Nov 23, 2003, 03:23 AM  

Actuator calculation spreadsheet.
Hi
I have made the actutator calculation spreadsheet from Gerhard Ringel available for download. Here is a direct link: http://www.tekmek.dk/copper.xls Here is Gerhards instructions for use: "Here is the spreadsheet. to use, just put in the inside diameter of the coil into H2, the outside diameter into I2, the length (width) of the coil into J2, it will show you the weight of the (copper in the) coil in K2, and the average length of each turn in L2. You can then determine the Ohms and number of turns form your wire size. I have listed the common American wire gauges and a few wires by mm thickness." "I have added a formula as you suggested on page 2. You can enter the wanted Ohms in M2, the inside diameter in N2, and the width of the coil in O2. It will calculate the total length of the wire, the Outside diameter of the coil, the number of turns required, and the weight of the copper in the coil. Note that all this is based on just the copper. Actual wire will include the lacquer insulation, so the actual OD and the actual weight will be a little more. To get the values for other wire sizes, you can input the diameter of the wire in mm in any of C29 or C30 or C31 or C32 and it will do all the calculations for that wire size. I am not familiar with the standard wire sizes for metric. Of course I would be happy if you could post this information on your web site. I want this to be available to as many as want to see it. I have also added a column for the maximum current for a give wire size. I came up with a formula based on various information I could find on the web and some experiments. This is approximate and some folks may want to be a little more aggressive, some a little more conservative." Thanks a lot to Gerhard for sharing this spreadsheet If anyone has suggestions for improvement or would like to have additional features, just post it here. Graham or Gordon, please add this thread to the Useful Threads. Michael 

Nov 23, 2003, 06:24 AM  

Thanks for posting this Michael, I was actually working on something similar because almost every wire chart that I found was a little different.
I was having trouble finding suitable magnet wire, and was going to go ahead and order some 42.5 AWG (smallest they have) from http://www.brigarelectronics.com/ until I found out a 200 Ohm coil with this size magnet wire would weigh almost a gram! The best one I found so far is based on NEMA standards for magnet wire. www.elektrisola.com/nema.xls It has a lot of other info like MIN, NOM and MAX for bare copper wire, single build, heavy build and triple build magnet wire as well as resistances and winding tensions. It has sizes from 24 AWG to 44.5 AWG. It has higher sizes but says "4558 AWG Theoratical bare wire diameter by resistance". Thanks! 

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