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

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

3.  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

4.  1887- 1 st electricity generation in Scotland by James Blyth  1888- 1 st automatically operated wind turbine was built in Cleveland by Charles F. Brush

5.  Horizontal Axis Wind Turbine  Vertical Axis Wind Turbine

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

7.  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

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

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

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

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

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

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

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

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

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

18.  Dry finishing  Sanding  Painting  PU paints

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

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

21.  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

22.  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

23.  Wikipedia: Internet Encyclopedia  Britanica Encyclopedia  Kemrock Industries and Export Limited- Windmill Division  Danish Wind Industry Association  http://guidedtour.windpower.org/en/core.htm  FRAM Building and Sailing Industry  www.fram.nl/workshop www.fram.nl/workshop

24. Thank you