New SSD Testbench #2 – Steel Clamp-Brackets Received

Hello, dear friend Ufopolitics,

I am pleased to inform you that today I received the new steel clamp-brackets required for building our completely separate SSD Testbench #2.
As you can see in the attached photograph, the brackets are now positioned on the laminated CRNO steel core, which has actual cross-sectional dimensions of 25.8 × 25.8 mm.

These brackets will be used to construct the new testbench with the corrected 1–1–1 coil configuration (Q1–Q3–Q2) and the shortened Main Secondary Center Coil.
The new Main Secondary bobbin has an overall length of 86 mm, with an active winding length of 76 mm, covering only the three central Q-coils.

The intended arrangement will be:
FC1 – Left Inner Steel Plate – Q1 – Q3 – Q2 – Right Inner Steel Plate – FC2
FC1 and FC2 will function exclusively as induced secondary output coils, without any external power supply.

We are planning to use your recommended AWG18 enamelled copper wire for the shortened Main Secondary winding.
Our existing Testbench #1 will remain completely intact as a reference, allowing us to compare its experimental results with those obtained from the new configuration.

This is another important step forward in preparing the new experimental setup.
I have attached a photograph showing the newly received steel clamp-brackets and the laminated square core.



I will keep you informed as construction progresses.

Best regards,
Alex / Kampen

Hello dear friend @kampen ,

That setup looks awesome!

Great you have the Main Center Secondary with 18 gauge!

And what about FC1 & FC2?
What are their gauge?
Because originally you had them on 23ga,
While all 3 Q Coils were 28ga?
Can you clear this spec's?
Prior I suggested to also make FC coils with 18 ga as well...but I don't know if you are going to test them on this Test Bench 2...

I am eagerly waiting for this test!

Regards and thanks again for all your time plus investments on this project!

Ufopolitics

Re: Message #951 – SSD Testbench 2 Coil Winding Specifications

Hello, dear friend Ufopolitics,

Thank you very much for your encouraging comments and your continued interest in our new SSD Testbench 2!
I am pleased that you like the new mechanical arrangement. We are making steady progress with the construction.

Let me clarify the winding specifications of our existing coils and the planned new windings.
1. Q1, Q3 and Q2 – Primary Coils
You are correct. Our existing Q-coils were wound with:

• Wire: AWG28 enamelled copper wire
• Resistance: Approximately 8 ohms per coil
• Configuration: Three individual coils, Q1 – Q3 – Q2

We intend to retain these coils for the initial experiments on Testbench 2.

2. Main Secondary Center Coil
For the new shortened Main Secondary Center Coil, we have selected your recommended AWG18 enamelled copper wire.
The new bobbin has the following dimensions:

• Overall length: 86 mm
• Active winding length: 76 mm
• Core opening: 26 × 26 mm

The Main Secondary bobbin is mounted directly over our 25.8 × 25.8 mm laminated CRNO steel core, with Q1, Q3, and Q2 sliding over the Main Secondary winding assembly.
This means the Main Secondary will cover only the three central Q-coils, as you recommended.

3. FC1 and FC2 – Feedback Secondary Coils
Regarding FC1 and FC2, our existing coils have approximately 8 ohms of resistance each.
The original winding specifications need to be distinguished from the new coils you proposed. I will verify the exact wire gauge of the existing FC windings with Guido before confirming it definitively.
We have certainly not forgotten your earlier recommendation to manufacture an additional pair of FC1 and FC2 coils using AWG18 enamelled copper wire.
I consider this a very useful experiment.

My proposal is to begin with the existing FC coils as a reference and subsequently compare their output with a newly wound AWG18 pair.
This would allow us to investigate the influence of wire diameter, winding resistance, number of turns, and coil geometry on the induced output voltage and delivered power.
As you emphasized previously, we will also aim to keep the axial winding length of the new FC coils as short as practically possible.

4. Our proposed testing sequence
Once Testbench 2 is ready, we intend to proceed systematically:

• Test the new AWG18 Main Secondary with Q1, Q3 and Q2.
• Measure the individual outputs of the existing FC1 and FC2 coils.
• Test FC1 and FC2 connected in series, after checking their induced voltage polarities.
• Prepare and test an additional AWG18 FC1/FC2 pair for comparison.

We will record the actual input power, output voltages, load currents, and waveforms so that the different winding configurations can be compared under controlled conditions.
Our original Testbench 1 will remain intact as a reference.

Dear Ufopolitics, thank you again for your patience, technical guidance, and encouragement.
We appreciate your support and look forward to sharing the first experimental results from the new SSD Testbench 2.

Best regards,
Alex / Kampen

SSD TESTBENCH #2 – UPDATED COIL WINDING SPECIFICATIONS AND NEW CONSTRUCTION

Hello, dear friend Ufopolitics, and hello to all forum members!

I would like to share another update on the development of our new SSD Testbench #2, together with the latest 3D rendering showing the intended coil arrangement, wire gauges and resistance values.

As previously explained, we have decided to construct a completely separate second testbench rather than dismantling our existing experimental setup. This will allow us to compare both configurations under controlled testing conditions.

1. NEW COIL CONFIGURATION
The intended arrangement, from left to right, is:
FC1 – Left Inner Steel Plate – Q1 – Q3 – Q2 – Right Inner Steel Plate – FC2
The shortened Main Secondary Center Coil will be mounted directly on the square laminated CRNO steel core.
The three primary coils, Q1, Q3 and Q2, will slide over this Main Secondary winding assembly.
FC1 and FC2 will be positioned outside the two inner steel plates and will function exclusively as induced secondary output coils.

2. UPDATED WINDING SPECIFICATIONS
The latest rendering shows the following specifications:

Coil	Copper Wire	Resistance
Q1 – Pulsed Primary	AWG28	Approx. 8.0 Ω
Q3 – Constant DC Bias	AWG28	Approx. 8.0 Ω
Q2 – Pulsed Primary	AWG28	Approx. 8.0 Ω
Main Secondary Center	AWG18	Estimated 0.95 Ω
FC1 – Secondary Output	AWG18	To be measured
FC2 – Secondary Output	AWG18	To be measured

The existing Q-coils have already been manufactured and measured at approximately 8 Ω each.
Following Ufopolitics' recommendations, we have selected AWG18 enamelled copper wire for the shortened Main Secondary and the new FC1 and FC2 coils.

Please note that the AWG18 Main Secondary resistance is presently an estimate, not a confirmed measurement.

The new AWG18 FC coils will also require their own winding calculations and resistance measurements.
The approximately 8 Ω values shown for FC1 and FC2 in the rendering refer to our earlier coils and should not be interpreted as verified resistance values for the new AWG18 versions.

3. SHORTENED MAIN SECONDARY CENTER BOBBIN
The new Main Secondary bobbin has the following dimensions:

• Overall length: 86 mm
• Active winding length: 76 mm
• Square core opening: 26 × 26 mm
• Actual laminated CRNO steel core: 25.8 × 25.8 mm

The shortened Main Secondary is intended to cover only the central Q1–Q3–Q2 group, without extending into the FC1 and FC2 sections.

4. NEW AWG18 FEEDBACK COILS
As suggested by Ufopolitics, we intend to manufacture FC1 and FC2 with AWG18 copper wire.
These new secondary coils will be designed with a relatively short axial winding length, while making use of the available winding height.
We want to investigate how the thicker wire, different number of turns, and lower winding resistance influence the induced voltage and output power under load.

The final number of turns and resistance values will be established during winding and verified by measurement.

5. PLANNED EXPERIMENTAL TESTS
Once Testbench #2 is completed, we intend to investigate:

• Individual FC1 and FC2 open-circuit voltages and loaded output power.
• FC1 and FC2 connected in series, with verified winding polarity.
• Output from the shortened AWG18 Main Secondary.
• Magnetic field distribution and the influence of Q3 constant DC bias.
• Performance at different switching frequencies, including 60 Hz and 120 Hz.
• Total electrical input power compared with the measured output power from all secondary circuits.

We will record the actual current waveforms, voltage waveforms, and resistive load conditions wherever possible.
Our objective is to establish reproducible experimental results and compare them with the measurements already obtained from Testbench #1.

6. CURRENT CONSTRUCTION STATUS
The new steel clamp-brackets have arrived, and the shortened Main Secondary bobbin design is available.
The attached 3D rendering (see below) illustrates the intended final configuration and winding specifications. 



It should be regarded as a construction concept rendering rather than a photograph of a fully completed and electrically tested assembly.

Dear Ufopolitics,
Thank you again for your valuable recommendations concerning the AWG18 Main Secondary and feedback coils.
We appreciate your continued guidance and encouragement.
I will keep you informed about the winding progress, final measured coil specifications, and subsequent experimental results.

Best regards,
Alex / Kampen