Help in designing electromagnets

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SUMMARY

The discussion centers on designing electromagnets based on the specifications used in the MIT Actuated Workbench. The electromagnets have a diameter of 1.9 cm and a length of 3.8 cm, utilizing 32-gauge copper wire with a resistance of 120-122 ohms, powered by 27 DC volts and drawing approximately 250mA. The user seeks to optimize the design for greater force output and is considering using a standard 24V power supply instead. Recommendations for simulation tools include FEMM, MaxFEM, Vizimag, Elmer, and OpenFOAM for further exploration of electromagnet strength calculations.

PREREQUISITES
  • Understanding of electromagnet design principles
  • Familiarity with 32-gauge copper wire specifications
  • Knowledge of electrical resistance calculations
  • Experience with simulation tools for electromagnetic analysis
NEXT STEPS
  • Research the calculation of amp-turns per unit length and permeability for electromagnets
  • Explore the use of FEMM for simulating electromagnetic fields
  • Investigate the impact of using a 24V power supply on electromagnet performance
  • Learn about the mechanical detection methods for positioning in electromagnet applications
USEFUL FOR

Engineers, hobbyists, and researchers interested in electromagnet design and optimization, particularly those working with the MIT Actuated Workbench or similar projects.

Nmbr6
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Hi all,
First post, be gentle...

I'm trying to build a system based on the MIT Actuated Workbench.
They used electromagnets with the following spec:
1.9cm (0.75”) diameter x 3.8cm (1.5”) length, wound with 32-gauge copper wire with a total length resistance of 120-122 ohms, with no metal housings so to not focus the magnetic field.
They used 27 DC volts and draws about 250mA.

From what I read, it seamed to be an almost arbitrary choice though, so I was hoping to optimist the design to create more forces. I was also hoping to use a more standard 24V power supply (not sure why they used 27...)

I'm not sure where to start this process and I was hoping to get some advice.

I thought maybe some trial and error through a simulation tool could work, but tell me what you think (also for that, so far I saw recommendations for FEMM, MaxFEM, Vizimag, Elmer and OpenFOEM, so I could also use a recommendation for which one to use)

Thanks!
 
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Nmbr6 said:
so I was hoping to optimist the design to create more forces.

So is the question "how does one calculate strength of an electromagnet? " ? Any search engine should respond to that question.
The basic approach is amp-turns per unit length X permeability.
With 32 gage wire it's a sure bet they used copious turns and meager amps to get the amp-turn product they wanted.
You already know the amps, around ¼ .
To estimate # turns figure length of #32 to make 120 ohms. How many times will that wrap around a ¾ inch core?

The video you posted is long on applications but short on mechanical details.
They gave no clue how they detect position of a puck over the array of electromagnets.

Nmbr6 said:
I'm not sure where to start this process and I was hoping to get some advice.
It's hard to figure out what you are asking.
 

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