A compact multi-wire-layered secondary winding for Tesla transformer.

A compact multi-wire-layered (MWL) secondary winding for a Tesla transformer is put forward. The basic principle of this winding is to wind the metal wire on a polymeric base tube in a multi-layer manner. The tube is tapered and has high electrical strength and high mechanical strength. Concentric-circle grooves perpendicular to the axis of the tube are carved on the surface of the tube to wind the wire. The width of the groove is basically equal to the diameter of the wire so that the metal wire can be fixed in the groove without glue. The depth of the groove is n times of the diameter of the wire to realize the n-layer winding manner. All the concentric-circle grooves are connected via a spiral groove on the surface of the tube to let the wire go through. Compared with the traditional one-wire-layered (OWL) secondary winding for the Tesla transformer, the most conspicuous advantage of the MWL secondary winding is that the latter is compact with only a length of 2/n of the OWL. In addition, the MWL winding has the following advantages: high electrical strength since voids are precluded from the surface of the winding, high mechanical strength because polymer is used as the material of the base tube, and reliable fixation in the Tesla transformer as special mechanical connections are designed. A 2000-turn MWL secondary winding is fabricated with a winding layer of 3 and a total length of 1.0 m. Experiments to test the performance of this winding on a Tesla-type pulse generator are conducted. The results show that this winding can boost the voltage to 1 MV at a repetition rate of 50 Hz reliably for a lifetime longer than 10 pulses, which proves the feasibility of the MWL secondary winding.