Umair Gaines
Railguns are devices that use electric current to accelerate objects along a pair of rails. They can be made at home with simple materials, such as copper wire, cardboard, magnets, and batteries, or with more advanced equipment, such as capacitors, voltmeters, and aluminium rails. The basic principle behind a railgun is that it uses an electric current to create a magnetic field, which propels projectiles made from conductive materials. The more current that is pumped through the system, the more powerful the magnetic field and the faster the projectile will travel.
| Characteristics | Values |
|---|---|
| Projectile | Aluminium |
| Rails | Aluminium |
| Voltage | 0-390V DC |
| Power Source | 12V battery |
| Capacitors | 15.6mF |
| Velocity | 120fps |
| Rail Material | 6x20mm aluminium |
| Rail Separation | 6mm |
| Wire Material | Copper |
| Wire Gauge | 25mm |
| Magnetic Field | At right angles to the magnetic field of the railgun trolley's wheels |
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What You'll Learn
Sourcing materials
Firstly, you will need to decide on the type of railgun you want to build. There are two main types: coil guns and railguns. Coil guns use magnetic projectiles and rely on magnetic propulsion, while railguns use direct current that runs from one rail, through the projectile, and to the other.
For the power source, you can use either a DC power supply or a battery. Zebralemur, a DIY railgun builder, used fifty-six 400-volt, 6000-microfarad caps charged by a bunch of 9V batteries stuck end to end. You can also consider building your own solar battery or hydrogen fuel cell.
The rails themselves can be made from aluminium or copper. Aluminium rails are mentioned in several sources, and Zebralemur's railgun used copper bars. Copper wire is also needed to connect the power source to the rails. The wire should be thick, around 25mm, and can be glued in place with super glue.
You will also need a projectile. Aluminium projectiles are mentioned in several sources, but you could also use a non-magnetic projectile if you are building a coil gun.
Other materials include a voltmeter to measure voltage, a PVC pressure chamber with a ball valve, a foot pump with a PSI gauge, a light bulb, switches, a camera, and a power supply.
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Building the structure
Materials and Components:
Firstly, gather all the necessary materials and components. These include copper or aluminium wires for the rails, a sturdy non-conductive material like wood or plastic for the base, a power supply such as a battery or capacitors, magnets, electrical tape, super glue, and a projectile.
Rail Construction:
Cut two strips of copper or aluminium wire to a length of 2 feet each, ensuring they are straight and free of bends. These will serve as your rails and need to be smooth and straight to allow the projectile to move smoothly. Prepare a base by cutting a sturdy meter stick from your chosen non-conductive material, ensuring it is long enough to accommodate the rails.
Magnetic Assembly:
Place two stacks of magnets on the base, with the magnets in each stack facing the same direction. Use super glue to secure the magnets and then wrap them with electrical tape for added security. Repeat this process until the row of magnets reaches the length of your rails. Ensure that the magnets are aligned correctly, as they will repel or attract each other depending on their orientation.
Rail Attachment:
Attach the rails securely to the base, positioning them directly above the magnets. Ensure that the rails are parallel to each other and that there is a smooth transition between the base and the rails to allow for uninterrupted projectile movement. You may need to sand the rails lightly to achieve a smooth finish.
Projectile Path:
Use non-conductive props, such as rulers or cardboard, to support the rails and create a path for the projectile. The projectile should fit snugly inside the barrel, with a close tolerance to prevent deviation from the intended path. Attach alligator clips to each end of the rails, ensuring they do not obstruct the projectile's path.
Power Source:
Connect your power source, such as a battery or capacitor bank, to the rails. If using a battery, pay attention to its polarity, as reversing it can change the direction of the projectile's movement. Capacitors can be charged using a step-up converter, and a voltmeter can be used to monitor the charge and ensure safe operation.
Remember to exercise extreme caution when building and operating an electric rail gun, as they can be very dangerous if mishandled.
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Wiring the circuit
First, you will need to gather the necessary materials and tools. These include a power supply, such as a battery or a capacitor bank, wires, conductive rails (usually made of aluminium or copper), a projectile, switches, a voltmeter, and other electrical components. Ensure that you have a clear understanding of the components and their functions before proceeding.
Next, prepare the rails and wires. Cut the wires to the appropriate length, allowing for some extra length to facilitate connections. The rails should be made of a conductive material, such as aluminium or copper, and be smooth and straight. Sand the rails if necessary to ensure a smooth transition between different materials, such as from Perspex to aluminium.
Now, it's time to attach the wires to the rails. Use alligator clips or other suitable connectors to attach the wires securely to the ends of the rails. Ensure that the connections are firm and that the wires are not bent or damaged. You may also need to attach additional wires or lugs to connect the rails to the power supply and other components.
After that, set up the power supply. If you are using a battery, connect it to the circuit, paying attention to the polarity. If you are using a capacitor bank, connect it to a DC power supply to charge the capacitors. Use a voltmeter to monitor the voltage across the capacitors and ensure they are charged to the desired level. A step-up converter may be necessary to achieve the required voltage.
Once the power supply is ready, you can connect the switches and any additional safety components. For example, a second switch may be included to discharge the capacitors through a resistor in case of a misfire, preventing dangerous voltage buildup. Ensure that all connections are secure and that the circuit can be safely controlled.
Finally, test the circuit. Before introducing the projectile, test the circuit by energizing it and ensuring that current flows as expected. You may need to adjust connections or component positions to optimize performance. Remember to prioritize safety and always be cautious when working with high-power electrical systems.
Building an electric rail gun circuit requires careful planning, a solid understanding of electrical principles, and strict adherence to safety protocols. It is important to recognize the risks associated with high-voltage circuits and projectiles and to take the necessary precautions to ensure a safe operating environment.
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Testing the gun
The first test can be a basic functionality test. Set up a camera to record at 120fps to capture the movement of the projectile. Ensure the projectile is in position, the capacitors are charged, and the pressure chamber is set to 20 psi. Then, open the ball valve to allow air to flow into the rail gun, pushing the projectile forward. Observe whether the projectile moves as intended, completing the circuit and discharging the capacitors.
Next, measure the velocity of the projectile. Place a board with lines of masking tape in 10cm increments in the path of the projectile. Review the high-speed footage to determine the velocity by observing the distance travelled by the projectile in the footage.
It is also important to test the safety mechanisms. For this test, intentionally create a misfire by interrupting the circuit before firing, causing the capacitors to charge to a dangerous voltage. Then, activate the safety mechanism by pressing switch 2 to discharge the capacitors safely through a bleeder resistor (lightbulb 2).
Finally, repeat the tests with variations in power supply and projectile weight to observe the impact on velocity and range. For example, you can increase the power supply and observe whether the rails are destroyed during firing due to arcing and flexing, as well as measure the increased velocity and range. Similarly, adjust the weight of the projectile by using a larger ferrite bead and observe the impact on velocity and range.
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Improving the design
To improve the design of a rail gun, several factors need to be considered.
Firstly, the choice of materials is critical. Copper wire is a good choice due to its high electrical conductivity, as seen in Zebralemur's DIY railgun, which used copper wire and aluminium projectiles. Aluminium rails can also be used, but they need to be smooth and have a close tolerance to the projectile to ensure a good fit. The use of non-conductive materials, such as wood or plastic, for certain components is also important to prevent short circuits.
Secondly, the design of the rails themselves is crucial. High-power railguns often use square-shaped rails for easier reinforcement, with steel and grade 8 bolts for added strength. The transition between different rail materials, such as from Perspex to aluminium, should be smooth to ensure the projectile moves smoothly.
Thirdly, the power source and capacitors play a significant role in performance. A higher voltage power supply, such as a 400V DC step-up converter, can increase the energy stored in the capacitors, resulting in greater projectile velocity. However, safety precautions, such as a voltmeter, are essential when working with high-voltage systems to prevent overcharging and accidental discharges.
Additionally, the use of an air injection system can help prevent spot-welding of the projectile to the rails by ensuring the projectile has some initial velocity before making contact with the rails.
Lastly, the design of the projectile itself can be improved. While railguns typically use magnetic projectiles, non-magnetic projectiles can also be used if an opposing magnetic field is induced in the projectile. This can be achieved through "induction trickery" or by using eddy currents, which Zebralemur employed in their railgun design.
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Frequently asked questions
A rail gun is a device that uses electric current to create a magnetic field to accelerate and shoot projectiles made from conductive materials.
You will need a power source, such as a battery, wires, rails made of a conductive material like copper, a projectile, and a way to measure voltage, like a voltmeter.
First, cut two strips of wire to be used as rails. Place the rails parallel to each other and attach the power source to one end of each rail. The projectile should be placed between the rails, and the wires from the power source should be connected to the projectile.
Turn on the power source to begin charging the rails with electric current. Once the desired voltage is reached, activate the projectile by completing the circuit. This will create a magnetic field that propels the projectile forward.
