Coil Winding for my 500bhp Rolling Road Eddy Current Brake, Mobile Rolling Road Restoration
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- เผยแพร่เมื่อ 23 ก.ย. 2024
- In this video I show you the process I used to wind the 8 coils in my rolling roads eddy current retarder. It took a lot of thought, prep, and hard work to get through this work. I used my Boxford 280T Metal Lathe with single phase conversion and VFD variable speed drive to help me wind around 800 turns of 1.6mm enamel coated copper wire onto the large iron cores.
Excellent work! Is your spreadsheet available?
@@EW_57 it's a real mess!!!! I can send it you if you like. Find my page on Facebook, LozL it's a group I think. There's nothing on it but it has this same logo. Send me a message there.
I would be interested in making a small dyno to test go kart engines with. Some people have built flywheel ones but a constant load dyno would be interesting.
Ross this sounds like an excellent project. I've had it easy really with a restoration, a build from scratch dyno would be a very cool project.
A brake is a very good idea. You can do so much more with the rolling road if you have one.
Get it done! :)
I wouldnt over think it. You will be fine.
Thanks buddy, yeah I tend to do that. In fact overthinking things is my speciality :)
Me too bud. Me too. It has its ups and downs. You have put alot of really good thought into this either way. Its going to be a really nice piece. Keep at it.@@lozl
@@MrJermbob thanks Mr Jermbob that means a lot. :)
3:29 I care 🙋♂️ 😂
I’m well into this mate, finding the whole project very interesting! Well done bud 😊
You're too kind Nick. Thanks a lot buddy
@@lozlthe first coil, I’d run it as is but that’s my bodgery side showing 😂
It’s really down to your piece of mind buddy, would it make you feel better re-winding it?
@@nickproofcertified thanks dude appreciate your input. I was on the fence for a while, but I just couldn't let it be hahahaha i have already re wound it :)
@@lozlnice! 😂
Youve already decided youre rewinding it as you've been staring at the camera...😉
Hahahahahhaha, you're very perceptive. And you're absolutely right. Since fiming this, I have redone the coil. Hahahahaha
Thanks for watching buddy, thanks for the supprt
@@lozl we've all been there mate. Sitting at the dining table after a day in the garage, quietly explaining your three choices to fix something to a partner who neither understands nor cares - silently and secretly waiting for them to agree and pick the "right" choice that you already made yourself... 🤣
@@stu.c hahahahahahahahaha, man this is all so accurate. Love it! Ahahaha
I'd rewind it mate, you've been so meticulous with the calculations and restoration so far, it will always be in the back of your mind imho.
Do it once do it right 👍
Thanka Buddy :) yeah, I wrestled with it until I had done 4 coils.... then I gave in, and redid it hahahaha.
Was it really necessary to insulate that much for 200V? I'm sure you can obtain wire that can handle more by itself, then there would be much less work needed. While winding, make sure your wire is tensioned. If your coils overheat that much during operation, maybe consider some cooling options?
I'm not expert in this field, so a lot of the work was based of the coils that I look apart when I dismantled the brake. My application of calculations has only gone as far as changing the thickness and number of turns etc to change to 192 volts.
The insulating of the coils I have just based on what I found. And there was a lot. There seemed to he a cement of sorts used around the core then a lott of asbestos type material on the edges and around the outside. I have just looked to go "belt and braces" and at least try and make sure its as good as it was in the original design. In addition, I feel that the more paint I can impregnate the fibre glass with the less moisture can sit around in the fibre glass if the coils are ever exposed to weather.
All this work has really only come from my thoughts on what the requirements are. But you have illuded to something that might be of concern. They are rather cosy and well insulated in there.....
This uis a double edged sword though, while I appreciate thwy won't cool brilliantly, they will be quite resistant to letting the heat in from the potentially red hot discs spinning around in close proximity.
The discs themselves have enormous cooling fins, the inlet to those cooling fins will draw a lot of air through the 8 coils so that will help keep temps sensible hopefully.
I can keep an eye on temperature with the internal thermocouple I have put in there. This is a case of suck it and see.
I did apply a good tension to the wire throughout most of the winding process
Do the rewind. It will just wind you up otherwise.
Thanks brosive. Everyone is saying the same as you. Its one of those "if you have to ask"......
(Since making the vid I have actually redone it :) )
I have no reason to believe that the differences in winding you’re concerned about are going to produce any relevant or much discernible difference in temperature.
Worrying about heat conduction differences when the wire has a layer of insulating fiberglass coating the entire thing seems a little much. It’s not like I’ve done any research on this nor looked into the effects that irregularities in winding compositions have on heat dissipation so take what I think with plenty of skepticism.
What I would throw out there is consider adding temperature probes embedded in the windings at the core and maybe a 2nd right before you close up the insulation on the outside. They are pretty affordable, small and would give you insight into how your creation performs overtime during testing.
Why not add one to the core in question and one to the other nicely packed ones so you can see for yourself. Yes it will make it a pain in the ass to tear down to replace after it’s up and running but in general my policy is not to waste money (and my time) without concrete evidence for doing so.
However if you have both a surplus of Money & Time then maybe redoing the coil to remove the possibility of the irregular core causing problems might make sense.
And I just heard you did add a thermocouple so good planning.
Chris thanks for taking the time to write up your thoughts. Much appreciated.
I have no skepticism of your reasoning. It all makes sense. I think you make a very valid point the conducting of heat through adjoining coils is a mute point when they're all wrapped up like that. At the time this was really the only reason I could think to redo it. That and the fact it just did sit well with me knowing it wasn't neat.....
Chris I must admit that since making the video I have redone the coil. Two bit of good news though. The copper all came off in very good condition so I reused it, and I'm really happy with it. So I didn't have to spend any money on doing it. And while I was redoing the cool I became apparent that I managed to get quite a significant number more turns out of the same mass of copper bh virtue of it being neat. So the same resistance and therefore current but many more turns (like maybe as many as 50...
So I am pleased I did it as that could will generate a stronger field like its 7 other coil buddies.
Thanks again for your thoughts though. It refreshing to hear from someone who can think for themselves and actually logically reason through some good points. Please let.me.know yours thoughts again if you watch more RR videos
@@TradeWorks_Construction I did, but I wish I'd put two in like you suggested. Thats a very good idea.
I have one only and fairly near the outside. I wish I'd put one in the middle. Trouble is they upset the neat windings so this pit me off