The relationship of wire diameter and electricity produced

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Discussion Overview

The discussion centers on the relationship between wire diameter and the electricity produced by generators, particularly focusing on the optimal American Wire Gauge (AWG) for coils in generator design. Participants explore various factors influencing generator performance, including wire thickness, coil design, and power output characteristics.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant is researching how wire diameter affects power production in generators and seeks information on the best AWG for coils to achieve a standard kilowatt-hour output.
  • Another participant challenges the notion of a "standard kilowatt-hour," suggesting that generators are typically designed for specific voltage and current capabilities.
  • It is noted that wire size is primarily associated with maximum current, but thicker wire complicates coil winding due to increased radius and reduced turns within the same volume.
  • A suggestion is made to look for online calculators that assist with generator design, similar to those available for transformers.
  • A participant mentions that the design of a DC generator is similar to that of a DC motor and provides a link to an AWG wire table for reference.
  • Another participant recalls that generators operate similarly to transformers, where core parameters and frequency determine maximum power, and emphasizes the trade-offs between wire thickness, current, and voltage.
  • The concept of "Turns per Square Inch of Insulated Wire" is introduced as a parameter to consider in generator design.

Areas of Agreement / Disagreement

Participants express differing views on the concept of a "standard" kilowatt-hour and the optimal wire size for generators. There is no consensus on a single best approach, and multiple competing perspectives on generator design and wire diameter effects remain present.

Contextual Notes

Participants highlight the complexity of generator design, including the physical limitations of winding coils and the interplay between wire thickness and the number of turns. The discussion reflects various assumptions about power output and design parameters that are not fully resolved.

Troymoore4
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im doing some personal research into building my own generator. i am looking for info on how wire diameter affects the power produced by the generator. specificaly: what AWG of wire is best for coils that are being used to generate as clost to the statdard killowatt/hour as possible.
 
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Troymoore4 said:
specificaly: what AWG of wire is best for coils that are being used to generate as clost to the statdard killowatt/hour as possible.

that doesn't really make sense ... there is no standard kilowatt hrs

generators would normally be designed to produce a given voltage and capable of a maximum current capability
 
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Wire size is most associated with maximum current.

But there is the problem of physically winding a coil. The thicker the wire, the larger the radius to the outermost winding. Equivalently, within the same volume and form factor for a coil, the thicker the wire the smaller the number of turns. It is not easy to calculate performance with alternate designs.

I have seen online calculators that aid with DIY transformer design. Perhaps there is something similar for generators. Try searching for "online generator design calculator"
 
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Troymoore4 said:
im doing some personal research into building my own generator.
The design of a DC generator will be very similar to a DC motor. Do you plan a DC generator or an AC alternator?
Here is an AWG wire table that gives diameter, ampacity etc; https://en.wikipedia.org/wiki/American_wire_gauge
 
It was some decades ago already, but as I recall in this regard generators works ~ the same way as transformers. The core parameters together with the frequency determines the maximal power: the maximal power and the available cross section for wire together fits with the wire thickness and turns in the coil.

So there is no real 'standard' or 'optimal': within the available cross section you can more or less freely trade between thick wire/high current/low voltage to thin wire/low current/high voltage.

You should think around the parameter 'Turns per Square Inch of Insulated Wire'.
 

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