The Top 7 steps for wind tower manufacturing process

Wind turbine towers play a pivotal role in the harnessing of wind energy, serving as the sturdy backbone of wind turbine systems. However, the journey from raw materials to functional towers is a meticulous process involving various stages of cutting, welding, and corrosion protection. Let’s delve into the intricate craftsmanship involved in the manufacturing of wind turbine towers.

The entire process of wind turbine tower manufacturing

1. Cutting: Steel plates undergo initial and secondary inspections before cutting to minimize welding deformities. Plates are then cut into sections and prepared for welding. Flange steel plates are cut using CNC flame cutting machines to ensure precise dimensions. After cutting, each piece is inspected and labeled for identification.
2. Rolling: Cut steel plates are rolled into cylindrical shapes using rolling machines. Quality inspection is conducted after rolling before proceeding to the next step.
3. Vertical Seam Welding: Welding of vertical seams is performed after cleaning, pre-heating, and flux baking to ensure high-quality welds. Circular correction is applied to compensate for shrinkage-induced deformation.
4. Pairing: Sections are paired with flanges and each other before welding. Flange-to-tower body welding is done prior to tower body pairing, with all flanges bolted tightly. Section pairing is done on a pairing cart, ensuring natural closure of sections.
5. Circumferential Seam Welding: Seam welding is performed using submerged arc automatic welding, first welding inner wall bevels, then exposing outer wall bevels for outer wall welding. Sections are rotated on welding rollers for inner and outer wall welding.
6. Tower Corrosion Protection: Sandblasting and rust removal are done on welded towers before painting. Towers are then painted within 4 hours of sandblasting to prevent surface contamination. Painted towers are stored indoors until primer curing.
7. Installation of Internal Attachments and Final Transport: Internal attachments such as platforms, railings, and lights are installed. Finished towers are packaged and transported to installation sites for assembly.

Conclusion

From cutting steel plates to the final installation of internal components, crafting wind turbine towers demands precision, expertise, and attention to detail. As these towers stand tall on the horizon, they symbolize not just the promise of renewable energy but also the dedication of countless individuals behind their meticulous construction. With each tower erected, we take another step towards a sustainable future powered by the relentless force of the wind.