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Author Topic: Eddy Current Heating  (Read 15831 times)

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Looking through my attachments I see there is one paper that I have not put on this forum. (If I have already posted it then put this down to memory loss  :-[ ).  It concerns reports of OU heating from eddy currents induced into a rotating disc.  My theory says that the phase shifted eddy current peaks occur when the disc has moved from the maximum induction position between the magnets to one almost over the magnets and that places a circular E field (of value needed to drive the current through the disc resistivity) both within the disc material and just outside its surface.  That E field is of polarity to load the electron spins within the magnet thus extracting energy.  Effectively each magnet sees a DC circular E field.  The combination of electrical phase shift and rotor movement creates the rectification effect that produces this DC field.

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Looking through my attachments I see there is one paper that I have not put on this forum. (If I have already posted it then put this down to memory loss  :-[ ).  It concerns reports of OU heating from eddy currents induced into a rotating disc.  My theory says that the phase shifted eddy current peaks occur when the disc has moved from the maximum induction position between the magnets to one almost over the magnets and that places a circular E field (of value needed to drive the current through the disc resistivity) both within the disc material and just outside its surface.  That E field is of polarity to load the electron spins within the magnet thus extracting energy.  Effectively each magnet sees a DC circular E field.  The combination of electrical phase shift and rotor movement creates the rectification effect that produces this DC field.

Smudge

Smudge

Reading the paper,i am wondering if we can do this on a smaller scale,as i am limited with the size of copper i have lying around.

Here is what im thinking-
I have some 5mm thick x 10mm wide copper buss bar.
What if i was to form a loop using this buss bar,and for the rotor i use the rotor from a medium size stepper motor. Reason being,the rotor from stepper motors have many alternating field magnets around them,and they are fairly strong neo's at that. This would then be an achievable frequency range,driven from a DC motor,due to the large amount of alternating magnetic field of the stepper motor rotor.

I have some good powerful 12 volt DC motors,and also a wide range of gears i could use to gear up the rotor.
20 000 RPM on the rotor would be quite doable.

Looking at your paper,at some point during the increasing of RPM of the rotor,i should start to see the load on the prime mover decrease,until such a point where the rotor places no load on the motor,but we still have eddy current heating -->? :-\


ADDED--In saying this,i did notice something a few years back,when using a stepper motor as a generator.
When the stepper motor is driven at higher RPMs with a prime mover,no matter what load you placed on that generator(the stepper motor),no load would be seen at the prime mover :o--i had totally forgotten about these experiment's,as i was carrying them out just a week before we had to shift house,and it only just clicked again when thinking about the above experiment-using the stepper motor in the setup.
5KHz is quite easy to achieve from the output of a stepper motor when being driven by a prime mover.

Brad


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To me, the use of your stepper motor rotor seems like a very good idea, but since your question was directed to Smudge, I'll defer to him.

Instead of bus bar, you might also cut a section of copper pipe that would just fit over the rotor, and if you have pipe expansion tools create a very close tolerance fit.

It seems there are many ways to build other versions of this device, some decisions of either axial or radial radial design and the trading of diameter for speed.

Yes, this paper was posted earlier, but it was nice to read it again. I especially like Smudge's model of the dynamo replenishing spin force to the rotating electron charge. Would that we could really tap that!


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To me, the use of your stepper motor rotor seems like a very good idea, but since your question was directed to Smudge, I'll defer to him.

Instead of bus bar, you might also cut a section of copper pipe that would just fit over the rotor, and if you have pipe expansion tools create a very close tolerance fit.

It seems there are many ways to build other versions of this device, some decisions of either axial or radial radial design and the trading of diameter for speed.

Yes, this paper was posted earlier, but it was nice to read it again. I especially like Smudge's model of the dynamo replenishing spin force to the rotating electron charge. Would that we could really tap that!

Yes,i would have some copper pipe of the right diameter here-some where.
The only reason i was thinking of using the buss bar,is because it is thicker,and would be easy to work with,in way of mounting,and machining to a close tolerance.

This would only take a couple of hours to knock up,and as it is going to be raining cats and dogs here tomorrow,it looks like im work shop bound ;).
So i'll throw it together,and see what we end up with. I will also revisit the high speed spinning of a stepper motor as a generator,and see if i can get that !no load! effect again.

Brad


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Brad, you said:

Quote
I will also revisit the high speed spinning of a stepper motor as a generator,and see if i can get that !no load! effect again.

Could you elaborate on this and how you ran the test? I have played with using stepper motors as generators in the past, but am interested in this "no load effect" you refer to.

Thanks in advance.


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Brad, you said:

Could you elaborate on this and how you ran the test? I have played with using stepper motors as generators in the past, but am interested in this "no load effect" you refer to.

Thanks in advance.

It was some time ago ION,but from what i remember,i had the stepper motor directly coupled to a larger size brushless motor(the hobby type motor from an RC car). At a certain RPM (higher end of what the motor could run at),with a load attached(i believe it was a small incandescent bulb)to one of the stepper motor outputs,the power draw to the motor would go down,and i could hear the load on the motor lift,but the bulb remained brightly lit. Disconnecting the load made no difference what so ever to the amount of power drawn by the motor or RPM. Lower than this RPM value,when connecting the load,you could both hear the motor load up,and see the power draw go up.

I dont have any of the RC gear now,but i have the parts lying around to knock up a quick PWM,and i have quite a few brushed DC motors here as well.
So i'll just finish my coffee,and get right to it,as i had always intended to re-visit this,but just forgot all about it till now.


Brad


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OK,here is the first video on the effect i was talking about.
At a certain RPM,i can draw around 2 watts of power from the stepper motor/generator,without it affecting the input to the prime mover-or reflecting on the prime mover.

At the end of the video,i ran the setup without the armature on the stepper motor,to see the difference in power draw from the prime mover.

More to come soon.

https://www.youtube.com/watch?v=8MaJ-Bmoe4Y


Brad


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Bellow is a picture of the eddy current DUT.
The copper ring is electrically looped. It is 40mm ID x 10mm wide x 3mm thick-->so OD is 46mm.
There are 4 x 12mm dia x 6mm thick neo N52s in the rotor,with an alternating field pattern-->N,S,N,S

This setup allows me to slide the copper ring over the rotor at different RPMs.
Even at 3200RPM,i still get a large reflection on the prime mover,in that the P/in to the prime mover rises about 900mA to 1 amp when i slide the copper ring over the rotor--the voltage remains as set at the PSU (31v max).
The copper ring gets very hot very fast at the full 3200RPM.

So it may be that my RPM is still to low for this size copper ring ?,as i have no idea as to how Smudge worked out the math in a previous post ???.

So success with the stepper motor/generator setup,but no success with the eddy current heating as of yet.


Brad


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Away from home with poor internet connection.  Will reply later when I get a WIFI connection.
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Got WIFI in the village hall so good connection now.  Brad, if the input power goes up by 30 watts, does that amount of power explain the fast heating of the copper ring?  It really needs some calorimetry.  Is there any possibility of fabricating a ring using copper tubing, then you can pass water through the tube, measure its flow rate and temperature rise to get a handle on the power output?

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It was some time ago ION,but from what i remember,i had the stepper motor directly coupled to a larger size brushless motor(the hobby type motor from an RC car). At a certain RPM (higher end of what the motor could run at),with a load attached(i believe it was a small incandescent bulb)to one of the stepper motor outputs,the power draw to the motor would go down,and i could hear the load on the motor lift,but the bulb remained brightly lit. Disconnecting the load made no difference what so ever to the amount of power drawn by the motor or RPM. Lower than this RPM value,when connecting the load,you could both hear the motor load up,and see the power draw go up.

I dont have any of the RC gear now,but i have the parts lying around to knock up a quick PWM,and i have quite a few brushed DC motors here as well.
So i'll just finish my coffee,and get right to it,as i had always intended to re-visit this,but just forgot all about it till now.


Brad

Thanks for rechecking this as your time permits. I may also give it a try, but I suggest a resistive load as a lamp can be very non-linear and present odd loading effects to the test.

I may give it a try if I can find a suitable stepper motor.

Edit: Just reviewed your video and it is indeed interesting, and while not OU does raise some questions regarding what is occurring . I suspect that power is being shifted from heating the stepper to the loads when they are connected, although it may be some other magnetic drag that is reduced when the loads are connected. Well done. I will watch it again and take some notes for Pin and Pout at the various settings.

Disregard what I said about the lamps non linear behavior as it does not seem to be a problem in these tests. Might be interesting to try the tests with a heavier load. Is there a sweet spot of loading current that provides a minimum amount of input current draw for each power input level?

Good work!
« Last Edit: 2016-07-30, 16:38:22 by ION »


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Got WIFI in the village hall so good connection now.  Brad, if the input power goes up by 30 watts, does that amount of power explain the fast heating of the copper ring?  It really needs some calorimetry.  Is there any possibility of fabricating a ring using copper tubing, then you can pass water through the tube, measure its flow rate and temperature rise to get a handle on the power output?

Smudge

Just put the whole assembly in a styrofoam (or even cardboard) box and measure temperature rise over ambient of the entire DUT at the inside top of the box. Then compare this to just a resistor in the box with the same wattage input.

This method also takes into account all motor losses.

Quick and simple fixed loss to ambient method, no messy water or plumbing. I've used it many times and it works. If there is OU in the system, you can determine how much by simply running one more test where you bring the resistor to the same heat level, and note the increase (difference) in power required to do so. This is then your gain.

I've used and recommended this method many times, and although not perfect it will get you close enough.

Edit: regarding your test, there may not be enough poles on the rotor to get the effect Smudge is looking for.
You can get lots of poles with just one magnet by fabricating 2 pieces of soft iron with articulations in the edges that sandwich a magnet,  such as in an automotive alternator's rotor. Creative design of the rotor assembly can lead to some interesting  shaped fields induced into the copper.


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Got WIFI in the village hall so good connection now.  Brad, if the input power goes up by 30 watts, does that amount of power explain the fast heating of the copper ring?  It really needs some calorimetry.  Is there any possibility of fabricating a ring using copper tubing, then you can pass water through the tube, measure its flow rate and temperature rise to get a handle on the power output?

Smudge

Smudge

Can the copper ring made from tube be open each end?,as eddy currents would still be induced into the copper tube with the ends open-much like dropping a magnet down a copper tube.

I could do as ION said,and house it all in an insulated box,and measure temperature rise over time against a resistor with the same power flowing through it.

@ ION

Would i have a small circulation fan in the box to circulate the air around in the box--like a small PCU fan ?.




Brad


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Thanks for rechecking this as your time permits. I may also give it a try, but I suggest a resistive load as a lamp can be very non-linear and present odd loading effects to the test.

I may give it a try if I can find a suitable stepper motor.





Good work!

Quote
Edit: Just reviewed your video and it is indeed interesting, and while not OU does raise some questions regarding what is occurring . I suspect that power is being shifted from heating the stepper to the loads when they are connected, although it may be some other magnetic drag that is reduced when the loads are connected. Well done. I will watch it again and take some notes for Pin and Pout at the various settings.

I can easily check the temperature theory.
I will place a temperature probe on the stepper motor housing,and let it run for 10 minutes unloaded.
I will then place the two loads on the stepper motor output's,and if the power is being shifted from heating to the loads,we should see a temperature drop at the stepper motor housing--correct?.

Quote
Disregard what I said about the lamps non linear behavior as it does not seem to be a problem in these tests. Might be interesting to try the tests with a heavier load. Is there a sweet spot of loading current that provides a minimum amount of input current draw for each power input level?

There is something odd going on with this setup,so see if you can make any sense of it.

No matter what load i put on the outputs of the stepper motor,the current value always remains at around 69mA per leg,and only the voltage value changes.
E.G,if i place those small incandescent bulbs across the outputs of the stepper motor,the current will be 69mA through each bulb ,at around 14.7V RMS. If i place larger incandescent bulbs across each leg,the current remains at 69mA,but the voltage across each bulb will drop.

The weather is bad again here today,so looks like another day in the workshop  O0 ,so i will keep at the stepper motor testing a little longer,and sort that out first,and then move onto the eddy current heating,as i believe the two are related,in that you can create a delay of the lorentz force<--would this be the correct term to use here?

Anyway,so first test is the temperature test, without load,and then with load.
Second will be using a VR,so as we can increase or decrease resistance on the fly,and watch the current as we do so.

Oh,and one last thing.
I placed a 240v AC LED bulb on one of the outputs of the stepper generator,and it lights up nice and bright--BUT the odd thing is the voltage and current are very close to being 90* out of phase from the generator output,but still places a load on the prime mover when connected--i have not had a look at the phase relationship using the incandescent bulbs yet,but will do so today.


Brad


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It would seem that we are indeed converting heat (or some of it) to electrical power.

So at a guess,i would say that we are reducing the amount of eddy currents flowing through the core,when we draw a load from the two generating coils. I will not know exactly how much until i box the whole setup,and switch to a much more stable power supply--E.G,batteries and a big VR.

The one mistake made here is the fact that i did not increase the P/in back up to the same value as it was without the load placed on the coils/generator. All things being equal,i should have raised the P/in back up to the same value,once i switched on the bulbs. But i would also have to switch to the batteries,to obtain a very accurate P/in value,as the mains power around this area is not very stable.

https://www.youtube.com/watch?v=1IVxO94mcB0


Brad


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It would seem that we are indeed converting heat (or some of it) to electrical power.

So at a guess,i would say that we are reducing the amount of eddy currents flowing through the core,when we draw a load from the two generating coils. I will not know exactly how much until i box the whole setup,and switch to a much more stable power supply--E.G,batteries and a big VR.

The one mistake made here is the fact that i did not increase the P/in back up to the same value as it was without the load placed on the coils/generator. All things being equal,i should have raised the P/in back up to the same value,once i switched on the bulbs. But i would also have to switch to the batteries,to obtain a very accurate P/in value,as the mains power around this area is not very stable.

https://www.youtube.com/watch?v=1IVxO94mcB0


Brad

Yes, the very same thing happens with power transformers that are operating in saturation, without a load. When a load is placed on them, the saturation eddy current losses are gone, and the heat that the core experiences is drastically reduced, as the transformer is now operating in it's linear design region.

This tends to fool a lot of folk that don't account for the transformer temperature in their observations.

Nevertheless, in a rotating machine, perhaps it can be exploited as Smudge teaches.

One note on the use of thermocouples: for very accurate readings best when up to 1-1/2 to  2 inches can be inserted into a hole bored in the motor casing, as the leads themselves tend to pull heat from the measuring junction (tip). Also good to note the ambient changes during tests such that they can also be factored in.

Good work, Brad


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OK, i think i may have the setup needed for the inductive heating test.

I went through a few boxes of parts i have lying around,and fount a 400 watt 180VDC motor,and a rotor from an old 3 phase washing machine motor,that has 10 alternating magnetic poles around it.

The motor will do 4000RPM,and so that gives us a frequency of around 660Hz--will this be high enough to get the effect we are looking for?.

So now all i need is a 180VDC power supply  C.C
Here is what im thinking-quick and nasty i know,but will it be ok for the job?-->see schematic below.


Brad


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Brad

I hope that is a large power rheostat for adjusting the current, otherwise you will let the smoke out.

Do you have a Variac you can throw on the front of the bridge rectifier? If not a light dimmer up front might work as long as you have the dummy light bulb load in also.

The rotor and motor look nice.


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Brad

I hope that is a large power rheostat for adjusting the current, otherwise you will let the smoke out.

Do you have a Variac you can throw on the front of the bridge rectifier? If not a light dimmer up front might work as long as you have the dummy light bulb load in also.

The rotor and motor look nice.

Yes,i have a large 500 watt wire wound rheostat-see pic below
The lightbulb was to keep the voltage at an RMS value,and not charge the cap to the P to P value.

I dont own a variac,but it is on my wish list.


Brad


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Just got temporary internet connection again.  I like Ion's styrofoam box idea and would recommend that rather than fiddling about with copper tubes and water pumps.

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Brad said:

Quote
There is something odd going on with this setup,so see if you can make any sense of it.

No matter what load i put on the outputs of the stepper motor,the current value always remains at around 69mA per leg,and only the voltage value changes.
E.G,if i place those small incandescent bulbs across the outputs of the stepper motor,the current will be 69mA through each bulb ,at around 14.7V RMS. If i place larger incandescent bulbs across each leg,the current remains at 69mA,but the voltage across each bulb will drop.

So the stepper motor output is acting like a near pure current source. The only way I can think this can happen is if due to the nature of the construction of the stepper motor, i.e. it reaches a limit in magnetic energy transferred per pole of rotation due to a shunting effect.

It may be useful to investigate this more fully. Perhaps Smudge has a much better explanation.


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To me, the use of your stepper motor rotor seems like a very good idea

Is this motor what you are talking about ?

Stepper motor

https://en.wikipedia.org/wiki/Stepper_motor

A stepper motor or step motor or stepping motor is a brushless DC electric motor that divides a full rotation into a number of equal steps. The motor's position can then be commanded to move and hold at one of these steps without any feedback sensor (an open-loop controller), as long as the motor is carefully sized to the application in respect to torque and speed.

Switched reluctance motors are very large stepping motors with a reduced pole count, and generally are closed-loop commutated.


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Is this motor what you are talking about ?

Stepper motor

https://en.wikipedia.org/wiki/Stepper_motor

A stepper motor or step motor or stepping motor is a brushless DC electric motor that divides a full rotation into a number of equal steps. The motor's position can then be commanded to move and hold at one of these steps without any feedback sensor (an open-loop controller), as long as the motor is carefully sized to the application in respect to torque and speed.

Switched reluctance motors are very large stepping motors with a reduced pole count, and generally are closed-loop commutated.

Yes ,that is a basic drawing, there are many variations on that theme.


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Brad said:

So the stepper motor output is acting like a near pure current source. The only way I can think this can happen is if due to the nature of the construction of the stepper motor, i.e. it reaches a limit in magnetic energy transferred per pole of rotation due to a shunting effect.

It may be useful to investigate this more fully. Perhaps Smudge has a much better explanation.

It dose seem to act in an odd way.

But first a question-->and this may sound silly,but C.C
When measuring AC current and voltage,how do we know which way-or,from what device(source) the bulk of the power is coming from?.
To make my question more clear,lets say we have two black boxes,and we have a common or neutral wire from one box to another,and a live (or hot) wire with a 1 ohm CVR in series on the hot wire to measure the current flowing from one to the other black box. Lets assume that it's an AC current flow. So we place one channel of our scope across the neutral/common and live wires to measure voltage. We then place the second channel of the scope across the CVR to measure current. Without knowing which black box is the power source,and which is the sink,how do we know which way the power is flowing ?.

There is a reason for this question.
Below is a schematic of two circuits-along with scope shots.
The first circuit you will see a VR (which is 200 ohm's-forgot to put that value in the schematic),a 1 ohm CVR,and the stepper motor,which is being used as our generator.
The first 4 scope shots show the various resistance settings on the VR(which is our load on the generator), and the associated voltage and current traces in the scope shot for the stated resistance value of the load.
You will see that the maximum current the stepper motor can produce is 76mA.

The last scope shot shows the values taken when the second circuit is use,and that is just replacing the resistive load with the 240v mains LED bulb. I have no idea as to what the circuit inside is,as i cannot get it apart without breaking it--it is not as simple as the CFLs to get apart.

So if the maximum current that the stepper motor can produce is 76mA,then how is it that it can now produce over 270mA of current when the LED bulb is used as the load. We also now have 256 volts across the LED,but as you can see,the phase relationship between voltage and current is near 90* out close to 80* i would say.

But my question is--when using the LED as the load,how do we know that the bulk of the power is flowing from the stepper motor to the LED,and not from the LED to the stepper motor,as the stepper motor just will not produce this kind of current-regardless of RPM. Even with a dead short across the stepper motor outputs,there is no reflection seen on the prime mover(as seen in other video's)and no increase of current above that 76mA.

The other thing is,there is suppose to be over 250 volts AC across that LED,and it dose light very bright-->but i can hold the bare wires in my hands while the LED is shining brightly,and i get hardly any sort of a tingle at all  :o

What kind of electricity is this  :D


Brad


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Dear Brad.

I have 7 W LED lamps in use all over the house. Our house is ancient, 316 years old! No ceiling roses, wall lights. I had to open one to direct the light more downward.

They are SMD LED's with a bridge and a storage cap, plus a few dropping resistors.

I can provide a photo if you want one.

Cheers Grum.


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