capacitor
providing a maximum rating of 30 kA per assembly. Table 5.2 gives the
technical data of the fuses used in 500-kJ PPS system.
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Table 5.2 Technical data of the Fuse (www.gaep.com)

Rated Pulsed Current amps 6000A at 1.5 m.sec


Cold Resistance 13 milli-ohms at 20°C
Hot Resistance 25 milli-ohms at 250°C
Rated Fuse Carrying Action 54,000 A2sec
Weight 2kg
Size 6.1(D)cm 30.4cm (L)

5.4.4 Crowbar Switch (diode)

The GA diodes selected for this design have a reverse voltage limit
of 10% of the rated voltage or 6500 V. As the current delivered by each
capacitor bank is 60kA under normal conditions and 120kA under fault
conditions, the diodes have to withstand this current. A total of six diodes in
two stacks parallel, with three diodes in series in each stack, form a crow bar
diode. Each diode is rated at 6 kV and 60 kA for a 8.3-ms half-sinusoid surge
current. The technical data of diode is given in Table 5.3.

Table 5.3 Technical data of the diode (www.siliconpower.com)

Rep. Peak Reverse Voltage and Current VRRM = 6000 V ; IRRM=100 mA


Non Repetitive Peak Surge Current IFSM(8.3 ms, VR=0) = 60,000 A
IFSM(8.3 ms, VR=0)
Maximum Average Current IF(AV) 3500A at T case =100oC
Size 14.35 3.86 cm
Weight 5kg

5.4.5 Spark Gap Switch

As the expected maximum current from each capacitor module is


60kA under normal condition and 120 kA under fault condition, the spark gap
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switch has to withstand the maximum peak current discharged by the each
capacitor bank. The spark gap used in this design is ST-150 spark gaps rated
at 300 kA with a standoff voltage of 22 kV at zero pressure. The spark gap
switch is manufactured by L3 communication. The switch shows ratings of at
least a factor of three over the required duty in peak currents to ensure long
life and reliability. The spark gaps are connected in series with each capacitor
module. The technical data of the spark gap switch is given in
Table 5.4.

Table 5.4 Technical data of the spark gap switch (www.Titanpsd.com)

Operating Voltage 20-40 kV


Peak Current 300 kA
Charge Transfer 120 coulomb per shot
Size 8 inch diameter,11inch height
Weight 10kg

5.5 DESIGN OF 500-kJ PULSED POWER SUPPLY USING


PSPICE SIMULATION

5.5.1 Capacitor Based Pulsed Power Supply

Capacitor based pulsed power systems can be described using a


simple RLC circuit as shown in Figure 5.3. In which, C is the system
capacitance, L is pulse shaping inductance, R is the internal resistance of the
inductor, L’ is the variable inductance of the rails and R’ is the variable
resistance of the rails. As the projectile moves along the barrel, the L’ and R’
values will be changed.
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S L R

R’
C Rail impedance
L’

L’ variable inductance
R’ variable resistance

Figure 5.3 An ideal rail gun circuit represented by using RLC circuit

When the switch S is closed, the capacitor will start to discharge the
stored energy into the system. During the discharging time of the capacitor,
the energy stored in a capacitor is transferred to the inductor and inductor gets
charged. The inductor will be fully charged, when the capacitor is completely
discharged and current flowing through circuit will reach to maximum value
at this point. After this point, the current value will exponentially decrease,
until the projectile exits the barrel resulting in an open circuit.

5.5.2 Problem Statement

The rail gun is essentially a current operated device. For maximum


piezometric launch efficiency, it requires a current pulse which rises rapidly
and is then maintained at a constant level and drops to zero, just before the
time of projectile exit (Fred Charles Beach 1996).In capacitor based pulsed
power supply, capacitor is used only to store the energy and initiate the
current pulse. The capacitor discharge phase does not provide majority of the
accelerating force to the projectile. But the inductor discharge phase gives the
majority of accelerating force to the projectile. That’s why it is important to
maintain the peak current level high in a rail gun system as long as possible.
Obtaining the constant level pulse depends on the values of L, C, and the
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delay between pulses. If the inductance value increases in PPS, the peak
current value delivered to the load decreases and the decaying time of the
pulse current increases. Also when increasing the inductance of the PPS, the
current density in the rails decreases, as it increases the barrel length, but
results in higher barrel current when the projectile leaves the rails. If the delay
times between the banks discharge increases, the peak current value reduces
which result lower acceleration force on the projectile, subsequently the
muzzle velocity also being lower. In order to balance for the loss in velocity,
it is necessary to increase the amount of capacitance in the power supply,
when the voltage is constant. Increasing the capacitance is in disagreement
with the stated objective to minimize the capacitance, and also results in
increased peak current and a current density that may be higher than in the
lower inductance case. From the above discussion, it is clear that designing a
power supply for a rail gun is an exercise in system optimization (Dwight
warnock 2003). In the multiple-bank model, it is possible to shape the pulse
by implementing a non-uniform capacitance and inductance distribution
among banks. The capacitance and inductance values are varied on a per bank
basis. In case of capacitor, it is necessary to keep large percentage of system
capacitor in first bank to deliver a high current to the load and then lower
percentage of system capacitor placed for the following banks to boost the
current. In the case of inductance, initially higher value of system inductance
is placed to limit the peak current and lower value of system inductance is
placed to following bank to reduce the decaying time current, resulting in a
lower exit current (Alexey Alexeev et al 1992). In order to identify optimum
solution for 500-kJ PPS in this work, different types of capacitor banks
connection are studied. Capacitors are grouped into single, double, triple and
five stages. For each capacitor connection pulse shaping inductance value,
peak current at exit, muzzle velocity, peak acceleration, pulse width, and
effective barrel length of the rails are calculated. These values are then used to
estimate the size of the capacitor banks and system inductances.
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5.6 IMPORTANT MODELS USED IN PSPICE DESIGN

The following PSPICE models are used in design of PPS for


electromagnetic rail gun (PSPICE Manual 1996).

5.6.1 Current Controlled Current Source (CCCS)

Figure 5.4 shows, the current controlled device used in simulation.


As name implies, the output current can be controlled by its input current and
gain. In a 500-kJ PPS design by using this model, the rail current can be
separated from the circuit without affecting rail gun circuit parameter. This
current can then be used to find the acceleration, velocity and distance
traveled by the projectile. As the output of this model depends on its input and
gain, in PPS design the gain of CCCS chosen as 1. So that input and output
current will be same.

Output function
F1

F
Input function

Figure 5.4 Current controlled current source model

5.6.2 Power Model

Figure 5.5 shows the power model used in the simulation. This
model is used to get the powered value of input and it depends on the gain
specified by the user. This model can be used to get the squared value of
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current in a simulation. When PWR value is 2, this block will square the input
current and gives as an output current.

PWR 2
Power

Figure 5.5 Power model

5.6.3 Gain Model

Figure 5.6 shows the gain model used in the simulation. This model
is used to multiply the given input with the gain specified by the user. This
model can be used to get the acceleration value of the projectile in simulation.
In a simulation, the squared rail current is multiplied by a gain of 7.3066x10-6
using this block and then output is obtained that will be equal to the
acceleration of the projectile.

Gain

Figure 5.6 Gain model

5.6.4 Integrator with Gain

Figure 5.7 shows the integrator model used in simulation. This


model is used to integrate the given input. This model can be used to get the
velocity and distance traveled by the projectile in simulation. The 500kJ PPS
design has two integrator models and they are connected in series. The first
integrator which is connected between gain model and 2nd integrator model
(see in Figure 5.10) gives the velocity of projectile as an output. The second
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integrator which is connected between first integrator and ZX model (see in


Figure 5.11) gives the displacement of projectile as an output.

1.0
0V

Figure 5.7 Integrator with gain

5.6.5 Variable Inductance and Resistance

In the operation of the rail gun, resistance and inductance of the


rails are varied with respect to distance travelled by the projectile. So rail
inductance and resistance are calculated with respect to distance travelled by
the projectile while simulating a rail gun model, for accurate performance
prediction. The implementation of rail impedance in simulation is difficult. In
order to implement variable impedance of rail using simulation, a suitable
model has to be developed. To incorporate above mentioned varying
parameter in simulation ZX model can be used. Figure 5.8 shows the ZX
element which can be used to represent the variable rail resistance and
inductance in simulation.

1 X2 4
+ ZX
2 _ Reference 5
1 X1 4
+ ZX 0 0
2 _ Reference 5 3
R1
3

Figure 5.8 PSPICE model of ZX (Wey et al 1997)


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The basic operation of the model is explained below

The resistance or inductance across the terminals 4 and 5 of ZX


element is the multiplication of voltage across the terminals 1and 2, and
resistance or inductance that is connected across the terminal 3 and ground. In
the rail gun simulation, output of the second integrator which is proportional
to distance travelled by the projectile is connected to terminal 1 and terminal
2 is grounded. This indicates that the voltage across the terminal 1 and 2 is
proportional to distance travelled by the projectile. The resistance or
inductance per meter of the rail is connected across terminal 3 and ground in
ZX model. The multiplication of voltage across the terminal 1 and 2, and the
resistor or inductor across the terminal 3 and ground, will give the live
resistance or inductance of the rails across the terminal 4 and 5 (Wey et al
1997).

5.7 THE ELECTRICAL EQUIVALENT CIRCUIT OF


CAPACITOR BASED PULSED POWER SUPPLY

Figure 5.9 shows, the electrical equivalent circuit of capacitor bank


pulsed power supply with electromagnetic rail gun load. The system has been
divided in to an energy storage module, rail module and projectile module.
The energy storage module consists of a capacitor followed by a spark gap
switch. The spark gap switch is modeled by the series combination of a
switch, a diode, and an on-state resistance. The crowbar diode is represented
by a diode and an effective forward resistance. The pulse-shaping inductor is
modeled as an inductance and a related conductor resistance. The output cable
is represented by its inductance and resistance. The inductance and resistance
of the rails are varies linearly with respect to projectile position. The rail
inductance value depends on the rail dimension and designs. The calculation
of rail inductance values with respect to rail dimensions and design have been
explained in chapter 3 and 4.
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Cable

Rail 2
Rail 1

Pulse shaping
inductance
Projectile

Spark gap

Energy Module

+
HV
_

Figure 5.9 Electrical equivalent circuit of capacitor bank PPS

5.7.1 Calculation of Acceleration, Velocity and Distance Travelled by


the Projectile

The equations of motion for the projectile in the barrel can be


solved using the rail gun acceleration equation (Jack Bernardes et al 2003).

I 2 L'
a (5.1)
2m
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where I is the current delivered to load in Amps.


m is the mass of the projectile in kg.
L' is inductance gradient of the rail in µH/m.

The inductance gradient of the rail is assumed as L’= 1.096µH/m

Mass of the projectile is assumed as m = 75 grams

Then the acceleration of the projectile is given as

6
0.5 1.096 10
a 3
I2 7.3066 10 6 I 2 m/s2 (5.2)
75 10

From the above equation 5.2, it is observed that the squared value
of current has to be multiplied by 7.3066 10-6 to get the acceleration of
projectile in simulation.

Velocity of projectile can be obtained by integrating the


acceleration of projectile and given as

v adt m/s (5.3)

The distance traveled by the projectile can be obtained by


integrating the velocity of projectile and given as

d vdt m (5.4)

In order to calculate acceleration and velocity of the projectile, and


distance traveled by the projectile using simulation, the total current supplied
to the rail has to be separated from the circuit without affecting the rail
parameter values.
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5.8 SINGLE STAGE CAPACITOR (SSC) BANK PULSED


POWER SUPPLY

Figure 5.10 shows the electrical equivalent circuit of single stage


capacitor bank of 500-kJ pulsed power system designed using PSPICE
simulation. Energy storage device used in simulation is capacitor of 2.3685mf
and manufactured by GEAP.

LC X1 X2
RC + + ZX
Lp
_ _ Reference
Rp 1.096µH
0.101m

Spark
Gap

TG FPOLY
PWR 2 7.3066 x10-6

C D 1.0 1.0
0V 0V

RD C = 23.69 mF
Rp = 6µ v
+ a d
6500V Lp = 5µH
_
LC = 70nH
RC = 60µ
TG = 0.1ms
a = acceleration of the projectile
v = velocity of the projectile
d = distance travelled by the projectile

Figure 5.10 Single stage capacitor bank design using PSPICE simulation

The energy stored by one capacitor is 50 - kJ. Totally 10 capacitors


have been chosen and they are connected in parallel to form a single stage
capacitor bank. Each capacitor is rated for 30 kA current, so the predicted
maximum current delivered by single stage capacitor bank to the rail gun load
is 300kA. The capacitor is initially charged to 6500V. To get the rated current
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of single stage capacitor bank module, the pulse shaping inductance value
varied from 1µH onwards and the output current is checked. It is observed
that for the inductance value of 5µH, the peak value of the load current is
270kA, which is less than the rated value of SSC bank module. So this value
has been chosen as a pulse shaping inductance value for single stage capacitor
bank module. The other components of pulsed power supply are selected as
per the design requirement and given in Table 5.5.

In order to calculate the rail gun parameters such as acceleration,


velocity, and distance traveled by the projectile using simulation, the total
current supplied to the rails has to be separated from the circuit without
affecting the rail impedance values. The portion FPOLY block, shown in
Figure 5.10, is used to separate the load current from the circuit to calculate
the rail gun parameters without affecting the rail impedance values. The
current obtained from the FPOLY block is squared and then multiplied by the
gain to calculate the acceleration of the projectile based on equation (5.1) and
then uses two integration ABM blocks to calculate the velocity of the
projectile and distance traveled by the projectile.

Table.5.5 Key components of pulsed power supply for SSCB

Number of component
S.No Components Value
required
1 Capacitor C= 2.3685mf 10 capacitors and
U= 50kJ connected in parallel
2. Inductor 5µH 1
3 Spark gap Operating Voltage = 20- 40 4
kV
Peak Current = 300 kA (ST-
150)

4 Diode Rep. Peak Reverse Voltage 30 (Ten stacks connected


& Current VRRM = 6000 V in parallel, each stack
; IFSM =60.000A consist of three diode
173

5.8.1 Performance of 500-kJ SSCB Pulsed Power Supply System

5.8.1.1 Capacitor Discharge Characteristics

Figure 5.11 shows the predicted capacitor discharge characteristics


of the SSCB PPS obtained from simulation. It is observed that all the
capacitors are simultaneously discharged at the same time. It is also observed
that the time taken to complete the discharge process is less than 1ms.
Capacitor Voltage (kV)

Time (ms)

Figure 5.11 Capacitor Discharge characteristics

5.8.1.2 Total load current delivered to the load

Figure.5.12 shows the predicted total current delivered to rail gun


load obtained using simulation. In SSCB all the capacitors are connected in
parallel and have the same rating, hence all capacitors will deliver an equal
amount of current to the load. As the current delivered by individual capacitor
is 30 kA and then the expected maximum current delivered by SSCB will be
300kA. From the Figure 5.12, it is observed that the maximum current
delivered to the load is 270 kA, which is less than that it’s rated value. From
the figure, it is also observed that the peak current value is 270kA at 0.5ms.
174

Total load current (kA)

Time (ms)

Figure 5.12 Total current delivered to the load

5.8.1.3 Acceleration of the projectile

Figure 5.13 shows the predicted acceleration of the projectile


obtained from simulation. It is observed that the peak acceleration of the
projectile at 0.5ms is 520 km/sec2. It is also observed that the total current and
acceleration pulse has same shape. This is because according to equation
(5.1), the acceleration force is directly propositional to the current which is
supplied by capacitor bank.
Acceleration (km/s2)

Time (ms)

Figure 5.13 Acceleration of the projectile


175

5.8.1.4 Velocity of the projectile

Figure 5.14 shows the predicted velocity of the projectile obtained


from simulation. It is observed that the velocity of the projectile is constant
after the time period 1.5ms.Therefore, the projectile under frictionless
condition would exist the rails at 1.5ms. This graph can be used to get muzzle
velocity of the projectile. The point after which the projectile velocity is
constant, called muzzle velocity of the projectile. It is observed that the
muzzle velocity of the projectile is 275 m/sec at 1.5 msec. From the Figure
5.12, it is observed that the current at exit is 10kA.
Velocity (m/s)

Time (ms)

Figure 5.14 Velocity of the projectile

5.8.1.5 Displacement of the projectile

Figure 5.15 shows the predicted distance traveled by the projectile


obtained from simulation. The distance travelled by the projectile graph can
be used to calculate the effective barrel length of the rail. The point at which
acceleration stops is called the effective barrel length, since the projectile does
176

not gain velocity after this point. It is observed that the effective barrel length
of the rail is 0.3m at 1.5ms.
Distance (m)

Time (ms)

Figure 5.15 Distance travelled by the projectile

5.9 FIVE STAGE CAPACITOR BANK (FSCB) OF 500kJ


PULSED POWER SUPPLY

Figure 5.16 shows the electrical equivalent circuit of FSCB of 500-


kJ pulsed power system for electromagnetic rail gun designed using PSPICE
simulation package. In this PPS, the capacitors are divided into five different
groups in which two capacitors are connected in parallel. Usually capacitor
groups are switched on sequentially in order to get nearby constant current.
Normally the capacitor banks will be fired at the peak current level of the
previous bank. As per the requirement given by the Government of India, in
FSCB connection, the duration of current that is supplied to rail is assumed as
5ms. So in FSCB connection the values of acceleration, velocity and effective
barrel length of the rails are calculated at 5ms.
Figure 5.16 Five Stage Capacitor Bank (FSCB) pulsed power supply system

177
178

The components that are used in the five stage capacitor modules
have already been given in section 5.4.

5.9.1 Performance of 500-kJ FSCB Pulsed Power Supply

5.9.1.1 Capacitor discharge characteristics

Figure 5.17 shows the predicted capacitor discharge characteristics


of the FSCB pulsed power supply obtained using simulation. Once all the
capacitors are charged to 6500 V, the first capacitor bank is fired at a time t=
0.1ms. The remaining capacitor banks are fired at peak current level of the
previous bank. From the figure, it is observed that remaining capacitor banks
are fired at 0.8ms, 1.45ms, 2.25ms and 3.0ms respectively, because these are
the time for which current will be maximum in each capacitor bank.

C1 Voltage
Capacitor Voltage (kV)

C2 Voltage
C3 Voltage
C4 Voltage
C5 Voltage

Time (ms)

Figure 5.17 Capacitor discharge characteristics of FSCB

5.9.1.2 Individual capacitor current delivered to the load

Figure 5.18 shows the predicted individual capacitor current


delivered to the rail gun load obtained from simulation. As the predicted
maximum current from each capacitor bank is 60kA from the figure, it is
observed that the current which is delivered by each bank is less than the
179

predicted maximum current of capacitor bank. It is also observed that the


peak current time period (time taken to reach peak current value) for each
capacitor bank is 0.8ms, 1.45ms, 2.25ms and 3.0ms respectively. The first
capacitor is fired at 0.1ms and the remaining capacitor banks can then be fired
sequentially at these time periods. It is also observed that each segment
current has the same pulse shape, this because all capacitor banks are
essentially identical.
Individual load current (kA)

C1 Current
C2 Current
C3 Current
C4 Current
C5 Current

Time (ms)

Figure 5.18 Individual Capacitor bank current delivered to the load

5.9.1.3 Total current delivered to the load

Figure 5.19 shows the predicted total current delivered to the rail
gun load obtained using simulation. From the figure, it is observed that the
total current which is delivered by PPS is a composite of the five segment
currents, which are introduced into the breach end of the rail gun at different
times by switching on the segments one by one. It is also observed that the
peak current value delivered by capacitor bank is less than the rated value.(i.e
300kA) From the figure, it is observed that the peak current value of the load
current is 214kA at 3.4ms . It is also observed that current in rail is 142kA at
5ms. This current is called exit current in which projectile gets into the space
from rail.
180

Total load current (kA)

Time (ms)

Figure 5.19 Total current delivered to load

5.9.1.4 Acceleration of the projectile

Figure 5.20 shows the predicted acceleration of the projectile


obtained using simulation. It is observed that the total current and acceleration
pulse has same shape. This is because according to equation 5.1, the
acceleration force is directly propositional to the current which is supplied by
capacitor bank. It is also observed that the peak acceleration value of
projectile at 3.4 ms is 334km/sec2.
Acceleration (km/s2)

Time (ms)

Figure 5.20 Acceleration of the projectile


181

5.9.1.5 Velocity of the projectile

Figure 5.21 shows the predicted velocity of the projectile obtained


from simulation. It is observed that the muzzle velocity of the projectile is
0.9 km/ sec at 5 ms.
Velocity (m/s)

Time (ms)

Figure 5.21 Velocity of projectile

5.9.1.6 Displacement of the projectile

Figure 5.22 shows the distance travelled by the projectile obtained


using simulation. It is observed that the effective barrel length of rail is 1.8m
at 5ms.
Distance (m)

Time (ms)

Figure 5.22 Distance travelled by the projectile


182

5.10 RESULTS AND DISCUSSION

In order to get optimum number of capacitor stages for 500-kJ


pulsed power supply, in this work the capacitors are grouped in to a different
module. Capacitors are grouped into single, double, triple, and five stages. For
each capacitor bank connection, pulse shaping inductance value, peak current
value, current at exit, muzzle velocity, peak acceleration, pulse width and
effective barrel length of the rails are calculated and the values are given in
Table 5.6. From the Table 5.6, it is observed that increasing the number of
stages in a capacitor bank module causes an increase in value of pulse width
time, muzzle velocity of projectile, the time at peak current value, effective
barrel length of the rails, current at exist and decrease in value of peak current
and peak acceleration.

Table 5.6 Comparison of capacitor bank configurations

Components No. of stages


S.
and rail gun
No. 1stage 2 stage 3 stage 5 stage
parameters
1 Capacitor 10x2.3685 1.5x2.3685 1.4x2.3685 Each stage
(mf) 2.5x2.3685 2.4x2.3685 has
3.2x2.3685 2 x 2.3685
Energy stored per 500 250per 1.200 100 per
bank(kJ) stage 2.200 stage
3.100
2 Inductor 5 1.10 1.18 45
(µh) 2.10 2.18
3.45
3 Current pulse 1.5ms 3ms 4ms 5ms
width
4 Peak current 270 kA 240 kA 220kA 214 kA
value
5 Time at Peak 0.5 ms 0.875 ms 1.4 ms 3.4 ms
current value
6 Peak acceleration 520 420km/sec2 360 km/sec2 334km/sec2
km/sec2
7 Muzzle velocity 275 m/sec 370m/sec 700m/s 900m/s
8 Length of rail 0.3m 0.8m 1.7m 1.8m
9 Exit current 10 kA 77 kA 75KA 142 kA
183

The aim of this thesis is to design a 500-kJ pulsed power supply


system which can be used to accelerate the projectile at a velocity of 1000 m/s
to 1500m/s. But from the Table 5.6, it is observed that by dividing the
capacitor banks into five stages, it can be able to accelerate the projectile at a
velocity of only 900m/s. In order to achieve the goal, the work is extended,
through which the firing time of capacitor banks have been changed. Two
options have been taken to fire the capacitor banks sequentially.

Case 1. The capacitor banks are fired before the peak level of previous bank
current.

Case 2. The capacitor banks are fired after the peak level of previous bank
current.

(a) Performance of 500kJ PPS for case 1 study

In order to improve the performance of the 500-kJ PPS, the firing


time of each capacitor banks have been changed. In case study 1 the
capacitors are fired before the peak level of previous bank current. The firing
times are randomly selected to fire the capacitor bank sequentially.
Individual load current (kA)

C1 Current

C2 Current
C3 Current
C4 Current
C5Current

Time (ms)

Figure 5.23 Individual load current for case study 1


184

Figure 5.23 shows the predicted individual capacitor current


delivered to the rail gun load obtained from simulation. It is observed that the
peak current time period (time taken to reach peak current value) for each
capacitor bank is 0.8ms, 1.45ms, 2.45ms and 3.0 respectively. The first
capacitor is fired at 0.1ms and the remaining capacitor banks can then be fired
sequentially at earlier to this time period. In this case, the capacitor banks are
fired at 0.4ms, 0.6ms, 1ms, and 1.2ms.
Total load current (kA)

Time (ms)

Figure 5.24 Total load current for case study 1

Figure 5.24 shows the predicted total current delivered to the rail
gun load obtained using simulation. From the figure, it is observed that
the peak value of load current is 263kA at 1.68ms which is less than the rated
value of PPS. It is also observed that current in rails is 112kA at 5ms. This
current is called exit current in which projectile getting into space from rail.
185

Acceleration (km/s2)

Time (ms)

Figure 5.25 Acceleration of the projectile for case study 1

Figure 5.25 shows the predicted acceleration of projectile obtained


using simulation. It is observed that the peak acceleration value of projectile
is 492km/ sec2 at 1.68 ms.
Velocity (m/s)

Time (ms)

Figure 5.26 Velocity of the projectile for case study 1

Figure 5.26 shows the velocity of projectile obtained from the


simulation. It is observed that the muzzle velocity value of the projectile is
1.2 km /sec at 5 ms.
186

Distance (m)

Time (ms)

Figure 5.27 Distance travelled by the projectile for case study 1

Figure 5.27 shows the distance travelled by the projectile obtained


using simulation. It is observed that the effective barrel length of rail is 2m at
5ms.

(b) Performance of 500kJ PPS for case 2 study

In case study 2, the capacitor banks are fired after the peak level of
previous bank current. The firing time of capacitor banks are randomly
selected to fire the capacitor banks sequentially. In this case, the capacitor
banks are fired at 0.1ms, 1ms, 1.65ms, 2.45 and 3.2ms.
Total load current (kA)

Time (ms)

Figure 5.28 Total load current for case study 2


187

Distance (m)

Time (ms)

Figure 5.29 Projectile positions for case study 2

The total load current and projectile position for case 2, obtained
from simulation is shown in figures, Figure 5.28 and Figure 5.29.

The rail gun parameters such as peak current, current at exit,


muzzle velocity, peak acceleration, pulse width, and effective barrel length
are calculated for the two case study and the values are given in Table 5.7.

Table 5.7 Comparison of five stage capacitor bank configuration with


respect to firing time of capacitor bank module

Firing time of capacitor banks


Rail gun
S. Peak level time Before the peak After the Peak
parameters
No. of previous level time of level time of
values
bank) previous bank previous bank
1 Firing time of Bank1= 0.1 Bank1=0.1 Bank1=0.1
capacitor bank Bank2= 0.8 Bank2=0.4 Bank 2=1
(ms) Bank3=1.45 Bank3=0.6 Bank3=1.65
Bank4=2.25 Bank4=1 Bank4=2.45
Bank5 =3.0 Bank5 =1.2 Bank5=3.2
2 Current pulse 5 ms 5 ms 5 ms
width
188

Table 5.7 (Continued)

Firing time of capacitor banks


Rail gun
S. Peak level time Before the peak After the Peak
parameters
No. of previous level time of level time of
values
bank) previous bank previous bank
3 Peak current 214 kA 263 kA 204 kA
value
4 Time at Peak 3.2 ms 1.68 ms 3.7ms
current value
5 Peak 348 km/sec2 492 km/sec2 320 km/sec2
acceleration
6 Muzzle 900 m/s 1200 m/s 850 m/s
velocity
7. Effective 1.8 m 2m 1.5 m
barrel length
8. Exit current 142 kA 112 kA 150 kA

From the Table 5.7, it is observed that as the capacitor banks are
fired before the peak level of previous bank

1. The peak current value delivered to the load, peak


acceleration value of projectile, velocity of projectile and the
distance travelled by the projectile are increased.

2. The current at exit and the time at peak current values are
decreased.

It is also observed that as the capacitor are fired after the peak level
of previous bank

1. The peak current value delivered to the load, peak


acceleration value of the projectile, velocity of the projectile
and distance travelled by the projectile are decreased.
189

2. The current at exit and time at peak current values are


increased.

It is also observed that the 500kJ pulsed power supply can be able
to accelerate a projectile at a velocity of 1.2km/s, when the capacitor banks
are fired before reaching peak level current of previous bank. These
parameters can be chosen as optimized parameters of 500kJ pulsed power
supply.

5.11 OPTIMIZATOIN OF 500 kJ PULSED POWER SUPPLY


DESIGN USING MATLAB SIMULINK

PSPICE has large library of electrical linear and non linear


components. It has a user friendly interface. It is only necessary to draw an
electrical circuit. Current and voltage can be obtained at every node or mesh
in the circuit. However there are disadvantages. Details of the solver are not
known to the user. The limit on the circuit complexity is not known and it
takes a long time, to become acquainted with the code, especially with the
large library of component (Wey et al 1997). To overcome the drawback of
PSPICE simulator package, in this work MATLAB software is also used to
optimize the pulsed power supply for electromagnetic launcher application.
MATLAB is a high-level technical computing language and interactive
environment for algorithm development, data visualization, data analysis, and
numerical computation. Using MATLAB, technical computing problems can
be solved faster than with traditional programming languages, such as C,
C++, and FORTRAN.

In this work, the 500-kJ pulsed power supply system is designed


using MATLAB software to optimize the rail gun design parameters. The
electrical equivalent circuit of 500-kJ PPS system and rail gun model is drawn
190

in MATLAB and value of rail parameters such as the velocity, acceleration of


the projectile and effective barrel length of the rails have been calculated.

5.12 DESIGN OF 500-kJ CAPACITOR BASED PULSED POWER


SUPPLY

Figure 5.30 shows, the capacitor based pulsed power supply and
rail gun model designed using MATLAB simulation package. The system has
been divided into energy storage module, rail module and projectile module.
The energy source used in this design is capacitors. An energy storage module
consists of capacitors, spark gap, and a diode. The metalized self healing
capacitors, which are used in a 500-kJ PPS, have a capacitance of 2.3685mF
and 50kJ of energy, and a maximum peak voltage of 6500V D.C. Each
capacitor is capable of delivering a peak current of 30kA under normal
condition. The capacitors are divided into five groups each will have two
capacitors and they are connected in parallel. So the total capacitance in each
bank is 4.767mF and the total energy stored per bank is 100-kJ.

In the simulation, triggering circuit of a spark gap is modeled as a


switch. The opening condition and closing condition of the switches are
specified by using voltage level. The voltage level is specified with respect to
distance traveled by the projectile. The crowbar diode is represented by a
diode and an effective forward resistance. The pulse shaping inductor is
modeled as an inductance and a related conductor resistance and the output
cable is represented by its inductance and resistance. The variable inductance
of rails is represented by variable inductance element. In MATLAB
simulation the variable resistance of rails cannot be taken into consideration
as its value is low, when compared to the rail inductance.
Figure 5.30 Capacitor based pulsed power supply with rail gun load

191
192

5.12.1 Implementation of Variable Inductance in MATLAB Simulation

Figure 5.31 shows the equivalent circuit of variable inductance


which can be used to represent a variable inductance of rails in MATLAB
simulation.

1
Voltage Discrete time
measurement integrator
+ 1/C
- X v/L
+ ÷
+ L’ is variable -
+
D L'

2
2 Injected
inductance
D = Distance travelled by the projectile
current
L’ = inductance gradient of the rail = 1.096µH/m

Figure 5.31 Variable inductance used in MATLAB

This block allows the modeling of the variable inductance of the


rail, which is dependent on projectile location in the barrel. The variable
inductor block represents a linear time varying inductor. This block provides
two options for the relationship between the voltage v across the device and
the current through the device is i, when the inductance at port L is L , the
equation parameter determines which of the following equations the block
uses:

di dL
v L i (5.5)
dt dt

where v is the voltage across the inductor and L ' is inductance gradient of
the rails.
193

The current flowing through the inductor can be calculated using


the formula

1
i vdt (5.6)
L

In the variable inductance block shown in Figure 5.35, the voltage


across the inductor is measured between the terminal 1 and 2. The measured
voltage which appears across the inductor is integrated and then divided by
inductance gradient of the rails to measure the current through the inductor.
The inductance gradient of the rail is multiplied by the distance traveled by
the projectile, so the inductance gradient of the rail value changes with respect
to projectile position. Once the L’ value changes, automatically the current
flowing through inductor and the voltage across the terminal will change with
respect to time. Once the voltage across the terminals changes, automatically
the impedance across the terminals will change with respect to time.

5.12.2 Realization of Projectile Motion

The equations of motion for the projectile in the barrel can be


solved by defining a separate series circuit, using current source and two
electronic integrators as shown in the Figure 5.32. The total current delivered
by the energy source is squared and then multiplied by the inductance
gradient value of the rail. The resultant value is then divided by 1/2m to get
the projectile acceleration (a) and then the acceleration is integrated using
discrete time integrator to get velocity of the projectile (v). The obtained
velocity is then integrated once again using the discrete time integrator to get
the projectile position (d). The distance would be used, as if it was a B-dot
signal to make the switches turn on. In simulation instead of B dot probe,
relays are used to sense the distance traveled by projectile.
194

Acceleration Velocity
a v

Discrete Discrete
I |I2| L' X time time
÷ D
Current integrator integrator
Divide Distance

2m

m = Mass of the projectile


L’ = Inductance gradient

Figure 5.32 Equivalent circuit of projectile motion

5.12.3 Implementation of B Dot Probe in MATLAB Simulation

A B-dot probe is a closed wire that will generate a signal from an


induced voltage, based on Faraday’s Law

d
vind N (5.7)
dt

The induced voltage will come from change in magnetic flux


density generated when the magnetic field passing through the wire. The B-
dot probe is placed over the path of armature and the current will be flowing
parallel to the B-dot probe through the armature, causing a magnetic field to
circulate through the closed wire. The signal induced by a B-dot looks like a
negative sinusoid. As nearer to armature, the induced voltage will go
negative. When the armature is directly over the B-dot, the induced voltage
goes to zero because the magnetic field that goes through the loop twice,
canceling itself.
195

Finally, when the armature passes the B-dot probe, the induced
voltage will be positive (Bryan Mcdaniel 2006). In simulation instead of B
dot probe, relays are used to sense the distance traveled by projectile. The
relays send the signal to spark gap switch once the projectile reaches specified
distance. Under normal condition the output of the relay will be zero volts,
once the projectile reaches specified distance the output of relay become one
volt (High level). If the relay output becomes one, the switch which is
connected to the corresponding relay will be closed, so that the spark gap
switch which is connected to that corresponding switch will be triggered.

Timer
Charging

Bank 1 Timer

Bank 2 Distance

Relay 1

Bank 3

Relay 2
Bank 4
Relay 3

Bank 4

Relay 4

Figure 5.33 Electrical equivalent circuit of controller circuit

Figure 5.33 shows, the electrical equivalent of control circuit


designed using relays in MATLAB simulation. The charging block is used to
196

protect the power supply. Once the capacitors are charged to its rated voltage,
it will send the signal to all switches which are connected between capacitor
banks and source voltage, which results open the switches. Once the switches
from the source side opens, the relay will send signal to the spark gap switch
which is connected to first capacitor bank (see in Figure 5.33 bank1) and it
gets triggered, once the spark gap gets triggered the current will be flowing
through rails. Remaining capacitor banks spark gap switches are then
triggered by other relays with respect to projectile position. In this work, the
blocks, charging and Bank 1 shown in Figure 5.33 are used to send the signal
to the switches which are connected to them by using the timer block.

5.12.4 Optimization of 500kJ Pulsed Power Supply and Rail Gun


Design

The aim of this work is to design a 500-kJ pulsed power supply


which can be used to accelerate the projectile with a velocity of 1.0 to
1.5km/s. In order to get the desired velocity of projectile, First, proper value
of inductance gradient of the rails has to be selected, since the force acting on
the projectile is directly proportional to mass of the projectile and inductance
gradient of rail. The inductance gradient value depends on rail geometry. The
calculations of inductance gradient of rails for different rail geometry have
been discussed in chapter 3. In this work, the inductance gradient value is
chosen as 1.096µH/m.

For this L’ of the rails, the rail dimensions are as follows

Rail height = 1cm


Rail separation = 4cm
Rail width = 4mm
197

The electromagnetic rail gun requires flat shape of current pulse to


utilize the entire barrel length of the rails effectively. To utilize the entire
barrel length effectively the capacitor banks are fired at different time period.
Usually capacitor bank are triggered at peak current level of previous bank. In
this work, an attempt is made to fire the capacitor banks with respect distance
traveled by projectile in order to utilize the entire length of barrel effectively.
In order to get desired velocity of the projectile in this work, two parameters
such as B dot probe positions of the rails and mass of the projectile have been
considered in MATLAB. For various B dot positions such as

1. 5cm,10cm, 40cm, and 70cm

2. 5cm, 20cm, 30cm, and 60cm

3. 5 mm, 10cm, 15cm, and 25cm

4. 1mm, 5mm, 1cm, and 5cm, the rail gun parameters such as
peak current value, peak value of acceleration, muzzle
velocity and effective barrel length of the rails are calculated
for various mass of the projectile using MATLAB simulation.

In order optimize the entire system, first the pulsed power supply is
considered to get desired output current pulse. Initially the B dot positions and
mass of the projectile are assigned as 5cm, 10cm, 40cm, 70cm, and 25grams.
For these rail gun parameters the desired current pulse can be obtained by
varying the C and L of pulse forming network. Since the capacitance is
already selected, in this work, the pulse shaping inductance value is varied.
The pulse shaping inductance value is varied from 10µH onwards and the
output current is checked. Figure 5.34 shows the individual capacitor current
and the total load current delivered to the load, for the inductance value of
10µH, obtained from simulation.
198

Individual load current and total current (kA)


Total Current
C1 Current

C2 Current

C3 Current

C4Current
C5Current

Time (ms)

Figure 5.34Capacitor individual and total load current

From the figure, it is observed that the current delivered by each


capacitor bank is 120kA. It is more than that it’s rated value. In order to get
the rated value of capacitor bank, the pulse shaping inductance values are
increased gradually until the desired output current is obtained. Figure 5.35
shows the individual and total current delivered to load by PPS for the pulse
shaping inductance value of 45µH.
Individual load current and total current (kA)

Total Current
C1Current

C2Current

C3Current

C4Current

C5Current

Time (ms)

Figure 5.35 Capacitor individual and total load current


199

It is observed that each capacitor bank delivered 60kA current to


the load and the total current delivered to the load is 240kA. It is less than its
rated value. So this value can be considered as a pulse shaping inductance in
pulsed power design.

Relay 1

Relay 2
Voltage (V)

Relay 3

Relay 4

Time (ms)

Figure 5.36 Output pulse from the control circuit

Figure 5.36 shows the output pulse from the control circuit for the
B dot probe positions 5cm, 10cm, 40cm, and 70cm. It is observed that before
the projectile reaching projectile to the specified distance of B dot probe the
output of the relay is zero. Once the projectile reaches specified distance the
output of the relay becomes one.

Figure 5.37 shows the acceleration, velocity and distance traveled


by the projectile graphs obtained from simulation, for the B dot positions
5cm, 10cm, 40cm, 70cm, and 25 grams of projectile.
200

Acceleration (km/s2)

Time (ms)

(a) Acceleration of the projectile


Velocity (m/s)

Time (ms)

(b) Velocity of the projectile

Figure 5.37 (Continued)


201

Distance (m)

Time (ms)

(c) Distance travelled by the projectile

Figure 5.37 Acceleration, velocity, distance travelled by the projectile

From the Figure 5.37, it is observed that as the distance between the
B dot probes is high, the firing time between the capacitor banks is higher in
values. It is also observed that the peak acceleration value of the projectile is
1200km/sec2, velocity of the projectile is 2800m/s, and the distance travelled
by the projectile is 4m at 5ms, for the projectile mass of 25 grams. These
values are more than that objective of this thesis. In order to get the desired
values, distances between the B dot probe positions are gradually varied and
muzzle velocity, effective barrel length are calculated. Figure 5.38 shows the
capacitor individual and total load current for the B dot probe positions 1mm,
5mm, 1cm, 5cm and 75 grams of projectile. From the figure, it is observed
that the current delivered by each capacitor bank and the peak current
delivered to the load is less than that it is rated value.
202

Individual load current and Total Current

C1Current
Total load current (kA)

C2 Current
C3 Current
C4 Current

C5 Current

Time (ms)

Figure 5.38 Capacitor individual and total load current

Figure 5.39 shows the acceleration, velocity and distance traveled


by the projectile graphs obtained from simulation, for the B dot probe
positions 1mm, mm, 1cm, 5cm, and 75 grams of projectile. It is observed that
the peak acceleration value is 520km/sec2, velocity of the projectile is
1250m/s, and the distance travelled by the projectile is 2m at 5ms, for the
projectile mass of 75 grams.
Acceleration (km/s2)

Time (ms)
(a) Acceleration of the projectile
203

Figure 5.39 (Continued)


Velocity (m/s)

Time (ms)

(b) Velocity of the projectile


Distance (m)

Time (ms)

(c) Distance travelled by the projectile


204

Figure 5.39 Acceleration, velocity, distance travelled by the projectile

For various B dot positions such as

1. 5cm,10cm, 40cm, and 70cm

2. 5cm, 20cm, 30cm, and 60cm

3. 5mm,10cm,15cm, and 25cm

4. 1mm, 5mm, 1cm, and 5cm, and various mass of the projectile
the rail gun parameters such as peak current, time at peak
current value, muzzle velocity and effective barrel length of
rails are calculated and given in Table 5.8.

From the above table it is observed that

The peak current value, peak acceleration of projectile, muzzle


velocity of the projectile and effective barrel length of rails
decreases with increase in value of mass of the projectile.

The peak current value, peak acceleration of the projectile,


muzzle velocity of the projectile, and effective barrel length of
rails increases with decrease in values of B dot probe positions.

The time at peak current value increases with increase in value


of mass of the projectile.

The time at peak current value decreases with decreases in


values of B dot probe positions.
205

Table 5.8 Rail gun parameters for different B dot probe positions

Effective Time at
Peak Muzzle
S. Weight Peak barrel peak
Position acceleration Velocity
No (grams) current(kA) length current
(km/s2) (m/s)
(m)
(a) Rail gun parameters for the B dot positions 5cm,10cm, 40cm,70cm
1 25 236 1200 2700 4 4ms
2 50 215 510 1000 1.5 5.2ms
1
3 75 200 290 600 1.2 6.3ms
4 100 188 196 500 1 7.5ms
(b) Rail gun parameters for the B dot positions 5cm, 20cm, 30cm, and 60cm
1 25 240 1250 2500 3.3 4ms
2 50 220 530 1100 1.6 5.2ms
2
3 75 205 357 750 1.3 6.5ms
4 100 193 205 550 1.0 7.5
(c) Rail gun parameters for the B dot positions 5mm, 10cm, 15cm, and 25cm
1 25 247 1340 3350 5 3.3ms
2 50 230 580 1600 2.5 4.2ms
3
3 75 217 340 600 0.8 5.0ms
4 100 206 235 400 0.6 5.8ms
(d) Rail gun parameters for the B dot positions 1mm, 5mm, 1cm, 5cm
1 25 288 1800 5000 11 1.8ms
2 50 280 860 2800 5 2ms
4
3 75 250 520 1250 2 2.2ms
4 100 260 342 1050 1.5 2.5

From the Table 5.8, it is inferred that for the B dot probe positions
1mm, 5mm, 1cm, and 5cm, and 75 grams of projectile, the PPS can be able to
accelerate the projectile with a velocity of about 1.25km/s. These parameters
have been selected as an optimized parameters for 500- kJ pulsed power
supply and the optimized values are given in Table 5.9.
206

Table 5.9 Optimized parameters of pulsed power supply

Effective
Charging No of Cap. No of capacitor per
barrel
voltage= 6.5kV Banks= 5 bank = 2.
length=2 m
Inductance of the Individual Muzzle -
capacitor Banks = capacitor Velocity =
45µH Value= 1250 m/s
2.3685mF
B dot probe Mass of the Max. Peak acceleration
position projectile = Current= 250 value= 520 km/s2
1mm,5mm,1cm, 75 grams kA
5cm
Rail separation Rail width Rail height Inductance gradient =
=4cm = 4mm = 1cm 1.096µH/m
(simulation)

5.12.5 Observations made in PSPICE and MATLAB Simulation

In order to design a 500 kJ pulsed power supply to accelerate the


projectile at a velocity of 1km/s to 1.5km/s, this work PSPICE and MATLAB
simulation packages have been used. In PSPICE simulation the capacitor
banks were fired before the peak current level of previous bank and in
MATLAB the capacitor banks were fired with respect to distance traveled by
the projectile. The peak current value, the time at which the peak current
occurs, velocity and distance travelled by the projectile has been calculated
using the PSPICE and MATLAB software and the value are given Table 5.10.
From the table it is observed that the optimization values obtained
using PSPICE and MATALAB are having a slight difference between the
results.
207

Table 5.10 Comparison between PSPICE and MATLAB

Method of firing
Rail gun Before reaching to
B dot probe
parameters peak current level of
Positions
previous
1 Bank1=0.1 ms Probe1-1mm
Bank2=0.4ms Probe 2-5mm
Bank3=0.6ms Probe 3-1cm
Bank4=1ms Probe 4-5cm
Bank5 =1.2ms
2 Current pulse width 5ms 5ms
3 Peak current value 263 kA 250 kA
4 Time at Peak current 1.68 ms 2.2ms
value
6 Muzzle velocity 1200m/s 1250m/s
7. Effective barrel 2m 2m
length

5.13 VOLUME AND WEIGHT CALCULATION OF 500kJ AND


4 MJ PULSED POWER SUPPLY SYSTEMS

As the Government of India is going to install the 4- MJ pulsed


power supply system in a compact space, hence they need the weight and
volume occupied by the pulsed power supply system. In this work, an attempt
is made to give the approximate weight and volume occupied by the 500-kJ
and4-MJ pulsed power supply systems.

The weight and volume occupied by the 500kJ and 4MJ, pulsed
power supply systems are calculated and given in Table 5.11 and Table 5.12.
208

Table 5.11 Volume and weight calculation of 500kJ pulsed power system

No. of
Components Volume
components Weight (kg)
Used (m3)
required
Capacitor 10 0.169 300
Fuse 50 0.0172 100
Diode 30 0.158 150
Spark gap 5 0.182 50
Inductance 5 0.022 20
20% of total volume 0.1204 -
allotted for other
component
Total 0.6686 620

Table 5.12 Volume and weight calculation of 4MJ Pulsed power supply

Components No. of components Volume


Weight (kg)
Used required (m3)
Capacitor 80 1.352 2400
Fuse 400 0.1376 800
Diode 240 1.264 1200
Spark gap 40 1.456 400
Inductance 40 0.176 80
20% of total volume 0.963 -
allotted for other
component
Total 5.1726 4880

From the Table 5.11 and Table 5.12, it is observed that the 500-kJ
pulsed power supply needs 0.6686 m3 of volume with a total weight of
620 kg and the 4-MJ pulsed power supply needs 5.1726 m3 of volume with a
total weight of 4880kg. In the total weight of PPS calculation, the weights of
209

the other components are not considered. The volume occupied by the
inductor and its weight have been calculated using inductor calculator
software (www.Olinbrass.com and www. gsu.edu).

5.14 SUMMARY

In this chapter, using PSPICE and MATLAB simulation packages


the 500-kJ pulsed power supply system that can be used in electromagnetic
rail gun system has been designed. In PSPICE simulation, trade off study has
been made to find the optimum number of capacitor stages to get desired
current pulse shape and rail parameters. In order to identify optimum solution
for 500-kJ PPS, in this work different types of capacitor connection have been
studied. Capacitors have been grouped into single, double, triple and five
stages. For each capacitor connection pulse shaping inductance value, peak
current value, current at exit, muzzle velocity, peak acceleration value , pulse
width, effective barrel length of the rails have been calculated. It has been
observed that an increase in number of stages in a capacitor bank module
causes an increase in value of pulse width time, muzzle velocity of projectile,
the time at peak current value, effective barrel length of the rails, current at
exit and decrease in value of peak current and peak acceleration. It has been
concluded that the 500kJ pulsed power supply can be able to accelerate a
projectile at a velocity of 1.2km/s, when the capacitor banks are fired before
reaching peak level current of previous bank. In MATLAB simulation the
optimization of pulsed power supply have been done by varying the mass of
the projectile and positions of the B dot probe. For various B dot probe
positions the rail gun parameters have been calculated and then by using these
values optimized parameters of 500kJ pulsed power supply have been
derived. It has been conclude that, the 75 grams of projectile can be able to
accelerate at a velocity of about 1.25km/s, for B the dot probe positions 1mm,
5mm, 1cm, and 5cm. As the government of India is going to be installed the
210

4- MJ pulsed power supply in a compact space, hence, they needed the weight
and volume occupied by the pulsed power supply. The work has also been
carried out to calculate the approximate weight and volume occupied by the
pulsed power supply using the manufactured data’s. It has been concluded
that the 500-kJ pulsed power supply needed 0.6686 m3 of volume with a total
weight of 620kg and the 4-MJ pulsed power supply needed 5.1726m3of
volume with a total weight of 4880kg.

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