By: Ngangkham Peter Singh 3 rd Sem, Advanced Materials Technology(M.E) UVCE Bangalore

1. History of windmills 2. Manufacturing of windmills 3. VARIM process 4. Manufacturing of nacelle cover and nose cone 5. Conclusions 6. References

 200 B.C.-1 st wind machines used in Persia for grinding grains  7 th century- 1 st practical windmill used in Sistan pumping and grinding  14 th Century- Dutch windmills were in use to drain areas of the Rhine River delta

 st electricity generation in Scotland by James Blyth  st automatically operated wind turbine was built in Cleveland by Charles F. Brush

 Horizontal Axis Wind Turbine  Vertical Axis Wind Turbine

 The wind direction and the rotor are in the same direction.  Mostly used design

 In earlier times  Steels  Wood  Poly foam and Aluminum  Present times  Fiber glass and Epoxy Resin, Vinyl Ester  Carbon Fibers and Epoxy Resin, Vinyl Ester

 Processes used  Hand lay up process  VARIM process  Materials required  EPS foam  Model table  Resin  Glass fabrics  Heaters  Accessories  Vacuum pump

 Model table and model  Preparation of mould  Manufacturing of windmill blades

 Model table preparation  Foam cutting  Joining of the separate blocks  Lamination  Finishing  Contour checking

 Hand lay up process  Multiple passing  Curing  Thermoset and heaters embedded  Metal frame also attached  Lay up of the mould  Finishing operations

 Steps  Layup of moulds  Vacuum testing  VARIM process

 Vacuum assisted resin infusion method  Vacuum pulls the resin through the lay out  P1=Atmospheric Pr  P2=Applied Vacuum Pr

 Preparation  Injection  Vacuum reduction  Curing  Additional materials are removed after curing

 Darcy’s Law:  Flow of fluid in a porous material  Software pack to determine the feeding point

 Cured parts are joined  Parts include  Nose insert  Root insert  Shear plate  Two halves of the blade

 Dry finishing  Sanding  Painting  PU paints

 Made by hand lay up process  Finishing operations  Assembly

 Dry glass  Air in laminates  Foam burning  Wrinkle  Variations in paint thickness  Corrosion  Improper bonding

 VARIM process is used for the production of windmill blades.  Advantages of VARIM are  Unskilled labour  Constant thickness  Minimum thickness and shrinkage  Faster cycle time  No pollution from volatile organic compounds  Better fiber to resin ratio

 Nacelle covers and Nose cone are produced by hand lay up process  Composite materials used are combination of Vinyl Ester or Epoxy resin and Glass fabrics or Carbon Fabrics in the manufacturing of windmills

 Wikipedia: Internet Encyclopedia  Britanica Encyclopedia  Kemrock Industries and Export Limited- Windmill Division  Danish Wind Industry Association   FRAM Building and Sailing Industry 

Thank you