Author Topic: Low tech hand made wire  (Read 419 times)

ClassicCrazy

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Low tech hand made wire
« on: September 19, 2021, 12:36:57 AM »
I thought this was interesting . How they make insulated multi stranded wire in India  ( think it is India )
https://youtu.be/9Hl0E12eKu0

Larry
system one
Classic 150 , 5s4p  Kyocera 135watt , 12s Soneil 2v 540amp lead crystal for 24v pack , Outback 3524 inverter
system two
Classic 150 ,5s 135 watt Kyocero , Jakiper 48v LiFePO4 , Outback VFX 3648 inverter
system three
Midnite KID MPPT 24 DC in to  12 volt AGM batteries

boB

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Re: Low tech hand made wire
« Reply #1 on: September 19, 2021, 06:56:07 PM »
Nice !  That is certainly multi strand wire.

Would be nice to see the actual drawing of the copper wire and varnishing process, part of which is probably company proprietary.  Especially the varnish.

Also, the insulation at the end.

Now, there is what is called Litz wire which is really braided wire and is important for high frequency power magnetics.
The machines that do the braiding work in the same way that cable and rope braiding works.  The machine was invented
and patented in the mid 1800s.

Slow motion...
https://youtu.be/2KfwAkc8Dpo

Here is how it works...
https://youtu.be/WlrzuZpJ2N8

Here is some braided ground strap and a larger machine
https://youtu.be/Yth06zgg5SY

There are some good videos showing large rope braiding machines on YT as well.

I also saw a toy hair braiding plastic machine for sale.

I am really impressed at how this works !


Also on YT you can find how to 3D print your own braiding machine.
K7IQ 🌛  He/She/It

ClassicCrazy

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Re: Low tech hand made wire
« Reply #2 on: September 19, 2021, 07:58:36 PM »
I am glad I wasn't the one who had to figure out how to make a braiding machine !
The machine sure beats doing it all by hand.
I have been watching a few videos from India where some small operations recycle of renovate things like motors, batteries, wheel barrows, etc.
The lack of any safety equipment is a bit scary  - people welding with nothing but squinting their eyes ( safety squints) or I did see one guy had on some sunglasses.
Also no guards on any equipment, people walking around barefoot in foundries, etc. The skills people have is amazing - sand casting new finned aluminum motor cases with the most basic supplies - a metal form , sand, and melted salvaged aluminum.

Larry
system one
Classic 150 , 5s4p  Kyocera 135watt , 12s Soneil 2v 540amp lead crystal for 24v pack , Outback 3524 inverter
system two
Classic 150 ,5s 135 watt Kyocero , Jakiper 48v LiFePO4 , Outback VFX 3648 inverter
system three
Midnite KID MPPT 24 DC in to  12 volt AGM batteries

ralph day

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Re: Low tech hand made wire
« Reply #3 on: September 23, 2021, 08:52:01 AM »
I watched one fella re-wire an electric motor.  Impressive.  Then I watched one from Britain where an electric motor was re-wired...included much testing, varnishing, baking and final testing.  The South asian testing consisted of touching wires together to see a light bulb light up. 

I think I'd want the British re-build.

ClassicCrazy

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Re: Low tech hand made wire
« Reply #4 on: September 23, 2021, 10:36:09 AM »
I watched one fella re-wire an electric motor.  Impressive.  Then I watched one from Britain where an electric motor was re-wired...included much testing, varnishing, baking and final testing.  The South asian testing consisted of touching wires together to see a light bulb light up. 

I think I'd want the British re-build.
I think I saw that video too.
I bet there is a big price difference between the two rebuilt motors.  I have a feeling that the people in India who buy or have their motors rebuilt are not going to care too much about the extra testing - just the price.

Larry
system one
Classic 150 , 5s4p  Kyocera 135watt , 12s Soneil 2v 540amp lead crystal for 24v pack , Outback 3524 inverter
system two
Classic 150 ,5s 135 watt Kyocero , Jakiper 48v LiFePO4 , Outback VFX 3648 inverter
system three
Midnite KID MPPT 24 DC in to  12 volt AGM batteries