Manufacturing process of a wind generator

           The manufacturing process starts with the preparation of he magnetic plates that will compose the alternator nucleus. For this purpose, an automatic press is used to cut a matrix which has been designed in our R&D department with a tooth form ideal for this application. The magnetic plate is silicon treated to obtain a higher efficiency. Once cut, the plates are grouped in packs of variable thickness depending on the alternator power.


 Preparation of the magnetic plate packets to wind
        After this the coils are formed on the packs, thus forming the inducer of the alternator. The electrical safety tests are then performed and the complete inducers are varnished and dried in a furnace.


Induced after getting out from the furnace
        In another section of the factory the magnet hopusing drums are prepared. They are painted and baked, and later balanced. The magnet drums forms the other half of the alternator, permiting the production of electricity as it moves around the inducer coils. In our wind generators the inducer remains inmobile and it is the magnet drum which turns and upon which the blades are mounted.
Mechanization and electrochemical treatment of the plates
Magnets fixing and painting in epoxy
        After this, the inducer is introduced into the magnetic drum, thereby finishing the alternator. At this time the operation under load test is performed by rotating the machine with a variable speed motor, and obtaining the power curve for each alternator.
Alternators finished

        The alternator is mounted in a metallic structure upon which the tail is also fixed. This structure allows, through the use of brush collectors, the connection of the alternator to the vertical cabling without obstructing the horizontal rotation of the wind generator. Once the structure is assembled the protective casing and the nose cone are attached, both are made of fiberglass and epoxy.

Internal structure of the wind generator and collector box
Quartering of the wind generator head
Cover manufacturing
Cover painted and finished

        The tail is mounted with a small inclination in order that it may fold up when the wind speed is very high, thereby avoiding damage to the generator. In normal operating conditions the tail is perpendicular to the plane defined by the blades, which in turn faces into the wind. The model Vélter B is a leeward design which means that the blades are also the tail (the generator faces away from the wind). In both models the pieces mounted on the blades are used to limit the rotational speed.

Vélter wind generator finished, mounted in a grid tower type.

        When the wind generator is not rotating, the blade profile presents a maximum surface area towards the oncoming wind, this allows start up at very low wind speeds. This can be seen in the previous photograph.
        You can see the manufacturing process of the new Velter XV by clicking here.