Article by by Donatella Fumagalli, FACCIN Group’s Marketing Manager
The efficient and sustainable production of offshore wind farm components is becoming increasingly vital in our quest for a greener future. With the help of cutting-edge renewable energy technologies, the potential to drive this industry forward is immense. With the increasing prominence of offshore wind farms as a reliable and eco-friendly energy solution, there has been a notable upsurge in the need for cutting-edge machinery that can efficiently produce the fundamental components required for these colossal structures. From wind towers to offshore foundations, the manufacturing process plays a pivotal role in ensuring the success of offshore wind farms.
Let us delve into the world of machines designed for the manufacturing of offshore wind farm components, exploring the innovative technologies and cutting-edge processes that are revolutionizing renewable energy production at sea. With the increasing global focus on sustainable energy, the demand for dependable and high-capacity machinery has never been more crucial.
These machines have been assigned the important task of manufacturing the large wind towers that play a vital role in supporting the key components of the turbine, optimizing the capture of wind, ensuring structural durability, and facilitating the transmission of generated power. Moreover, these machines enable the fabrication of the sturdy foundations that securely anchor the towering turbines to the seabed, as well as a range of components that form the core of offshore wind farms.
Advancing Sustainability with Plate Rolls in Offshore Foundation Manufacturing
Offshore wind foundations play a vital role in ensuring the stability and support of wind turbines in marine environments. Given the challenging conditions of offshore installation, the production of these foundations requires specialized processes tailored to this unique environment. The manufacturing process includes design and engineering, the construction of monopiles (suitable for shallow to moderate water depths), jackets (designed for deeper waters), tripods and TPs.
The Faccin Group, thanks to its extensive expertise in the wind industry, provides an all-encompassing range of rolling solutions enabling the fabrication of all types of offshore foundations. These massive and sturdy rolling machines, known for their immense rolling power and durability, are capable of effortlessly bending plates with thicknesses that surpass 150 mm.
The Faccin® 3-roll or 4-roll rolling machines for cans and cones manufacturing stand out due to a multitude of features that further elevate the overall performance. These remarkable machines boast a sturdy design and a heavy-duty base frame, ensuring unparalleled precision in every rolled piece. With their powerful bending force, they enable precise pre-bending of plates. Moreover, their electronic balancing system guarantees maximum precision. The optimized automatic calibration functions not only save valuable production time but also enhance overall efficiency. The hydraulic system of these machines is highly effective, providing high speed while reducing power consumption. The micro positioning technology ensures repeatability and enhanced productivity. Additionally, the special transmission system, along with the centralized lubrication system, guarantees reliability.
In the wind industry, no other rolling system currently available in the market offers such an impeccable blend of precision, power, efficiency, and high productivity.
Offshore Wind Tower Manufacturing: Advanced Plate Rolling Systems for Unmatched Precision and Reliability
The manufacturing of offshore wind towers demands a synergy of advanced engineering, steel fabrication, meticulous quality control, and specialized surface protection. The result is a robust, resilient structure that fearlessly endures the challenges posed by offshore wind farms.
Plate rolling systems play a pivotal role in the construction of offshore wind towers by transforming flat steel plates into curved, cylindrical, or conical segments through a controlled rolling process. These cylindrical segments are then welded together to form a tower section.
The Faccin® plate rolling system, known as the “Faccin® Wind Tower Automation System”, achieves even the most ambitious goalsby producing hundreds of cans and cones per month. The system enables the fabrication of pieces boasting an impressive plate thickness of over 100 mm.
It is composed of a heavy-duty and robust 4-roll plate rolling machine. In addition to their large size and capacity, Faccin’s machines symbolize innovation, incorporating advanced features and intelligent automation to streamline the manufacturing process. With sophisticated control systems and precise instrumentation, these machines deliver unmatched accuracy and consistency. To excel in high-volume manufacturing and challenging industrial applications, the machine is equipped with an advanced hydraulic system that not only ensures flawless performance and mass production but also energy efficiency.
The system also includes a motorized feeding table with an alignment device, top and side supports, a clamping system for on board tack-welding, and efficient handling systems. All these accessories are controlled by a highly advanced fully programmable Siemens CNC, which can be operated by a single operator. With its advanced engineering, the Wind Tower Automation System ensures the automation of even the most intricate wind rolling projects.
The FACCIN GROUP: Pioneers of Excellence in Metal Forming
With over 200 years of combined experience, the Faccin Group has positioned itself as a key player in the metal forming industry by directing innovation. Our group comprises industry-leading brands – Faccin®, Boldrini®, and Roundo® – and provides advanced solutions for plate rolling, profile bending, and dished-head manufacturing. United under one roof, Faccin Group present the most extensive selection of top-tier solutions currently offered in the market. The group, committed to driving progress in green energy production, also provides solutions for the manufacturing of onshore towers, as well as door frames & flanges.
For further information about our solutions, do not hesitate to contact us at info@faccingroup.com or meet us at stand D401B in Hall 2 & 3 during the WINDERGY event in Chennai, India from 23rd to 25th October 2024.
