Should I wind coils for voltage or amps?

Question

If I'm building a DC motor with pemanent magnet stator, is it best to use large gauge wire for a low resistance, high ampage coil or use thinner wire to get a higher resistance and therefore require higher voltages for the same output power?

The intention is to power a vehicle with the finished motor, so a wide speed range and low speed torque are important.

I'll make the power pack up to suit the optimum motor design.

Answer 1

It all depends. Like the previous comments..what is the limitation of your power supply? Thicker wire means more stall torque...but higher current.....and higher heat.

Not sure if you are varying the voltage or not. I'm assuming it's fixed. But you need to know your torque. Normally, by design, I specify motors at about 20% of their full amp capacity. This is where the DC motor has the highest efficiency. Not sure what you mean by "low SPeed". At a fixed voltage, the motor will put out more torque the slower you force it to go, usually by applying more load...but at that point you are driving the motor very hard.

Heat will by your biggest killer...so force air cooling is best. Also use the highest grade insulation grade materials. This will help with the high amp draws. Your brushes may suffer too if they are not equpped to handed the currents you intend to produce. So if you want the largest speed range....use the thickest wire you can find. This will give you the highest torque output. But because you will run out of room fast in the stator slots...your motor will run "fast".

Eventually.....without knowing your load requirements and power capacity...your question can be answered in a myriad of ways with no single solution. As applications engineer for motors....your question is very vague. Should you design for voltage or amps? You can do both..but you have to know what you want the motor to do...and the power you have available to the motor.

Answer 2

I suppose that would depend a lot on what sort of battery pack you'll be using. If you will be using a large number of cells to get sufficient energy anyway, then putting them in series for the higher voltage/ lower current will reduce I/R losses in the controller and wiring.
However if your energy requirements do not necessitate a large number of cells, then figuring your most economical battery pack, winding the motor for that voltage and living with the I/R losses may be best.
Note that since to lower resistance motor winding will have a higher current, than the higher resistance one, the motor heating may not differ much.

Answer 3

You need current for torque, so larger wire, higher current flow for a more efficient motor. You need more windings as well, so you have to compromise. Don't worry about the voltage, as you are under 220 volts, so you don't have to worry about arcing.

DC motors are known for high start torque, but poor high end performance. Gasoline and diesel engines are just the opposite.

Answer 4

Wind them for power, you need to know how much power you can provide without destroying your system then you need to make the winding to limit the power accordingly.

You need to study up on motor design, there's more than one way to make an electric motor and some give better starting torque and others run better at high speed.

Answer 5

particular you ought to use the place as your load is often related or no longer pass to very low point.same technique is used in Breakers with out any exterior ability,the present out placed one CT, are used & Voltage out placed(yet another transformers) used for cover device (enjoying cards) & used with Magnetic holiday solenoid.this variety of device will artwork fantastic with over load protection device.those technique used till now by making use of M/s Siemens >40years earlier.I used same technique for length of very low modern & sensor circuit used for some spl.holiday Relays, for the time of faculty days,

Answer 6

Sounds like you know what you are doing, but I would look at the possibility of high heat with higher resistance.

Answer 7

You need to choose whatever will be compatible with the voltage of your power source.