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#1 2026-08-04 08:13:25
- Void
- Member
- Registered: 2011-12-29
- Posts: 9,767
Carbon wrapped rotor?
This topic can be folded into another one if the moderators desire or it can be deleted.
Motors on Mars or in space will be important.
But I am also speculating that Carbon Wrapped Rotors will make generators more efficient. Therefore I wonder about solar power from concentrating mirrors and super-critical CO2.
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Carbon-Wrapped Rotor Technology
A carbon-wrapped rotor is a next-generation electric motor design where the rotor of a permanent magnet motor (PMM) is encased in a precisely wound carbon fiber sleeve. This sleeve is made from Carbon Fiber Reinforced Plastic (CFRP) and is applied under high tension to compress the internal rotor assembly Addcomposites+1.How It Works
Containment & Compression: At high RPM (often 20,000+), centrifugal forces cause metal rotors to expand outward. The carbon sleeve applies hoop-direction tension, holding magnets or copper inserts in compression (50–150 MPa) to prevent loosening jotaintl.com.Tighter Air Gap: By limiting expansion, the air gap between rotor and stator can be narrowed to micrometer-level tolerances, strengthening the magnetic flux and torque output jotaintl.com.
Eddy Current Reduction: Carbon fiber’s low electrical conductivity (~2×10⁴ S/m) minimizes eddy current losses, cutting hundreds of watts of parasitic heat and improving efficiency jotaintl.com+1.
Thermal Management: Less heat generation means lower steady-state temperatures (often 20–30°C cooler), reducing magnet demagnetization risk and extending motor life Yahoo Autos+1.
Performance Benefits
Higher RPM: Enables operation at ~25% higher RPM than previous generations, boosting power density Yahoo Autos.Stronger EM Field: Compression and tighter gap increase torque for the same current Yahoo Autos.
Lighter, Compact Motors: More power from a smaller, lighter package — critical for EV range and acceleration Addcomposites+1.
Improved Reliability: Prevents rotor deformation and maintains precise alignment under extreme conditions jotaintl.com.
Tesla’s Implementation
Tesla first used this in the Model S Plaid motor, making it the first production EV motor with a carbon-coated rotor Yahoo Autos. The challenge was overcoming differential thermal expansion between carbon and copper, solved by custom high-tension winding and compression preload Yahoo Autos.
The technology is now being scaled for the Roadster with plans for even higher torque (10,000Nm) and 0–60mph in under 1.9 seconds jotaintl.com.Why It Matters
Carbon-wrapped rotors represent a shift from traditional steel or titanium sleeves, offering higher speed capability, efficiency gains, and reduced losses. They are a key enabler for next-gen EVs aiming to push performance and efficiency boundaries Addcomposites+2.In short, a carbon-wrapped rotor is a material and manufacturing breakthrough that could redefine EV motor performance, making them faster, lighter, and more efficient than ever before.
So, I am wondering about the relative performance of Solar Panels vs. Concentrating Mirrors in Space to generate power.
I am sure that it will not be "One Size Fits All".
Ending Pending 
Last edited by Void (2026-08-04 08:18:01)
Be careful what you wish for.
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#2 2026-08-04 08:54:22
- tahanson43206
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- Registered: 2018-04-27
- Posts: 25,528
Re: Carbon wrapped rotor?
This post is reserved for an index to posts that may be contributed by NewMars members.
Any posts should be about this specific subject. They should NOT be about solar panels or concentrating mirrors, and each such post should very clearly relate in some way to life support.
For Void... the technology you have shown us is important for improvement of performance of electric motors.
It **might** easily translate into improved performance of life support systems that depend upon electric motors.
Please make sure that every post you add to this topic is focused tightly on this particular advance in the technology of electric motors, in the context of life support.
My sense of this topic is that it has significant upside potential in terms of Mars habitats. Every habitat on Mars is going to be served by many electric motors and large habitats such as Calliban's or that of SpaceNut will need thousands of motors of various sizes.
The particular advance you showed us here is about increasing the efficiency of motors as they turn more rapidly. Increased efficiency ultimately leads to lower rent for Mars residents.
If you keep this topic tightly focused, it may grow to become valuable for someone to read.
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#3 2026-08-04 12:41:47
- Void
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- Registered: 2011-12-29
- Posts: 9,767
Re: Carbon wrapped rotor?
I specifically intended to do Concentrating Mirrors, in the asteroid belt and Saturn, but also Mars.
Why the restriction?
MY best guess is that if you can make a generator do more RPM's and can shrink the air gap, thus concentrating the magnetic flux, you may reduce eddy currents and so waste heat, perhaps getting more efficiency from a generator system.
If you want to restrict this topic as you have, then go ahead.
Do we have a topic that will cover thermal power generation in space, including concentrating mirrors, somewhere else?
Ending Pending
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