I guess the balancing starts with the ratio of Copper to Iron when designing the motor?Thud wrote: It really is a ballancing act of copper & magnets & ellectricity after all is said & done.
I found this:Jeremy Harris wrote:If silicone will do the job then that has to be the best option, as at least you could still get the motor apart again if you had to. It's probably well worth doing so research to see how effective it might be.
Jeremy Harris wrote: I wonder if you can get something that's highly heat conductive, yet still an insulator that could be mixed with a high temperature resin and infused around the windings?
texaspyro wrote:Aluminum oxide and diamond are two excellent insulators. Unless your diamonds are boron doped blue diamonds... they conduct and are used as pacemaker electrodes.
Another good possibility is silicon carbide... The best possible conductor is isotopically pure C6 diamond... twice the conductivity of natural diamond.
bobc wrote:Thought about this a bit more: How about putting a single copper tube in amongst the windings, zig zag it all the way round the motor & bring it out with the power wires. Pump water through this. Now you will get effective cooling of the windings.
PS the highest thermal conductivity I've seen for a thermally loaded paste has been in single figures (W/mK) (I think that had a load of silver in it) (why is it always expensive stuff....??)
olaf-lampe wrote:... zigzagging pipes is not as easy as it sounds...
Thud wrote:Active cooling:
Given the design or the motors, I would think it would be easyer to encase the entire unit in a liquid tight enclosure.
Just some attention to details to remove all the "pumping" surfaces & sharp edges that would create drag & a shaft seal on the output. An coolant input through the stator & a few proper designed orafaces for flow...
Again, that would be for a much larger motor than my 7kw rebuilt turnigys
Jeremy Harris wrote:olaf-lampe wrote:... zigzagging pipes is not as easy as it sounds...
Plus it'd probably cause increased eddy current loss and take away winding space that could be used for more copper to lower the winding resistance that would reduce losses.
Biff wrote:Did you ever do any tests to measure the thermal conductivity of the epoxies you mixed?
http://cgi.ebay.co.uk/COPPER-CAPILLARY- ... d2ffceb7ee Something to experiment with....Ludo91 wrote:I was thinking to to rewind it with a copper tube, something with 1.8mm ext diameter and .5 external diameter so i could pump coolant in it.... Seems some of u had the same Idea, I`ll let u know if I find something intresting my friends
Miles wrote:http://cgi.ebay.co.uk/COPPER-CAPILLARY- ... d2ffceb7ee Something to experiment with....Ludo91 wrote:I was thinking to to rewind it with a copper tube, something with 1.8mm ext diameter and .5 external diameter so i could pump coolant in it.... Seems some of u had the same Idea, I`ll let u know if I find something intresting my friends
Maybe you could fill it with MCP70 alloy before you wind it?texaspyro wrote:Not to mention the near impossibility of winding a motor without kinking it and blocking the bore...
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