Wind turbine tower processing solution

Steel structures for the wind power industry fall into the category of super-long, super-heavy components, with production limits pushed much further than conventional steel structures. Cylindrical structures with diameters up to 15m, thick steel plates, large component mass, along with long welding lines and large welding cross-sections, pose special requirements for machining, shaping, assembling, welding, and quality control capabilities. Weldcom builds an ecosystem of solutions to serve the manufacturing of tower segment structures, 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 the billet to assembling, welding, surface finishing, and 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 begin with the precision of each steel plate. The material is not only large and thick but also requires cutting profiles, beveled edges, and geometric accuracy suitable for the subsequent shaping and welding process. Weldcom provides high-capacity steel plate machining solutions, accommodating everything from straight cutting to beveled cutting with various joint types, suitable for thick steel and large-sized plates. The current machining system has a workbench range extending to tens of meters, serving components that far exceed conventional structural production.

Welding super-long structures with large metal deposition

For large-diameter cylindrical structures, the challenge lies not only in the length of the weld line 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 a crucial foundation for businesses to meet the increasingly large components of the wind power industry.

Mastering the challenge of component size and mass

As the diameter of components increases to tens of meters, accessing welding positions, changing working heights, rotating the billet, and maintaining stable production becomes a unique technological challenge. Weldcom's solutions are developed to expand the working space, adapt to the actual size of the components, and minimize intermediate operations with super-long, super-heavy products. In reality, Bruco has successfully developed a specialized system for welding wind power steel tube structures with diameters up to 14 m, demonstrating the capability to design solutions according to specific large-scale production requirements.

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 industry, 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.