Working with high voltage is like working with high pressure plumbing. You can spring a leak in your plumbing, and of course you fix it. And now that you’ve fixed that leak, you’re able to increase the pressure still more, and sometimes another leak occurs. I’ve had these same experiences but with high voltage wiring. At a high enough voltage, around 30kV or higher, the leak manifests itself as a hissing sound and a corona that appears as a bluish glow of excited ions spraying from the leak. Try to dial up the voltage and the hiss turns into a shriek.
Why do leaks occur in high voltage? I’ve found that the best way to visualize the reason is by visualizing electric fields. Electric fields exist between positive and negative charges and can be pictured as electric field lines (illustrated below on the left.) The denser the electric field lines, the stronger the electric field.
Weak and strong electric fields
Ionization in electric fields
The stronger electric fields are where ionization of the air occurs. As illustrated in the “collision” example on the right above, ionization can happen by a negatively charged electron leaving the electrically conductive surface, which can be a wire or a part of the device, and colliding with a nearby neutral atom turning it into an ion. The collision can result in the electron attaching to the atom, turning the atom into a negatively charged ion, or the collision can knock another electron from the atom, turning the atom into a positively charged ion. In the “stripping off” example illustrated above, the strong electric field can affect things more directly by stripping an electron from the neutral atom, again turning it into a positive ion. And there are other effects as well such as electron avalanches and the photoelectric effect.
In either case, we wanted to keep those electrons in the electrically conductive wires or other surfaces and their loss constitutes a leak in a very real way.
In high voltage applications involving tens of thousands of volts, too often people think about the high voltage needed but don’t consider the current. This is especially so when part of the circuit that the charge travels through is an air gap, and the charge is in the form of ions. That’s a far cry from electrons flowing in copper wire or moving through resistors.
Consider the lifter. The lifter is a fun, lightweight flying machine. It consists of a thin wire and an aluminum foil skirt separated by an air gap. Apply 25kV volts across that air gap and it lifts into the air.
Lifter flying with high voltage power supply
So you’d think that the small handheld Van de Graaff generator pictured below, that’s capable of 80kV, could power the lifter. However, like many high voltage applications, the lifter works by ionizing air, in this case ionizing air surrounding the thin wire resulting in a bluish corona. That sets off a chain of events that produces a downward flowing jet of air, commonly called ion wind, lifting the lifter upward.
Having hacked away with high voltage for many years I’ve ended up using a large number of very different high voltage sources. I say sources and not power supplies because I’ve even powered a corona motor by rubbing a PVC pipe with a cotton cloth, making use of the triboelectric effect. But while the voltage from that is high, the current is too low for producing the necessary ion wind to make a lifter fly up off a tabletop. For that I use a flyback transformer and Cockcroft-Walton voltage multiplier power supply that’s plugged into a wall socket.
So yes, I have an unorthodox skillset when it comes to sourcing high voltage. It’s time I sat down and listed most of the power sources I’ve used over the years, including a bit about how they work, what their output is like and what they can be used for, as well as some idea of cost or ease of making. The order is from least powerful to most powerful so keep reading for the ones that really bite.
You’ve no doubt encountered this effect. It’s how your body is charged when you rub your feet on carpet and then get a shock from touching a door knob. When you rub two specific materials together there’s a transfer of electrons from one to the other. Not just any two materials will work. To find out which materials are good to use, have a look at a triboelectric series table.
Materials that are on the positive end of the table will become positively charged when rubbed against materials on the negative end of the table. Those materials will become negatively charged. The further apart they are in the table, the stronger the charging.
A few weeks ago, we took a look at the best badge hacks at the Hackaday Supercon. These were the best badge hacks anyone has ever seen – including what comes out of DEF CON and the SDR badge from the latest CCC. I’m ascribing this entirely to the free-form nature of the badge; give people a blank canvas and you’re sure to get a diverse field of builds. Now it’s time to take a look at the cream of the crop, hear what the jolly wrencher sounds like, and how to put 1000 Volts in a badge.
There were three categories for the badge hacking competition at the SuperCon – best deadbug, best blinky, and most over the top. A surprising number of people managed to solder, glue, and tape some components to a the piece of FR4 we used as a conference badge, but in the end, only three would win.
If you’ve already dipped your toes into high-voltage power supply pool you may be thirsty for a bit more knowledge. Here’s a neat illustration of how to build a voltage multiplier that can output a positive or negative supply. It is based on a design known as the Cockroft-Walton Multiplier. It’s the add-on housed in the plastic box seen in the image above. It uses diodes and capacitors in an orientation very common for generating high voltages. In fact, the same thing can be found in that high-voltage bulletin board. The place this differs is when it comes to connecting the multiplier to the PSU.
If you look closely you can see one red and one black banana plug jack poking out the end of the plastic container. There is also a pair of these on the other end. The multiplier has been designed so that reconfiguring the inputs and outputs changes how it works. Each jack has been labeled with one possible input and one output. Choose the desired output (DC+ or DC-) and then follow the labels for the rest of the connections.
What can you do with this setup? Check out the clip after the break that shows it powering a lifter.