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The IRON MAN™ Windmill is a modern version of the Traditional American Water Pumping Windmill.
This legendary machine has dependably provided significant amounts of water, serving the needs of farms, families and communities with only minimal attention for over 150 years.
First designed in the mid 1800's, the traditional American windmill has been improved with countless innovations and is now a highly refined and successful technology that is only
slightly reminisent of it predissors. The Iron Man Windmill is able to pump impressive amounts of water in very light breezes as it lifts water economically to
elevations greater than 1200ft (400M). It has a practical working life greater than 1/2 a century with proper maintenence.
They routinely survive storms that wreck buildings without suffering damage.
Many earlier models of the traditional American Windmill are still working today after providing 70 or more years of dependable service.
Iron Man Windmill Co. is proud to continue this long tradition while working consistently to improve our windmills and striving to make them even more affordable.
While they are simple in operation, they incorporate many details that are necessary for proper operation, protection from storms, providing correct lubrication of the moving parts and ultimately a long and trouble free life. We will describe and attempt to explain the operation of the major components here. Two or more heavy steel bands support the sails and maintain proper alignment. They also provide strength to hold the wind wheel together in strong winds, when the centrifugal forces can be great. Strong steel Wheel Arms connect to the Hub to hold the Bands in alignment and provide strength like the spokes in a bicycle wheel. 
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All IRON MAN™ Windmills use a steel multi-bladed wind wheel. Multiple curved sails are rigidly mounted at an angle to the wind. As the wind passes through the opening between the sails, it is compressed on the face of the sail. As it exits the wind wheel, an area of low pressure is created behind the sail. It is this difference in pressure that applies a force against the sail, causing it to rotate. This design provides a high torque at very low wind speeds. Because low wind speeds are the most common, it is essential that water-pumping windmills work in low wind speeds. This design is not a product of accident! It is the result of two years of meticulous scientific study where more than 2000 tests were conducted on 65 different designs of wind wheels and many variations of these designs. The result is the lightest, strongest and most efficient wind wheel ever used on a water pumping windmill. Although there has been many attempts to improve on this design, it still stands unchallenged as the most practical design yet produced. It is interesting to note that the design has been so well refined, that small changes, even to the curvature of the sail, result in a reduction of pumping ability. While countless efforts to improve this design have been made, it still reigns supreme, especially when working in very low wind speeds. |
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The Hub in the center of the Wind wheel is attached to the Wind Wheel Shaft (often called the “Main Shaft”) of the windmill gearbox. The wind wheel rotates and causes the Wind Wheel Shaft to turn. The Wind Wheel Shaft is supported by bearings, usually made of Babbitt metal, which has been found over many years to provide excellent service in windmills. The Main Shaft supports 2 Drive Gears, often called the Small or Pinion Gears. The two Drive Gears rotate causing the two Driven Gears (often called large gears) to rotate. Two Pitman Arms are caused to move up and down as the Driven Gears rotate. The Pitman Arms cause the Guide Wheel and the other parts attached to the Guide Wheel Shaft to move up and down, completing one pumping cycle. The Oil Ring is one of many special devices used to lubricate the various parts. In this case it carries oil from the outside of the large gears up to the Guide Wheel Shaft and the Guide Wheel. The Wind Wheel of most Traditional American Windmills turns about 3-1/3 times to complete one cycle. Some direct drive windmills that do not use gears have been produced, but have not been as successful as back geared windmills, like the examples shown here. |
PUMP ROD IS SHOWN AT THE TOP OF THE STROKE
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PUMP ROD IS SHOWN AT THE BOTTOM OF THE STROKE 
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Left, the Pitman Arms are at the bottom of the stroke. The Guide Wheel keeps the Pump Rod moving in a straight line for the full length of the stroke. If you look closely, you can see that the Large Gears have two provisions for supporting the Pitman arms. The common position provides a long stroke, which is the normal stroke. The other provisions allow the windmill to operate with a short stroke. The use of the short stroke allows water to be pumped in lower wind speeds or to pump water higher than is usual. This can be a very important feature if the water level in your well drops, or there is a long period of very light winds. With normal wind and water conditions, the short stroke is not used. When the short stroke is used, it is also necessary to change the guide wheel shaft to the lower set of holes at the top of the Pitman Arms. If this is not done, the oil ring(s) cannot come in contact with the large gears and no oil will get to the parts at the top of the gearbox! |
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The IRON MAN™ Windmill uses two sets of gears and Pitman Arms. This has the advantage of dividing the load so each Driven Gear and Pitman Arm carries only half the load. This type of pumping mechanism is very important for long life and efficient operation. The windmill gearbox provides the motion and lifting force necessary to literally lift the water from its source. The windmill pump lifts the entire column of water from the surface of the water in the bottom of the well. This is why it is necessary for windmills to have a strong and efficient mechanism. Additionally, this design provides a balanced and even lift. This is one of the reasons IRON MAN™ Windmills lasts so long! With a simple annual oil change, IRON MAN™ Windmills can work well for 50 years or more! |
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WINDMILL PUMP
This type of pump Is typically used in deep wells. 
The piston moves up and down with each stroke.
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The windmill pump is the device that actually pumps the water. Water is pumped to the surface when the pump rod raises the piston. The piston check valve closes and holds the water above the piston. As the piston rises, water is moved up the pipe towards the surface. Water is also drawn into the lower section of the pump cylinder through a screen and the lower check valve. When the pump rod reverses and begins to descend, the lower check valve closes and the piston check valve opens allowing the water in the cylinder to pass through the piston check valve and become trapped above the piston when the check valve closes. This cycle is constantly repeated as the wind wheel turns, operating the reciprocating mechanism in the gearbox, which operates the pump rod and pump. Deep well pumps, as seen on the left, connect to the bottom of a string of pipe, which is supported at the surface of the ground in the center of the windmill tower. The Pump Rod that operates the piston passes through the full length of pipe all the way to the surface and connects with the pump rod in the windmill gearbox. The pumping cycle is slow and therefore friction is very low as opposed to rotary pumps that must operate at a much higher speed and hence suffer from significant losses due to friction. It is also possible to locate the pump some distance from the windmill and operate it with cables or other mechanism to pump water from a river, lake, pond, spring or even a water tank used to collect and hold water. It is always best to locate the pump cylinder below the lowest level of water for dependable operation. The best windmill pumps for deep well use are made of stainless steel, alloy steel with proprietary ultra hard linings or with brass or bronze bodies or liners. They allow the pump rod to be disconnected and easily removed, without having to remove th well pipe. Many pumps are designed to allow the piston to be lowered and remove rotated, causing the bottom of the piston to connect with the top of the lower check valve. Both can then be lifted to the surface for servicing without any need to remove the pipe. This is a great convenience when servicing deep well pumps. Iron Man Windmill Co. can provide standard or special pumps of all sizes and types for every pumping application. |
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The standard well pump setup shown on the right is commonly used for shallow wells - less than 100 ft - 30M Pumps up to 16in - 0.4M in diameter are in regularly production. Larger pumps are available by special order. The pump cylinder should be located below water level for the best results. The foot valve is of a large diameter with an extra large valve port for minimal resitance. The second stage pump balances the load on the windmill providing easy starting in low wind speeds. The second stage pump also seals the pump rod allowing water to be pumped to elevations as high as the windmill is able to pump. These pumps use special seals that are the result of extensive research and development work with pumps in regular heavy duty service and are available only from Iron Man Windmill Co. |
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Draw pumps, as seen to the left, are used for pumping from lakes, rivers and tanks. They are used when the pump must be located above water level. These heavy duty pumps are available in either one or two stage models depending on the elevation water must be pumped. Iron Man Windmill Co. Draw Pumps are the result of years of practical experience and incorporate propritary seal and large - oversized valves - technology developed and available only from by Iron Man Windmill Co. Many features are incorporated to insure ease of use and many years of dependable service. Pump cylinders are made of alloy steel with an ultra hard corrosion resistant proprietary lining with a polished miror finish to provide a perfect seal, extremely low friction and to insure maximum pump and seal life. These pumps are a lifetime investment. |
IRON MAN WINDMILL CO. LTD
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