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« on: October 11, 2016, 11:15:29 PM »
Each individual wire does not carry the full amperage. It's distributed by the commutator.
The reason why more windings creates more torque is because you generate a more powerful magnetic field (running a current through any wire generates a magnetic field, more wires means a more powerful field).
Higher TPA motors generate less heat because they pull less amperage, which is also why they're more efficient. The magnetic field is stronger, so less amperage is required.
I've never seen failures on the armature because, while you do have small diameter wires, they're bundled. Keep in mind that for large industrial applications (thousands of amps), power cables are made of bundled wires. The concept is the same. The more likely point of failure is at the motor brushes.