Wind Tower Manufacturing & Production
Wind turbine tower manufacturing consists of many different production processes. SENLISWELD focuses on the wind tower production line for over 20 years.
- One-stop wind tower manufacturing production line solution.
- The professional technical team supports you and quick response.
- Fast delivery time could meet your requirements.
- Many years of projects experience make things more efficient.
Wind Turbine Tower Welding Production Line
With the shortage of energy, new energy wind power has become a very environmentally friendly energy source. The production of wind towers is divided into land wind towers and offshore wind towers.
The production line of the wind tower is mainly welded by multiple cylinder bodies. Blades are provided by professional blade manufacturers, as well as drives. SENLISWELD focuses on wind turbine tower welding production lines for the main body of wind towers.
SENLISWELD Wind Tower Manufacturing
CNC plasma flame cutting machine is used to cut the raw materials. High efficient and easy to operate, good cutting quality also. Precision digital servo drive system.
The beveling machine mainly processes the edge of the steel plate, which is more conducive to welding. Good milling finish, a wide range of applications.
The plate rolling machine mainly rolls the flat steel plate into a cylindrical body, fully automatic or manual. Then enter the next welding process.
After passing through the plate rolling machine, the straight seam needs to be welded to make a single can. Will use welding manipulators and welding rotators.
The connection and welding of the two cylinders need to be done by hydraulic fit-up welding rotators and the welding manipulator at the same time. Wireless remote control.
When welding several pipes, it is necessary to weld one by one after the previous welding is completed. Inner and outer circular seam welding, and joining the next pipe.
The wind tower production line requires a reasonable workshop layout and space, which can facilitate the transportation of the welded pipes.
The sandblasting turning rolls adopt high-strength polyester amine material rollers to support the workpiece, which is not easy to cause damage to the sandblasting species.
When painting, a fake flange will be installed at both ends of the pipe to ensure the integrity and quality of the painting during the painting process.
SENLISWELD Wind Turbine Tower Welding (4)
SENLISWELD Wind Tower Manufacturing Advantages
Provide pre-sales and after-sales technical consultation
Rigorous production process and high-quality standards.
Design and OEM according to your project requirements.
Wind tower welding automation machines one-year warranty.
Why SENLISWELD Wind Tower Manufacturing Production Line
SENLISWELD is an expert in the welding automation machines industry. With over 20 years of experience in manufacturing, both great in production and R&D ability.
The wind turbine tower manufacturing production line needs many works to do, that’s why we have the confidence to support you with our best team.
Contact us 24/7, always helping you with solutions and technical consultations.
Wind Tower Manufacturing Process
Inner and outer longitudinal seam welding, longitudinal seam welding. Can use GMAW/STT for backing welding. Single wire or tandem SAW welding. The tapered barrel can be adjusted by screw adjust rotators.
Column and boom welding inner & outer seams. Also single wire or tandem SAW welding. 4 sets of hydraulic lifting rollers to work together to finish 1+1 fit up.
Main equipment: LH series column and boom, HGKZ series fit-up welding rotator. 1 piece motorized travel and 1 piece hydraulic roller seat to suit different length pipes.
Load one pipe, and two pipes, then the next pipes. Welding inner and outer circular seam after finish fit up together. The welding rotators and welding manipulators could travel on the rails.
Several pipes fit-up and welding station could be a long distance work to do. Tendam SAW welding. Hydraulic fit-up welding rotator, column, and boom welding manipulators.
The sand blasting welding rotator will use high-quality satndard PU rollers, to support the pipes. Keep the surface from damage during the sand blasting process. Will install fake flanges at the two ends of pipes when painting. Make sure the painting is perfect and complete.
About SENLISWELD Wind Tower Manufacturing
- Prodcution Layout
- Simple Diagram
- Production Process
- Factory
Related Welding Automation Machines For Wind Tower Manufacturing
Wind Tower Manufacturing: The Ultimate FAQ Guide
The wind tower manufacturing process is not as complicated as it seems.
If you want to understand the basics of wind tower fabrication and its wind tower production line, this is the right place to come.
We will tell you about wind turbine tower manufacturing and its parts.
Here is a complete FAQs guide consisting of basic to complex knowledge about wind tower manufacturing.
The entire wind power-producing system revolves around the wind turbine tower.
Wind turbine towers are utilized to hold the upper wind turbines to attain an elevation and absorb the wind turbine’s motion (vibration) as the wind speed rises with altitude.
Wind turbine towers are not just steel tube poles with a specific altitude so that the wind turbine may operate in the proper position.
Wind Turbine Tower
But they must also maintain sufficient intensity and stiffness so that the wind turbine tower does not collapse and fall during a hurricane or storm.
Steel cylindrical wind turbine towers and steel conical wind turbine towers are currently used in most wind turbine generator plants with capacities greater than 100kW around the globe.
The wind turbine tower is high-quality hot-rolled, low-alloy, robust steel with integral forging flanges.
Steel wind turbine towers now lead the wind turbine tower industry due to their attractive appearance and reliable and safe working efficiency.
With the increasing capacity of wind turbine generating systems and the strength of wind turbine towers, the relevance of steel wind turbine towers becomes increasingly apparent.
The weight of such a turbine tower is half that of a whole wind turbine generator system.
Similarly, the price of a wind turbine tower is roughly 15% of the price of a whole wind turbine generator unit.
An experienced engineering team is required to improve the vibration-reducing features of wind turbine towers.
These reduce their performance and stability.
Because the usual height of a wind turbine tower is many meters, manufacturing an entire steel wind turbine tower with such a height would be impossible.
Furthermore, transporting such a massive wind tower is highly challenging.
That is why the engineers split the wind turbine tower into multiple steel cylinder segments having a height of 20-30 meters.
Structure of Wind Turbine Tower
Flanges are present on both sides of segmental wind towers.
The flanges and longitudinal connections of the segmental wind tower are welded together. The wind tower flanges are bent steel plates.
The segmental wind turbine tower is treated for corrosion protection after welding.
The segmental wind turbine towers will then be hauled to the building site, where they will be bolted together.
Many wind turbine internal parts, including platform, ladder, lift, illumination device, and power cables, are additionally welded to the internal side of the wind turbine towers to facilitate future operation and maintenance.
To maintain the wind turbines, commercial windmills often utilize steel or concrete wind turbine towers, depending on the materials used in the wind turbine towers.
Lately, a new style of wind turbine tower having a lower concrete portion and an upper steel section has been introduced.
As a result, comparing the various types of wind turbine towers can assist clients in selecting the most appropriate wind turbine towers.
Steel Wind Turbine Tower
- Transport and installation are simple
- Mature manufacturing technology
- Affordable
- Exceptional corrosion resistance
- Both onshore and offshore wind power generator systems are compatible
Concrete Wind Turbine Tower
- Low-cost
- No restriction on the thickness of the tower wall
- Construction time is extended.
- Wastes that have been rejected cannot be disposed of
- For onshore wind power generation systems
Concrete and Steel Hybrid Wind Turbine Tower
- Large-scale construction challenges
- Wind turbine towers with less than 100 meters demand a high price.
- Low-cost wind turbine towers have a height of more than 100 meters.
- Only for onshore wind power generators
You can get these wind turbine towers as per your demand or site area.
They are affordable and give maximum benefit.
Wind tower manufacturing lines employ several automation devices to control costs and improve weld and production excellence.
There are various types of machinery utilized in a wind energy growing line.
Several metal plates of varying thicknesses can be shaped into steel cans using a can roller.
A weld rotator can then be employed to revolve the can manually while another machine seals it with an exterior circumferential weld.
The pace of the rotation is controlled by the operators, who also keep an eye on the quality of the weld.
Wind Tower Production Line
Wind turbine manufacturers can enhance output and quality while cutting costs by automating welding operations for both circumferential and longitudinal welds.
After the cans have been sealed, positioners and turntables can be employed as part of the manufacturing line for various weld procedures before being automatically moved to a fit-up bed.
Each can is completed and ready to be transported to its final destination on a fit-up bed.
As wind turbine tower welding automation experts, SENLISWELD offers various services to wind tower manufacturers, starting with a specialist consultation after an initial RFQ.
We start by talking about the project’s goals and then see where we can fit in.
Down below are some of the areas in which we work:
- Consultations on the spot
- Instrument supply and installation to increase health and safety requirements.
- To boost throughput, provide a variety of specialized wind turbine tower welding machinery.
- Operators must be trained in the proper usage of machinery.
- Welding equipment services and maintenance are provided across our product line, even under a rental agreement or protected by an extended warranty.
Our purpose is always the same: to deliver solutions that help businesses achieve their objectives.
We occasionally deliver comprehensive solutions from our workshop, complete with installation instructions and operator training.
Other times, projects are so unusual that our technical team will develop and produce bespoke machinery to satisfy the needs of specific projects that demand made-to-order machinery.
Welders utilize welding rotators to turn big cans, allowing them to work in any location and inclination of any tubular segment.
Wind Turbine Tower Welding
They may weld longitudinally as well as circumferentially.
Buttwelds can be done in numerous passes with automatic submerged ARC welding systems, reducing the operator’s burden.
Welding the cans’ outside surfaces is achieved with a weld-head suspended from a column and boom, which automates the entire outer welding operation.
Thicker steels are being employed in all parts of the fabrication process as the altitude of wind turbines rises.
The welding process is more demanding on the operator as the steel thickness increases, leading to fatigue.
Wind turbine technology is cutting-edge and cost-effective. Both onsite and remote processes must be automated.
Wind turbine makers can use SENLISWELD Automation’s machinery to improve their operations, welding proficiency, and productivity and reduce operator fatigue.
It also allows operators to keep a close eye on the operation, ensuring consistently high-quality welds.
Many various components have been installed within wind turbine towers to hold up and sustain the continued operations of wind turbine systems.
And all of these components are referred to as wind turbine tower internals.
Wind turbine tower internals is separated into two groups based on their uses.
- Electrical wind turbine tower internals
- Infrastructure wind turbine tower internals.
Internals of an Electrical Wind Turbine Tower
Numerous electrical components, including lights, cables, and other electrical components, have been mounted on the internal surfaces of wind turbine towers.
1. Wind Turbine Tower Light
Wind turbine towers are often dozens of meters tall.
Therefore, employees must walk inside the tower to investigate when something goes wrong with the wind turbine system’s functioning or wind tower maintenance.
It’s a suffocating environment within the wind tower.
You must install some lights on the interior surface of wind turbine towers to help with inspection and maintenance because there is no natural light indoors.
Within wind turbine towers, there are several different types of interior lights, such as regular tower lights, door lights, floodlights, aviation lights, and so on.
Types of Wind Turbine Tower Lights
The most popular lights within wind turbine towers are the tower lights, which are positioned on the inner surface of the tower every few meters.
There are two types of door lights available right now.
- LED lights
- Fluorescent lights
The wind turbine tower door has a door light attached.
Floodlighting is utilized for big area lighting, and because wind turbine towers are around a hundred meters tall, floodlighting is commonly employed inside them.
Offshore wind turbine towers typically employ aviation light. It is a piece of equipment that is used to alarm people.
2. Wind Turbine Tower Cables
The cables that convey the generated electricity to the subterranean grid are one of the essential wind tower internal parts.
There are numerous different sorts of cables for various uses in wind turbine towers.
Offshore wind tower manufacturers have power and control cables to carry the electrical current produced by the wind turbine’s back and provide the required electricity for the inside lighting of wind turbine towers.
Wind Turbine Tower Cables
You may see a few data cables used to link the upper wind turbines.
They have been put inside the wind turbine towers realizing the online monitoring of wind turbine functioning.
Because wind turbine towers have a significant number of cables, cable trays secure these cables in wind turbine towers for easier maintenance.
There will also be some junction boxes required to connect the cables.
This is also a standard part of a wind tower’s inner cable kit.
Any reputable wind tower internal cable provider can create a unique cable and junction box solution for you.
Infrastructure Internals of Wind Turbine Tower
We can view objects in wind turbine towers and carry electricity back to the underground system using lights and cables. But how will the wires be installed within the massive wind turbine towers? How will we be able to reach heights of dozens of meters? Inside wind towers, infrastructural components such as tower doors, stairways, and inner platforms are required.
1. Wind Turbine Tower Door
Wind tower doors are the entrances to wind turbine towers.
Each wind farm owner needs a wind tower door that is safe and sturdy.
Aluminum and steel are among the most famous materials used to construct wind tower doors.
Since various wind farm owners have different requirements, both aluminum and steel wind tower doors are standard.
2. Wind Turbine Tower Entrance Stairway
Because wind tower doors are commonly thought to be higher than the surface, a wind tower access stairway is required so that we may easily access the doors.
The only infrastructural tower inside the outer wind turbine towers is this one, which is completely exposed to the elements.
Wind tower entry stairways are similarly made of aluminum and steel, and the base of the stairways is highly resistant to corrosion to extend their service life.
3. Wind Turbine Tower Ladder
The wind turbine tower comprises a steel sheet with a very flat inside and exterior surface.
Wind Turbine Tower Ladder
As a result, we must install ladders on the inside in order to reach a specified height. Most wind farm operators choose to weld the ladders on every tower part during the wind turbine tower production process and put them together on site.
4. Wind Turbine Tower Platform
When employees have to walk up the wind turbine towers to do some monitoring and maintenance, the tower platform provides a safe area to organize their working equipment and take a break.
An aluminum platform has been constructed within these towers at regular intervals along the length of the wind turbine towers.
Platforms will be built within wind turbine tower fabrication to lessen the complexity of the building.
A full steel wind tower is usually around a hundred meters tall.
To carry the wind turbine tower to the job site, the wind tower maker creates various wind tower pieces assembled on site.
As a result, flanges are installed on the terminals of each wind turbine tower component during the manufacturing process.
The connecting elements of wind turbine towers are called flanges. It’s a large ring with a uniform distribution of holes.
The strong face-to-face contact stress between the flange faces resulted in a strain-tight metal-to-metal sealing.
Wind Tower Flanges
An additional sealing feature on the flange face can be incorporated for underwater attachments to provide a sealing function even for unexpected loads of the order causing some flange separation.