Wind Tower Manufacturing

wind tower machine

Are you still manufacturing wind towers with a normal plate roll? Are you still dealing with long manufacturing times, high labor costs, and facility requirements?

What if you didn’t have too?

The Old Way

With a standard plate roll you feed the plate straight in, but the cone must slightly rotate while fed. Using a “Cone Guiding Shoe” you rotate the plate by rough friction on the edge. Which can cause many problems….

A) Pre-bending on a press brake, to round the edges
B) Bevel damaged by the Cone Guiding Shoe.
C) Cranes and forklifts to hold plate from collapsing,
D) Frequent re-position of the plate for deviation
F) Three-Four persons required to handle the process
G) Skilled and experienced operator needed.
H) Re-roll the cone after welding, to improve roundness
I) Cylindrical capacity must drop by 50%
J) Totally manual process
K) Long production time: 60-120 minutes and even more

Davis’ Wind Tower Manufacturing Package offers a much better solution.

How the “DAVI WindTower Manufacturing Package”, works:

1) Loading the plate on the In-feed Conveyor
CNC automatically tilts the two bending rolls to the right angle.
The CNC Automatically TILTS the rolls at the correct cone angle

2) Square the plate into the machine
The In-feed Powered Conveyor Automatically squares the plate against the back roll Y.
The Hydraulic pushers move and align the plate during that transfer.

3) Leading Prebending positioning
The pinching roll (W) clamps the plate, for an excellent prebending.
CNC rotates the two pinching rolls S and Wbackward, till tangent
(easier and safe with the In-feed conveyor).

4) Prebending the leading edge
The X front roll raises to prebend the Leading Edge.
The In-feed Conveyor impressively raises by Tilting Mode.. The highest safety available !
The Hydraulic Front Support raises as well.
All those movements are CNC interfaced and controlled.
(Usually the overhead crane holds the plate at that phase).

5) Rounding the edge
The two pinching rolls S and W rotate rounding the plate edge (Leading Prebending).
The operator checks the right diameter by template.

6) Rolling phase positioning (inverse the rolls)
The In-feed conveyor, the Front Support and the front roll X drop the plate down to horizontal.
The back roll Y raises to the leading edge, already prebent.
All controlled by the CNC.

7) Feeding the plate, rolling the entire cone
The (W) lower pinching roll drops to de-clamp the plate.
The top roll feeds the plate, at a fast speed, cutting the rolling time substantially.
The operator checks by template the consistent diameter.

8) Rotate the plate
The Top Roll S rotates forward to feed and continuing rounding the whole plate.
The Hydraulic Pusher slightly rotate the plate, when required by different angle of the cones.
The LASER-Positioning System, monitors if the plate correctly rotates according with the cone geometry.
In case of deviation, the laser activates the concerned pusher (CNC interfaced), to rotate the plate accordingly.

9) Holding by the Back Support
The Hydraulic Back Support, CNC interfaced, raises to hold the plate avoiding it collapses.
Davi engineered a special back support, pivoting and self- aligning, to perfectly hold the cone, with its own angle.

10) Holding by Overhead Support
The Hydraulic Overhead Support raises, CNC interfaced, to avoid the plate collapses.
Davi engineered a special Overhead support, longer in size, pivoting and self aligning, holding the cone, at its own angle and at its correct position.

11) Pull-back phase
Puller re-open phase:
– The Front Support raises to reach the cone,
– The pusher hydraulically “hooks” the collapsed leading edge,
-The Front Support pull it back, re-opening the diameter, avoiding the leading edge overlaps the tail.

12) Trailing Prebending
The plate is re-clamped by the W pinching roll, to prebend the trailing edge.
The operator checks by template the consistent diameter.

13) Positioning the cone for the Internal Welding
To be welded, the cone should be positioned with the two heads leaning on the front side roll using:
-the Hydraulic Overhead Support
-the Front Hydraulic Support
-the Hydraulic Pushers
– either to Pull Back the plate from collapse
– and to align the edges, in case of mismatch.
It is recommended to weld completely, all the edge long, the inside first seam of the cone.

14) Removal of the cone
After the first seam has been completely welded inside, it is possible to hydraulically open the machine to remove the cone.

15) Machine positioning for the next plate
The CNC automatically re-position all the machined axis at the starting phase, ready for the next plate to roll.

The Davi Wind Tower Package offers lower costs, shorter fabrication time and higher accuracies, all at an affordable price. If you would like to learn more about the Davi Wind Tower package give Modern Machinery a call at 1-800-589-1444.