Calculate length of wire needed for solenoid

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Discussion Overview

The discussion revolves around calculating the length of wire needed to wind a solenoid coil, focusing on the relationship between wire dimensions, cylinder dimensions, and the number of turns versus layers. Participants explore different interpretations of the parameters involved in the calculation.

Discussion Character

  • Technical explanation
  • Debate/contested
  • Mathematical reasoning

Main Points Raised

  • One participant expresses confusion over the calculation results from a wire length converter, suggesting that the output seems exaggerated for the given parameters.
  • Another participant proposes that the term "layers" refers to the number of wires above a given point, suggesting that the length needed for a single layer would be significantly less than the initial calculation.
  • A participant clarifies the distinction between "layers" and "turns," indicating that the misunderstanding may have led to the inflated wire length calculation.
  • One participant estimates that a single layer would require less than 50 feet of wire, while another provides specific calculations based on the dimensions given, indicating that 100 turns would require a longer cylinder and more wire.
  • There is a suggestion that if 100 turns were to be considered, the cylinder length would need to be adjusted accordingly to accommodate the turns.

Areas of Agreement / Disagreement

Participants do not reach a consensus on the correct interpretation of "layers" versus "turns," and there are multiple competing views on how to calculate the required wire length based on these definitions. The discussion remains unresolved regarding the exact length needed for the specified conditions.

Contextual Notes

There are limitations in the assumptions made about the definitions of layers and turns, as well as the implications of wire dimensions on the overall calculations. The discussion does not resolve these ambiguities.

Pepelepoe
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Hi,

I'm trying to calculate the length of wire that I need to wound a coil using a spool and wire of known dimensions. I was trying to use this converter but I'm not getting good results:

http://www.had2know.com/technology/solenoid-coil-wire-calculator.html

For instance: with a wire radius of 0.32258 mm (22 AWG), cylinder radius of 12mm, cylinder length of 33mm and 100 layers (which I'm assuming is the number of turns) I'm getting about 1419179mm of length which is about 4656 feet of wire. This number seems exaggerated to me. I really don't care about parameters such as magnetic flux, force or current for that matter. I just want to know the length of wire I need to be able to wound the coil using a drill and not take ages doing it manually. Help would be greatly appreciated. Thanks.
 
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My guess is that the number of layers refers to how many wires there are above a given point on the inner cylinder. So with 100 layers, you will be winding from one end to the other (about 100 turns for the first layer), then back again to the end where you started the winding to put a layer on top of that, then repeat the exercise fifty times.

The length of wire you need for what you want, which is only a single layer, will be less than one hundredth of the length you got. Put 1 layer into the calculator.

Edit. I just read further down on the page you linked and it confirms my guess.
 
But why layers? What I want is turns. How much length do I need given a number of turns. Sorry, I'm a bit confused about this. Just realized that "layers" are not the same as "turns" like I thought which is why I was getting such a big number.
 
Sounds like you want one layer, which will be < 50 feet.
 
Hi did you determined it's about 50 feet? Thanks.
 
Do you want 100 turns or a 33mm long cylinder? Given a wire radius of 0.32mm, a 33mm cylinder will only hold 50 turns in a single layer, in which case the wire will be just under 4m. If you want 100 turns and only one layer, the cylinder must be about 66mm long and you'll need almost 8 metres of wire.
 
Pepelepoe said:
Hi did you determined it's about 50 feet? Thanks.

If 100 turns is a mile, and you want only 1 turn, it's 50 feet.
 

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