1000w wrote:I'm pretty sure its better to run a heavier gauge 'wire with thin insulation than a lighter gauge wire with thick insulation.
The heat issue in the standard phase wires is due to them being too thin, ie higher resistance, for the extra amps we wish to push through to the motor.
I fail to see how thick insulation can help with the amp carrying capacity of the wire.
yes a heaver gauge will not heat as easily
but that being said
the winding gauge is not user adjustable so it will heat up regardless
the larger wire will wick heat of the windings
so the thicker wire becomes heated
heat that a wire can take (not amps specifically) is in many ways directly affected by the isolation
look at different wires of the same gauge but of different coatings .. one thing you will notice is that the failure temp of the isolation is increased by material and thickness of the coating
silicone seems to be one of the best for its ability to handle heat wile maintaining the flexibility required in a ev application due to vibrations being driven
so with a thinner wire and different insulation (though you will be generating more heat due to the thinner wires higher resistance) you will be able in some cases to handle more current b4 the wire will fail(casing melting down)
just for a easy to do quick experiment hold a flame to your shrink tubed wire ... and now to a quality silicone insulated wire
i already have a good idea of what is going to happen
considering the windings are the load
and the most heat will be found closest to the load
and motor manufacturers do not use heat-shrink were the windings make contact to the power leads they instead use a fiberglass sleeve
and considering that thees sleeves are more expensive then a piece of shrink tubing
and many motor manufacturers are trying to safe money on production to maximize profit and minimize consumer cost
they will save a penny anywhere they can were it wont compromise safety
so one can make a logical assumption that the heat-shrink is far too likely to fail in this environment (without any prior information received on the topic in the first place)
if at first you don't succeed...dont force it just grab a bigger hammer
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