The offshore wind sector is standardizing around 15 MW+ mega-turbines, necessitating monopile foundations with diameters up to 15 meters (49 feet) and steel plate thicknesses over 150 mm (6 inches).
Fabricators face the challenge of rolling plates with precise geometric tolerance, minimized flat ends, and optimal cycle times to reduce material waste and downtime.
The Challenge: Overcoming Edge Deflections and Rolling Cones on a Mega-Scale
Structural steel’s thickness leads to spring-back and bending resistance. Standard machines struggle with flat ends, requiring costly post-rolling trim and re-work. Fabricating conical sections for wind towers demands precise force distribution. Traditional methods depend on operator experience, causing long cycle times and inconsistent accuracy.
The Davi Solution: 3-Roll Variable Axis and Automated 4-Roll Systems
Davi offers automated, customized systems for towers and heavy foundations like monopiles and transition pieces.
1. Davi MAV: 3-Roll Variable Axis Technology
Designed for heavy monopiles, the Davi MAV series combines high-tonnage pressing capabilities with plate rolling flexibility.
· Individually Tilting Rolls: Tilting up to 100 mm per 3 meters (4 inches per 10 feet) of roll length, allowing precision on heavy cones using Progressive Bumping Mode.
· All-Rolls-Drive with Flat Gearboxes: Motorized and synchronized side and top rolls minimize flat ends by pinching the plate at the shortest tangent point.
· Hydraulic and Mechanical Symmetry: Configurations prevent asymmetrical frame deformation, ensuring even load distribution.
2. Turnkey Integration and Material Handling
Davi integrates heavy-duty feeding systems for manufacturing continuity:
· Adaptive and Extended Feeding Systems: Systems manage oversized and heavy plates without overhead cranes.
· High-Accuracy Re-Rolling: Essential for fixed-bottom foundations, allowing post-welding calibration to maintain structural tolerances.
Speed, Safety, and Immediate ROI
Davi’s automated lines enhance wind energy manufacturers’ performance:
· Minimized Handling and 24/7 Operations: High productivity lines align with fast-paced offshore project schedules.
· Precision with “iRoll eXtreme” and “iCone”: The system features a live 3D interface and AI-assisted programming for conical rolling.
· Operator Safety and Labor Optimization: A laser measuring system allows a single operator to manage heavy rolling sequences safely.
The Global Wind Benchmark
Davi leads the wind energy rolling sector with over 300 automated lines worldwide and a 70% market share. Manufactured and tested in Italy, Davi products offer financially stable operations and multi-decade lifecycle support.
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Original Story at www.offshorewind.biz