Onshore Wind Tower Manufacturing
Your Partner in Welding Automation for Onshore Wind Ventures.
Revolutionise onshore wind energy manufacturing with our tailored solutions for wind tower and foundation production. Our expertise in heavy steel structures ensures effective and efficient manufacturing processes for onshore wind towers and foundations. From precision fabrication to seamless assembly, our automation solutions are engineered to optimise productivity and quality. With Key Plant Automation, manufacturers in the onshore wind energy industry can elevate their operations to new heights, driving sustainability and profitability.
State-of-the-Art Solutions
Discover the advantages brought forth by innovative solutions, such as advanced automation, to provide you with a unique edge within the competitive market landscape.
Enhanced Productivity
Our systems are designed to optimise productivity, enabling you to meet demanding deadlines and expand your operations. Take advantage of streamlined processes that improve your workflow and boost overall efficiency.
Elevate Safety Standards
Our systems grant you full authority, reinforcing safety measures throughout the entire journey of the vessel/workpieces, from inception to completion. Your peace of mind stands as the cornerstone of our design ethos.
Welding automation revolutionises onshore wind tower fabrication by streamlining processes and elevating precision. Our cutting-edge automated welding systems tackle complex welds with exceptional accuracy, ensuring the robustness and durability of tower components. These systems work non-stop, driving down production costs and time while delivering consistent, top-tier welds.
Fit-up and growing line solutions play a crucial role in ensuring that wind tower components are accurately aligned during the welding process. Specialised systems and manipulators are utilised to position tower sections with millimeter precision, facilitating seamless assembly and minimising rework. By optimising alignment, these positioning systems contribute to the overall structural integrity and performance of the finished wind towers.
When considering the fundamentals of wind tower infrastructure, we prioritise strength, precision, and dependability above all else. At Key Plant Automation, we excel in these aspects. Our automated systems are meticulously designed to manage the robust, thick-walled steel tube foundations of wind towers, guaranteeing stability for your projects.
Upholding impeccable weld and production standards is a firm requirement for us. Our systems are outfitted with quality control measures to guarantee that every component produced meets or surpasses industry standards without compromise.
Key Plant Automation is committed to pioneering innovation in wind tower and monopile production. We take pride in our integral contribution to wind energy projects worldwide, aiding manufacturers in optimising production efficiency and fostering sustainability.
Material Selection
The manufacturing process of an onshore wind tower typically begins with the selection of appropriate materials. Common materials include steel, primarily due to its strength and durability. The steel used is often in the form of coils or plates, which are sourced from steel mills.
Plate Cutting and Forming
The steel plates are cut to specific dimensions using large cutting machines such as plasma or laser cutters. These machines ensure precision and accuracy in cutting the plates to the required sizes and shapes. Subsequently, the cut plates are formed into cylindrical sections, which will eventually compose the main body of the wind tower.
Welding
Once the cylindrical sections are formed, they are welded together to create the complete tower structure. Welding is a critical step, and it requires skilled welders and advanced welding techniques to ensure structural integrity and strength. Various welding methods such as submerged arc welding or metal inert gas (MIG) welding may be employed depending on the design specifications and material thickness.
Flange and Tower Base Assembly
At the bottom of the tower, a flange is typically attached. This flange serves as the connection point between the tower and the foundation. Additionally, other components such as internal platforms or ladders might be installed during this stage. The tower base assembly ensures stability and structural support once the tower is erected.
Surface Treatment
After the welding process is completed, the entire tower undergoes surface treatment to protect it from corrosion and environmental degradation. This often involves processes such as sandblasting to remove impurities and applying protective coatings such as paint or galvanization. Surface treatment not only enhances the aesthetic appeal of the tower but also prolongs its lifespan in harsh outdoor conditions.
Quality Control and Testing
Throughout the manufacturing process, quality control measures are implemented to ensure that the wind tower meets industry standards and safety requirements. This involves inspecting welds, conducting non-destructive testing (NDT) for weld integrity, verifying dimensions, and performing various other tests to assess the structural integrity and functionality of the tower. Once the tower passes all quality control checks, it is ready for transportation and installation at the designated onshore wind farm site.
Factory Layouts
Optimise your operations with our forward-thinking factory layouts – enhance efficiency and maximise throughput for wind towers and monopiles.
Welding Systems
Optimise welding—choose innovative manipulators and seam welding systems for increased deposition rates, productivity, and arc-on time.
Rotators / Roller Beds
Tailor-made solutions for wind tower and monopile production – explore our conventional, self-aligning, and anti-drift rotators to meet your capacity needs.
Internal Transport
Revolutionise internal transport – effortlessly maneuver cans and sections with our innovative transfer and tilting transfer systems.
