one of two inductors I designed and wound. molypermalloy powder toroidal core
the 0.003" copper foil and mylar primary and secondary windings for the high frequency isolation transformer (over 60 ft. of copper!)
soldering flat leads onto the ends of the transformer windings
beginning winding the transformer copper and mylar sandwich onto transformer bobbin
completing the transformer winding
completed transformer windings with core (minus metal clamp)
failure of prototype transformer driver (full bridge converter)
PFC PC board, designed by me, manufactured by Advanced Circuits
one of three custom heatsinks I machined from salvaged stock
all three heatsinks (the other two are for the bridge board transistors and diodes)
completed PFC stage, before testing
left to right on heatsink are: thermistor, MOSFET, diode, and diode snubber resistor (later removed from circuit)
me after a successful PFC board test day in the lab!
PFC stage manual capacitor precharge and IC enable controls (for testing)
120Hz PWM for PFC (a somewhat bizzare scope capture, since the FET is switching at 100 kHz and we're in the ms's here, but it looks cool)
testing the bridge converter, with some copper foil for noise reduction around the IC (unnecessary once we implemented zero voltage "soft" switching)
first test with both power converters running together - success! the microprocessor board is monitoring, but not controlling, the system for this test
ben (right) and I (left) after a successful, nervewracking test
the graveyard