Home stator rewind

[Steve]

Well, there's always the option of using Square Enameled Magnet Wire as suggested by Jim (Pos).
http://www.mwswire.com/microsq1.htm

From what I have heard, it's already quite a challenge to keep round wire nice and tightly packed.
I can't imagine the added "fun" of keeping the square wire from twisting, too.

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[rustybronco]

You haven't considered thickness of the enamel coating on your chosen wire gauge. will the thickness of that coating be the same for each the chosen wire gauges? just one more thing to consider that will reduce the available space for the conductors.

and, you still will have to make a winding tool (bobbin) that can keep both conductors parallel to each other, in order to be able to optimally wind each pole.


you may want to consider using a square cross section enamel coated wire. (my .02)

***edit***

I can't imagine the added "fun" of keeping the square wire from twisting, too.

Incorporate the wire alignment function (a delrin guide perhaps?) into the head of the winding tool.

 

[Steve]

OK, I now see that the numbers are actual area covere, not the percentage of the area. Makes more sense.

I don't have the engineering background to get into the thermal characteristics and all that, so, although what you said seemed logical enough, it was a bit over my head.

Using the FET regulator will certainly help, but I think the extra windings will really help with maintaining output at lower rpm, if you have your accessories on while in town.

I have a feeling you might get to rewinding yours first, so keep us informed.

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[bakalorz]

Well, for my design model, I had to find the closest form factor packaging to accommodate a closer variance factor to better illustrate the difference in total area coverage of the cross section of each wire. The picture demonstrates that, while occupying the nearly identical volume of space, (the wires at 100x magnification) there is a higher concentration/density of copper in the 22GA wire windings then the 18GA wire. In this example, the 18GA wire cross section occupies 16.085 in^2. Whereas the 22GA wire cross-section occupies 37.699^2 while taking up the same amount of form factor real estate. The theory is the only option demonstrated here. I am aware that the heat would increase exponentially from a lesser gauge carrying the same current/voltage as a higher gauge wire of the same turns and length. However, the illustration was to demonstrate the cross sectional benefit of additional conductive material able to fit into the same original form factor. As the scale illustrates, the cross sections displayed are 100/1 enlargement. This shows us in in^2 that using SIMILAR amount of windings, we can use less wire, taking up less space, and reaping the benefit of additional surface valence conductivity AND throughput valence conductivity. So to sum this up: to use two (2) 22GA wires in parallel, instead of one (1) 18GA, I find that there is BOTH a greater surface area AND cross-sectional area through which current can flow. This is proportional on a parabolic level to the heat loss for the same surface and cross-sectional area of an 18GA with significantly reduced surface valence. The result: hotter wire is the single 18GA according to heat equation. the form factor can be reduced in size to allow for identical passage of current, however, since I'll be using the FH10BA 50A rectifier and I want a few running lights, I'll need a lil higher output to accommodate this. Therefore, a slightly increased voltage output is prefered while maintaining a similar or even lessened thermal effect from identical or even increased current. I'm just asking questions here. But my theory ( I feel) is not yet disproved. Maybe I'm just THAT GUY that wants to be some stupor hero.. I dunno. but so far as I can see, the theory is sound. Effort is not a part of my equation here. It's going to suck to rewind my stator either way... But if I can make it better, why wouldn't I?

I couldn't see your drawing ...

But, a couple of things:

to get similar current capability and heat rise you would need 2 parallel conductors of 21 guage to equal a single 18.
For an equivalent # of turns, (twice as many for the paralleled 21 guage)
you will have an equal area and only equal current capability.

I wasn't able to see your drawing, but I suspect that you cannot get more copper area to fit in the area you have to wind it. infact, I suspect that due to difficulties winding it, you will be able to get in fewer turns, thus resulting in less voltage.

Additionally, assuming an equally thick coating of varnish on the wires, the varnish takes up a proportionately larger percentage of the 18 guages available winding area.

Better conduction due to the extra skin area is irrelevant in this application, it only applies at very high frequencies.

You didn't show the heat calculation, but I suspect it ends up misleading as well. It will assume that the 18 and 21 guage wires have similar environments, but this ends up not being true. effectively the 18 guage wire has a greater percentage of wires "inside" the bundle, where they cannot reject much heat because all their neighbors are hot too.
In the end it winds up a wash between 18 and 21 guage.

I don't think using a pair of 21 guage wires will hurt (assuming you can do as good a job winding them, which I actually doubt) but it won't gain you anything either.
BTW, if you DO use a pair of parallel 22 guage wires, you will have less area, less max current, and more heat (a loser all the way arround)

 

[doctorgonzo]

Remember seeing some posts on here incl one very comprehensive one a year or so back... guy doing it in his office at work

Personally for what they cost aftermarket & the hassle involved I think I'd buy one.

Same here. The number of hours of my life involved in winding one is worth WAY than $130.