I got 14 links of 5/16" (8.8 mm thick) zinc coated chain. It is 18.25" long. They weigh 533 grams. Link's outer dimensions are about 28x48 mm. It was US $2.97 per foot @ homedepot.
I also bought 1 lb of 20 AWG magnet wire for around $16 US on Amazon. 1 lb of wire should be about 323 ft and I am hoping to use it for 3 breaks. At about 1 Ohm each. I need 14 total for 7 DOF. $5/brake $75 total. Each brake will be about 190 g. 2646 g (5.8 lbs) total.
This is getting heavy and expensive... (OR not https://temcoindustrial.com/20-awg-copper-magnet-wire-5-lb-mw0027-magnetic-coil-red-soderon155.html OR https://temcoindustrial.com/20-awg-copper-magnet-wire-5-lb-mw0167-magnetic-coil-gpmr200.html) I was hoping to make the whole robot for under $100.
Next thing to do is to anneal it in sand using a torch to improve its magnetic qualities. This should also strip the zinc coating. For this reason I bought zinc coated and not galvanized chain. It is harmful to inhale zinc vapors. Do it outside !!!
After annealing I will cut a slot in each link and try to separate the chain by bending them open. Close the links back and leave about 3 mm gaps for disks to spin through.
Looking at a 1 lb spool of wire it seems big. I hope I will be able to wind 107 ft (32.6 m) around the link. It will take some time :)
I don't know how much current a 20 AWG wire will take. Reference materials on the web state anywhere from 1.5 A wound (http://www.magnetwire.biz/magnet_wire_current.html ) to 18 A for a single conductor in air. The brakes will not be operated at 100% duty cycle. I am guessing 25% max. This might need to be enforced in software. Spinning disks can be equipped with blades for air cooling the brakes. Therefore, I am hoping to be able to operate the brakes at 12 V through IRFZ44 mosfets or MCP14A1202 or even MCP14A09? Anyone has a schematic to recover the conductor EMF energy after it is turned off?
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