Junkyard sized Large electromagnet

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    Electromagnet
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SUMMARY

The discussion centers on the construction of a large electromagnet using a portable generator rated at ~240VAC and ~3500 watts, which is stepped up to ~540VAC through a transformer and then rectified to DC. The project involves a semi truck rim with a ~3.5" solid core axle as the base for the electromagnet. Participants seek advice on the optimal winding placement and wire gauge to ensure sufficient induction resistance while maintaining generator longevity. The conversation emphasizes the necessity of consulting experienced individuals for safety and effectiveness due to the high voltages and currents involved.

PREREQUISITES
  • Understanding of AC to DC conversion using full wave bridge rectifiers
  • Knowledge of electromagnet design principles
  • Familiarity with wire gauge selection and its impact on resistance
  • Experience with high voltage safety protocols
NEXT STEPS
  • Research the design and construction of electromagnets using solid core axles
  • Learn about the effects of wire gauge on induction resistance in electromagnets
  • Explore safe practices for working with high voltage systems
  • Investigate the use of transformers in increasing voltage for electromagnet applications
USEFUL FOR

Engineers, hobbyists, and DIY enthusiasts interested in electromagnet construction, particularly those working with high voltage systems and seeking practical guidance on design and safety considerations.

midknight
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what we have to work with is a portable generator ~240vac ~3500watts then to a step up transformer so output ~540vac. then a full wave bridge rectifier to make the DC

thought is we have a semi truck rim (will get the diameter/size soon) (due to this will get slammed around and banged into other scrap yard items) with a ~3.5"solid core axle welded into the center.

we have access to unlimited amount of thhn* wire of pretty much any awg (solid or stranded) to use in this project we would like to create a scrap yard size electromagnet

extra equipment can be implemented in this project suggested. (bigger than a rim if needed)

questions are:
1) best way to place the windings or just wrap the center pole?
2) best size wire to use for the windings to make enough induction resistance so the generator will last a lil while

will post pictures and more pictures and more pictures of the build and progress and end results so everyone can see how it works when completed so others can build one if they would like or use as a reference for their own projects.
 
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I'm sorry, but we cannot help you with this question. You will be dealing with voltages and currents high enough that anonymous guidance from an anonymous internet forum about how to design your field coils isn't going to be good enough - you need input from people who have actually done it before, who are familiar with the specifics of your project.

So this thread is closed. (Somewhat regretfully, because it is a fascinating project).
 

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