high current inductors from copper tubing? - Page 4

star882 · 9th November 2009, 10:42 PM

And I realized that since it would need to be a bidirectional converter in order to be able to regen, there would be no need for a separate charger buck converter. Simply rectify mains voltage (using a voltage doubler for 120v) to the boosted rail and run the converter as a buck converter to charge the batteries. In a DIY EV where cost is a major concern, it can be very helpful for saving cost.

Eva · 04:48 PM

Quote:

Originally Posted by infinia

I would look at copper braid and powered iron cores (distributed gapped iron) depending on core choice and frequency, the cores losses could rival the Cu loss.

140uH 30A (with 50% inductance drop at full current) requires 33 turns on Arnold magnetics 60u 1.8" O.D. MPP core (A-759135-2), approx. 2.20 meters of 1.9mm O.D. magnet wire.

150uH 50A (again with 50% inductance drop) would require two stacked cores of that size and 24 turns (approx 2.5m of 1.9mm O.D. magnet wire).

blueyes · 27th December 2009, 06:06 AM

The inductance for an air coil is L=uKN^2A/l
u=4pi*10^-7H/m, K~1 (Nagaoka coeficcient), N=turns, A=area of cress section, l=length

A 20' copper tube wound with d=10cm: 33uH, d=20cm: 66uH

gorgon53 · 9th September 2011, 11:52 PM

Copper tube that are intended to hard-solder contain among other things phosphor and have therefore considerable lower conductivity than copper intended for electrical applications. Allow for at least a 20% increased resistance if compared to the best electrical grade copper (wich by the way is nowdays just as good as silver and makes the use of silver in transformers a total waste of money).

9th November 2009, 10:42 PM	#31
star882 diyAudio Member Join Date: Mar 2007	And I realized that since it would need to be a bidirectional converter in order to be able to regen, there would be no need for a separate charger buck converter. Simply rectify mains voltage (using a voltage doubler for 120v) to the boosted rail and run the converter as a buck converter to charge the batteries. In a DIY EV where cost is a major concern, it can be very helpful for saving cost. __________________ "Fully on MOSFET = closed switch, Fully off MOSFET = open switch, Half on MOSFET = poor imitation of Tiffany Yep." - also applies to IGBTs!

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27th December 2009, 06:06 AM	#33
blueyes diyAudio Member Join Date: Dec 2009	The inductance for an air coil is L=uKN^2A/l u=4pi*10^-7H/m, K~1 (Nagaoka coeficcient), N=turns, A=area of cress section, l=length A 20' copper tube wound with d=10cm: 33uH, d=20cm: 66uH

9th September 2011, 11:52 PM	#34
gorgon53 diyAudio Member Join Date: Nov 2006	Copper tube that are intended to hard-solder contain among other things phosphor and have therefore considerable lower conductivity than copper intended for electrical applications. Allow for at least a 20% increased resistance if compared to the best electrical grade copper (wich by the way is nowdays just as good as silver and makes the use of silver in transformers a total waste of money).

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