generator tips » Making PERFECT coils for my axial flux alternator (DIY wind turbine)

The video shows the whole production process from the wire to the finished coil. I built this alternator for a 1,7m diameter windmill. Some nice coil winding action. Interesting design facts. Coils fixed with instant glue. If you got questions please leave a comment or visit my blog where you can e-mail me! Watch my blog for more wind turbine and DIY stuff:

I am building another Axial Flux. My first one was sorta a success, it had dual 22 gauge wires per coil at 48 wraps and made open voltage of 83 volts at 350 rpms. However, that one was a 9 coil, I am now making a 12 coil and I am using double strands of 15 gauge (1.45mm wire) wrapped 38 times to build one to charge 12 volt system, NOT another 24 volt system. Does 38 wraps of double( 15 gauge) 1.45 mm wire (4 coils per phase) sound right for a Axial to make 30 volts at 350 RPMS for a 12" rotor and using 32 magnets (2"x 1" x 1/4" Neo-42 magnet)? Whats your perspective? You can improve your design be leaving less air gap in your coils, instead of making them into triangles it would be more efficient to make them into more of an elliptical shape. Since voltage and current are induced by a conductor cutting through magnetic lines of flux, if you are able to increase the amount of lines being cut with the same shaft rpm you will generate more power. Credit: electrician and studying electrical engineering. I apologize if you have already discovered this. Great jig by the way! I wish you success. In lieu of instant glue, wrap thread to secure coils. Apply varnish, or wood sealer to the thread and let dry for a day. You can also use wood glue. Your instant glue has hazardous vapors and so does your cfc spray. I wish you lived in the USA I would send you materials for your project. Maybe somebody in your country could give you the supplies you need. good luck.

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