OK, I have a project I'm working on, where I need to increase the available stall torque of some existing motors, it's important not to change the motor size if at all possible. The motors are already having some issues with heating up and losing power after about 30 minutes of continuous use. They are DC brushed motors, (ball-bearinged) of the 550 variety and run at 24V, about 4000 RPM no-load, and about 4 amps at stall. Most of the time they are running near stall, and work in pairs. They are already running a pretty minimal air-gap. Will switching to neo magnets increase torque without too much current increase? What about switching to a larger motor (If I can convince them) and running a limiting resistor? Would I get more torque than the smaller motors? I'm sure this would help combat the heat/power loss issue since the wire gauge would be larger but with less current running through it, wouldn't it? I'm hoping someone has some insight so I don't have to go through a whole bunch of experimentation/prototyping.
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