Zeusaphone: Musical Tesla Coil

Team: Andrew Wada

Project

  • Tesla coils use extremely high voltages to produce electric arcs.
  • By modulating these arcs using a musical frequency or signal, it is possible to form recognizable audio using these discharges as a medium
  • The goal of the Musical Tesla Coil is to use CMOS electronics, in conjunction with fast switching MOSFETs, to produce music from a control line, such as an AUX cable.
  • Why build this?
    • This device will be a unique medium for simultaneous production of music, as well as visuals to go along with it.
    • Requires full systems engineering perspective to design and integrate a full hardware stack
    • Adds an interesting flair to any music played on it.

System

System diagram

Methods

  • Design:
    • The Musical Tesla Coil uses a high speed analog comparator, PLL system, Teensy 4.0 microcontroller, and custom power stage to process an analog audio signal and modulate it onto a high frequency carrier wave to keep a tesla coil in resonance.
    • A phase lock loop(PLL) is used with a feedback pickup to keep the drive signal within the tesla coil’s resonant range.
    • 3.5mm AUX cable used for audio input to improve compatibility with audio sources.
    • Custom rectifier stage for high power delivery at up to 180VDC.
    • Isolated and non-isolated electrical buses to reduce costs while maintaining user safety
  • Software:
    • Minimal software overhead
    • Teensy 4.0 applies PWM to drive signal to allow for duty cycle adjustment

Conclusion

  • Square wave low-frequency RF modulation to drive a solid state tesla coil with audio frequency pulses.
  • Power electronics, RF design, and Systems Engineering principles combined to drive high-power audio/visual display
  • Future steps:
    • Dedicated PCB for quicker manufacture
    • Emergency stop button
    • Current monitoring safety system
    • Multiple channel audio
    • Multiple volume levels