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Re: BLDC design

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Thanks dc42 for chiming in. I have tried to keep things simple but I mostly agree with your points.

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dc42
3) there is a maximum current (the rated current of the motor) that you can put through the windings without the motor overheating, because of the resistance of the windings. To allow more current, you have to make the motor bigger so that you can use thicker wire having lower resistance.

While it does sound right, it may become ineffective due to 1) and the inductance of the coils.

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dc42
Real motors can maintain the same torque as you increase the speed
That is what I was suggesting with "with the proper control can keep a good torque value for higher speeds". I intentionally did not say the same torque due the difficulties of achieving a constant current at high speeds.

On the other hand ...
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dc42
If you add turns, you have to use thinner wire to fit the extra turns in...
if you add turns [of the same wire] you will increase the ampere-turns of the windings (as you mentioned) and that will give you more torque but it will reduce the max speed.

Reducing the section of the wire will increase the resistive load and definitely will reduce motor speed and current consumption, even more so if besides you add more turns.

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