Wind Power Structure Manufacturing Solutions

Steel structures for the wind power sector fall into the category of super-long, super-heavy components, with production limits pushed far beyond those of conventional steel structures. Cylindrical structures with diameters up to 15m, thick steel plates, large component weights, along with long weld seams and large weld cross-sections, require special capabilities in machining, shaping, assembly, welding, and quality control. Weldcom builds an ecosystem of solutions to serve the manufacturing of tower segment sections, foundation structures, and many other super-long, super-heavy steel components in wind power projects. The solution covers the entire process from preliminary processing, shaping, assembly, welding, surface finishing, to production management, meeting the manufacturing requirements of large-diameter tower segments and heavy cylindrical structures in the wind energy sector.

Machining thick, large steel plates with high precision requirements

The final dimensions of wind power structures start with the precision of each steel plate. The material is not only large and thick but also requires cutting profiles, beveled edges, and geometric precision suitable for subsequent shaping and welding processes. Weldcom provides high-capacity steel plate machining solutions, ranging from straight cutting to bevel cutting of various joint types, suitable for thick steel and large-sized plates. The current machining system has a worktable range extending to tens of meters, serving components that far exceed conventional structural production scales.

Welding super-long structures with large metal deposition

For large-diameter cylindrical structures, the challenge lies not only in the length of the weld seam but also in the amount of metal to be deposited, the ability to control penetration, input heat, and the stability of the weld across the entire cross-section. Weldcom provides high-productivity automatic welding solutions for thick steel plates and heavy cylindrical structures, aiming to increase deposition productivity, maintain continuous welding processes, and control stable weld quality. This is an important foundation for businesses to meet the increasingly large components of the wind power sector.

Mastering the challenge of component size and weight

As the diameter of components increases to tens of meters, accessing welding positions, changing working heights, rotating workpieces, and maintaining stable production processes become a unique technological challenge. Weldcom's solutions are developed towards expanding the workspace, adapting to the actual size of components, and minimizing intermediate operations with super-long, super-heavy products. In reality, Bruco has successfully developed a specialized system for welding wind power steel pipe structures with diameters up to 14 m, demonstrating the ability to design solutions according to specific production requirements on a very large scale.

From welding productivity to the ability to control the entire process

With wind power structures, output only matters when accompanied by the ability to repeat quality and trace the production process. Therefore, Weldcom's solutions aim towards digital control, storing technological parameters, connecting device data, and integrating with the factory management system. After machining and welding, the ecosystem continues to expand into cleaning, surface treatment, coating, and drying to meet the requirements of protecting steel structures for long-term operation in harsh environments. 

From conventional components to super-long, super-heavy steel structures in the wind power sector, Weldcom focuses on simultaneously solving three core challenges: large-scale machining capability – high-productivity welding technology – the ability to control quality throughout the production process.