Electric winch has been designed & developed for an organization involved in windmill blade testing.

1. Development of Electric Winch for Wind mill blade testing
Here it is, as an initiative of imparting our footprints all over the world,
achieved another milestone by exporting our Winches to one of the
esteemed organization involved in testing of Wind blades. Our ultimate
goal is to indirectly contribute in field of renewable energy sources by
designing and developing wide range of products best Suitable for its
use in this field.

2. Electric winch has been designed & developed for an organization
involved in windmill blade testing. Wind turbine blades are one of the
most critical components and hence they have to be tested properly in
order to ensure that their specifications match with the actual
performance of the blade. International Electro technical Commission
(IEC) report states that, the fundamental purpose of a wind turbine
blade test is to demonstrate that a blade type, when manufactured
according to a certain set of specifications, has the prescribed reliability
with reference to specified limits, or, more precisely, to verify that the
specified limit states are not reached and the blades therefore possess
the strength and service life provided for in the design. It must be
demonstrated that the blade can withstand both the ultimate loads and
the fatigue loads to which the blade is expected to be subjected during
its design service life. There of blade testing can be broadly classified
into two major types, static testing and fatigue testing. Testing of the
blades statically and dynamically helps in to maximize and predict
blade’s service life for economic feasibility and safety. Our highly
reliable winches are designed for its intended use in Static testing of
blades.

3. Static test is for verifying the ability of the blade to withstand design
load or ultimate strength. Static tests are performed with the purpose
of predicting a blades ability to withstand extreme loads such as those
caused by hurricane wind forces or unusual transient conditions, in
order to determine the ultimate strength of the blade. The bending
moment distribution in several directions along the blade span is
defined from the design load cases. During the test, these bending
moment curves are simulated by application of load at discrete
locations. The static test gives information on the ability of the blade to
withstand the loads, and also provides valuable information on blade
structural properties, deflections and strains depending upon
instrumentation used for testing. Static tests generally involve pulling
on the blade by means of winches, cranes or hydraulic actuators.
Hydraulic actuators were used in the past but large displacements in
longer blades make them an expensive option, Moreover, use of

4. winches provides ease of control. The load can be applied vertically
downward, in this case gravity will contribute to the test load, but
horizontal load application or vertical upward pulling can also be used.
In all cases the additional load component due to gravity has to be
accounted for. The number of load application points is not strictly
defined. It may depend on, amongst other things, the shape of the
target moment distribution along the blade, the allowable loads locally
on the blade (shear loads also need to be considered), costs, or
preferences of the test designer.
Winch is designed and manufactured, in such a way that it meets the
functional requirement of Wind mill blade test without any errors or
uncertainties. Basically, this winch consists of multiple planetary
stages, designed with Four planets at each stage to withstand the high
loads. The load is shared uniformly amongst the internal teeth of
planet gears. The input of winch is designed to make it suitable for
mounting of DC servo motor. This kind of arrangement favourable for
DC servo motor, helps the motor to achieve high efficiency and great
precision. The Servo Motor is used so that the output shaft can be

5. moved to a particular angle, position and velocity according to output
load requirements. Thereby sensing the load and accordingly
controlling the movement. The winch is equipped with continuous
tension device used for sensing the load. It requires huge R&D to
design these kind of winches, where reliability is most important. Top
gears Engineering for more than two decades in this field has enabled
to provide winches with low backlash and High torsional stiffness most
suitable for testing of windmill blades. To ensure the reliability and
efficiency, these winches are tested as per stringent quality standards.
These all is possible only due to The-State-Of-The-Art testing facilities
and experienced quality team associated with us. Top Gear has testing
facilities for testing the winches effectively up to 50 Ton capacity.