h a l f b a k e r y
Extruded? Are you sure?
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Think of a simple magnetic motor,
all the magnetic field motive activity occurs right at the outer perimeter of the winding where it pushes at the magnetic field of the surrounding
Ive read that pole pieces change and concentrate magnetic fields
Thus using some kind of electrodeposition of pole
piece shapes on a prewound wiring (even over insulation) would create noticeably intensified magnetic field right at the perimeter causing greater push force to the surrounding magnetic field yet the pole pieces could just be microns thick electrodeposited coating on the winding.
It would look like sparkly glitter covered wiring from the tiled pole pieces electrodeposited on the outside of the winding.
Along with the microarea at the perimeter having higher magnetic flux intensity from pole pieces It is a thought that placing these pole pieces at the motive perimeter would "draw" more of the volume shape of the magnetic field towards the perimeter further increasing efficiency
There is another available benefit, magnetic generators at power plants have vast gaps between the rotating core and the outer field. Thus even if we create gigantic 1mm pole pieces It might give 1 to 5 pct higher efficiency at electrical generators which represents dozens or even hundreds of entire power plants energy worldwide
||I am going to read it after tea.
||Does this outer winding come close to the rotor / stator gap?
||A diagram would be great.
||I don't know where to start with this. I
suppose that 200 years of development have
pretty much exhausted any obvious gains in
efficiency in pole and air gap design.
||Next is just my opinion, maybe wrong...
But there has been a relatively recent
materials development that could be
applicable. That is thermal spraying.
Compared to electro-deposition, thermal
spraying can use alloys, which will be better
for magnetic application. Moreover, the
process is relatively 'cold'. Maybe the copper
wire plus insulation could be coated by
thermal spray before winding?
||would this be applied to the metal frame of the rotor
or the windings themselves? because most windings
use copper for it's conductivity, but a lot of care is
taken in how it lays in there because its a much
software metal. It flexes enough just from vibration
and field strength for the wire coating to weaken..
this is one of the most common reasons for failures is
a shorted winding. Often the entire assembly gets
potted in resin to reduce this as much as possible.
||microglitter sized pole pieces on the wire above the insulation
||it would be wonderful if the magnetic field simulation software Ive seen modelled it Im really wondering about the pole pieces
||Actually the material would migrate in such a way to better convert the field strength into heat. Fail.