Aluminum Foil Coils for Human Scale Wind Turbines

A novel coil design for an axial flux permanent magnet generator to be used in small wind turbines has been realized. While traditional designs comprise enamel copper wire, the novel coil uses aluminum foil for it being low cost and readily available. Commercial home video tape is employed to provide insulation between turns, promoting the recycling of video cassettes and enhancing the magnetic properties of the generator. Three study cases were analyzed and tested; their manufacturing process and performance were recorded. The test results are presented in terms of comparison with the original copper design, indicating that aluminum foil coils have the potential to enhance the performance of the generator. The design and manufacturing approaches are unveiled so that a fabricator may redesign and build similar coils based on the materials available.