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Participant

Join Date: Dec 2011
Posts: 3

Electrical Conducter Size

02/10/2013 7:14 AM

why we use smaller diameter wire for motor winding while we use greater diameter wire for power up the same motor?

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Guru
Engineering Fields - Mechanical Engineering - New Member

Join Date: May 2008
Location: CHENNAI, TAMIL NADU, INDIA.
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#1

Re: electrical conducter size

02/10/2013 7:42 AM

Dear Mr.zafariqbal,

Required Level of Magnetic Field to be produced, where Ampere Turns are involved and no. of coils will have to be more, hence thin wire for small motors and thick wire for bigger motors. For very large capacity Motors , bars will be used.

FLEXIBILITY of the thin wire is also a criterion. Space available for small motors also a consideration.

DHAYANANDHAN.S

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Guru
Engineering Fields - Electrical Engineering - Been there, done that. Engineering Fields - Control Engineering - New Member

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#3
In reply to #1

Re: electrical conductor size

02/10/2013 9:32 AM

You've very aptly listed here many of the desires or advantages of using small gauge wires in a motor. However, I believe the OP wishes to know why wires in a motor can be considerably smaller conductor diameter than the wires feeding the motor.

First there is a common layman's misconception about the current capacity of a conductor. The maximum amount of current that can flow through a conductor is not limited by the conductor. The best example any technician can see that proves this is an examination of any glass ampule fuse like a 3AG style fuse. The fuse element inside is considerably smaller diameter conductor than the wires to and from the fuse. Yet this thin conductor must handle the same current as those wires because it is in series with those conductors.

Assuming that the voltage remains constant, the maximum amount of current in a circuit is limited by the impedance of the circuit. The series component with the largest impedance will dominate what will be the maximum current in a circuit. Now the problem with pushing too much current through a conductor is the self heating of that conductor may overheat the insulation to the point of ignition or even liquefy the wire of that conductor. The tiny conductor in a fuse deliberately has no flammable insulation and the glass envelope and atmosphere inside is designed to contain the arc flash of the circuit opening.

So the wires in the motor are at the location that sets the current. The very thin insulating coating of magnet wire maximizes the number of conductors that can fit in a space. This insulation usually has a high temperature tolerance. These wires are fixed in place so a solid conductor can be used. Magnet wire in a motor is also in contact with core material. Thermally this core material will act as a heat sink. The mechanical motion of the motor will also often simultaneously draw a coolant through the motor.

In contrast the wires that feed the motor will not be in contact with a heat sink. They will also have to flex from motor vibration if not actual movement. Frequently feed wiring will feed additional circuitry (starter circuit, status indication) that can significantly increase the current loading of this wire.

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Guru

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#2

Re: electrical conducter size

02/10/2013 9:09 AM

The incoming wire feeds two smaller wires feeding both the stator and rotor...

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Participant

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#4
In reply to #2

Re: electrical conducter size

02/10/2013 11:15 AM

thank you sir you good explain answer

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Guru
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#5
In reply to #2

Re: electrical conductor size

02/10/2013 11:55 AM

Not this motor. This motor is a squirrel cage induction motor. The current in the stator squirrel cage conductors are coupled from the stator windings. There is no direct wire connection between rotor and external wiring. All of the current flowing through the external wiring flows through the stator windings. In this motor a centrifugal switch adds and removes stator starter windings that likely get phase shifted through a capacitor not shown but the capacitor is an assumption on my part. During start up these added stator windings with a locked rotor condition can significantly exceed the rated current draw of the motor. This is when circuit protection should prevent overheating, thermal runaway and even fires from happening.

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Guru

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#6

Re: Electrical Conducter Size

02/10/2013 11:15 PM

The external cables connected to the windings have thicker insulation therefore larger cable is used to enable heat developed can be dissipated easily to atmosphere. Inside the motor the magnet wire has only one layer of (enamel)insulation therefore the conductor size can be smaller.

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Users who posted comments:

dhayanandhan (1); pnaban (1); redfred (2); SolarEagle (1); zafariqbal (1)

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