The MAG Megaflex is cutting a 18,144-kg spherical hub that measures about 3.6 x 3.6 m and has a blade bolt circle of about 2.5 m.

Astraeus Wind Energy’s MAG Megaflex machining system has passed its initial supplier qualification by completing “Operation 20″ metal-cutting processes in record time on a Clipper Windpower C96 turbine hub, one of the industry’s largest. The system simultaneously machines all three blade faces, which lets it complete the qualification hub in less than one shift, a first in the industry. “Completing hundreds of features on this hub in such a short time, and meeting the extreme tolerances required, is a world first for U.S. manufacturing technology,” said Astraeus President Jeff Metts. “We should be able to do the industry’s simpler hubs in even less time,” Metts added. “This is, without a doubt, world-leading technology that no one else can compete with. The system is operational now and we are taking orders, forecasting a capacity of about 1800 hubs per year.”

The 18,144-kg (40,000-lb) spherical hub was about 3.6 x 3.6 m (12 ft x 12 ft), with a blade bolt circle of about 2.5 m (8.2 ft). Operation 20 for this part included milling the blade faces, drilling and tapping or counter-boring more than 60 39-mm (1.5 in) holes per face, boring and drilling the blade-pitch gear mounting surfaces, and cutting various other features. Tolerances on the part, which was laser inspected after machining, include 0.05 mm (0.002 inch) true position on holes and ±1 degree on angles.

Look closely and you can see two of the spindles. The third is behind the hub.

Conceived by MAG in 2009, Megaflex development was funded in part with grants from the Michigan Economic Development Corporation (MEDC), which audited and approved the progress of Astraeus in meeting its performance requirements. MAG developed the entire system on a turnkey basis, including the process concept, programming, machine systems and tooling package. The patent-pending Megaflex design, which is based on three MAG FTR 5000 floor-type boring mills surrounding a B-axis rotary table, simultaneously machines all three blade faces on a wind turbine hub in one setup, a concept widely used in mass-production of automotive components and small parts. “This is automotive machining technology scaled up an order of magnitude,” explained Pete Beyer, MAG Director of Product Development. “We are using multiple spindles, specialized tools, and clever process technology to finish a part in one setup, in the shortest time possible, while maintaining the flexibility to process a family of different hubs.”

Concepts borrowed from the automotive industry include offline setup and quick part loading, using a fixture interface plate and a lifting bracket for the workpiece. The interface plate is bolted offline to a locating feature on one side of the casting; the plate then mates with a locating feature on the worktable for fast part setup. The lifting bracket attaches to the top of the part to allow a single crane to transfer the part in and out of the workzone safely and quickly. “These are classic part handling techniques on a gantry-type automotive line that we have adapted for very large parts,” said Beyer. “We can setup the next part offline on an interface plate, and quickly exchange a completed part to maximize utilization of the spindles.”

MQL, another automotive machining technology little used elsewhere, eliminates need to control splashing and misting coolant in the shop. “MQL is a green and sustainable technology that saved the initial and ongoing cost for pumps, filters, energy, regulatory compliance, and coolant acquisition and disposal,” Beyer explained. “MQL also produces dry chips, which do not have to be cleaned or treated, but can go straight into the melting furnace.”

Unique features on the boring mills include a specialized tooling package utilizing numerous extension tools, and a servo-controlled tilting A-axis on the W-axis ram. The tilting A axis allows the ram to be positioned for a normal approach angle to the work face. This is required because the blade face of the hub is not always perpendicular to the hub’s axis of rotation, but may be two to three degrees off, depending on the manufacturer. “The tilting ram is much stiffer than other solutions, such as a multi-axis A/C head, and it eliminates the need to interpolate axes,” Beyer explained. “The tooling package allows efficient machining of the challenging features on these parts, such as the back bore on most of the bolt holes.”

As part of the Megaflex design, each machine has a latch-plate interface to accept attachments from a head changing rack. However, for cost economy, the system currently has only one attachment rack, which can be moved for use by any of the machines. Rotation of the worktable allows the machine using the attachments to access all three faces of the part. Synchronous/asynchronous processing is then used to balance out the cutting times and cutting forces of the three spindles when doing similar and dissimilar operations.

“MAG delivered on the concept for a purpose-built system in terms of the budget, major reductions to cycle time and future flexibility,” Metts added. “Customers who have seen it say it never occurred to them to create a multi-spindle system with giant machines. When it’s running, it’s like watching an orchestra play. This sets the benchmark for the rest of the world and helps level the playing field with low-cost countries. Now that the U.S. has the tools to regain the lead in wind turbine manufacturing, it’s vital for Congress to extend the wind energy production tax credit to invigorate the industry, which is already softening. In addition, we believe there is an ideal opportunity for a forward thinking company to open a foundry nearby to cast hubs to feed this system.”

MAG
www.mag-ias.com

Windpower Engineering & Development

The Flextec 650 is IP23 and Desert Duty rated, meaning it can operate in extreme field environments. Welding outputs are rated for extreme temperature operation up to 55° C. Tough PC boards stand up to dust and humidity, while the Fan-As-Needed feature reduces power consumption, dirt intake and damaging thermal cycling.

The recent high amperage Flextec 650 multi-process welder from Lincoln Electric delivers up to 815 amps of welding power. Its FLEXible TEChnology lets welders use a variety of processes – stick, Touch Start TIG (DC), MIG, flux-cored CV submerged arc and arc gouging – on numerous applications, including heavy equipment and transportation, construction, and welding education.

The inverter-based Flextec 650 is rated at 650 amps at 100 percent duty cycle with a robust amperage range of 10-815 amps, while weighing in at only 165 pounds in a case that measures only 21.83 inches high by 16.3 wide x 29.33 deep. Lincoln Electric Ready-Pak and One-Pak packages configured with Lincoln Electric wire feeders and accessories are structured for easy ordering. Job site-ready rack packages are also set for future release.

Welder features include:

• Flexible multi-process capability for handling the widest range of welding applications
• Low-power consumption resulting in operating cost savings
• Lighter in weight for easier transport
• Selectable hot start for extra starting amperage
• Faster arc response with variable arc control
• Remote control operated by a foot pedal or hand control up to 100 feet away

To request a copy of the Flextec 650 product literature, call (888) 355-3213 to obtain bulletin E5.96.

Lincoln Electric
www.lincolnelectric.com

Windpower Engineering & Development

When a free-fit hinge is needed, the Coiled Pin’s pre-installed diameter is of negligible importance because pin diameter is determined by the retaining or smallest hole(s). Coiled Pins are functional springs, so consider recovery and retention in free fit locations. The amount of recovery and retention depends on the diameter of the tight (retaining) hole(s) and the ‘free span’ of the pin. Free span would be defined as the distance a pin passes through a free-fit component. As free span increases, the pin diameter also increase as it “recovers” a portion of its pre-installed diameter. The illustration A few dimensions and terms, shows them. For better load distribution and closer tolerance hinges, it is recommended that the tight fit of the Coiled Pin be in the outer members of the hinge. The minimum thickness of the outer members should be 1 to 1½ times the diameter of the pin. If the thickness of the outer members are less than the diameter of the pin, then the tight fit should be in the inside hole.

In a friction-fit hinge, all holes should be identically sized within the assigned tolerances. If the manufacturer is unable to maintain the same hole size within each component, the tolerance should be split between the components. It is most common to assign the smaller half of the tolerance to the outside holes and larger half to the inside hole.

The Coiled Pin simplifies design because there is no need to incorporate misalignment between holes to achieve friction, as is the case with rigid solid pins. Also, Coiled Pins perform best when installed in straight, properly aligned holes. Although the complete this article offers general design guidelines, it is recommended that Application Engineers who specialize in fastening and joining be consulted to ensure the optimum hinge design is employed for each application. Here is the link to the complete White Paper: http://www.spirol.com/library/whitepapers/How_to_Design_the_Optimum_Hinge.pdf

Spirol International 
Spirol.com

Windpower Engineering & Development

A Davi four-roll plate rolling shapes wind-tower sections called cans. The latest versions can bend plate up to 145-mm thick.

The largest manufacturer of offshore wind towers in Northern Europe has ordered a new DAVI heavy four-roll machine with the capability rolling steel 4.0-m wide by 145-mm thick. “It’s the largest four-roll machine in the world completely dedicated to building foundations for offshore wind towers,” says Davi President Orazio

“The Davi High Productivity Package convinced that top player to buy our Wind Tower system for its benefits in building giant parts with only one operator, all the while requiring less production time than competitive machines,” adds Orazio.

The Davi Productivity Package for wind towers has been updated with the Davi iRoll CNC. The software, based on Apple iPad, lets an operator draw a part to roll and then starts production by sending the program by iPad Wi-Fi to the machine.

The iRoll puts all the information about the machine at a user’s fingertips. Then it connects to the Davi Service Center to dialog directly with a technician, dedicated to supply the required support.

Orazio adds that the European company had purchased several four-roll rolling machines in 1999 and 2001, and that let it work its way into the heavy duty offshore wind market with a machine capable of rolling steel 3.600-m wide by 125-mm thick (12 ft x 5 in.).

Davi
www.davi.com

Windpower Engineering & Development

Dynamic CNC Ram Balance System dynamically corrects for effects of spindle and ram droop when either are advanced and retracted.

A milling-boring specialist has patented a Dynamic CNC Ram Balance System which and dynamically corrects for effects of spindle and ram droop when the ram or quill of a machine are advanced and retracted to their programmed positions. This system is effective where the machine’s working envelope which can be up to 280 in. (7 m) of travel in the vertical axis. It adjusts the ram traverse over the Y and Z axis correcting the position and the angle of the cutting tool with respect to the horizontal working plane.

Key features of the system include:

CNC control - The system is driven by a numerically controlled (NC) servomotor. It is monitored and measured by the control using an internal scale to confirm the performance of the system.

Dynamic Ram Droop Control - In addition to compensation tables in the CNC control for each head, a Heidenhain feedback scale with a servo-motor adjustment system is mounted on the ram provides dynamic real time compensation of ram droop.

Balance system – It works in positive and negative directions compensating for heads in a wide variety of weights and positions.

Also, this NC controlled electro-mechanical system, which is carried in the vertical saddle, can also be integrated with the automatic head-changing system and can self-correct the true position of the quill or ram for different milling heads that can vary in weight between 44 lb (20kg.) and a massive 3,500 lb (1,600 kg.) The Ram Balance System guarantees a maximum deviation of less than 0.00157 in. (0.04 mm) for the ram droop at the spindle nose and 0.00048 in/ft (0.04 mm/m) over the complete ram traverse of 76 in. (1,900 mm), with actual results typically below 0.00098 in. (0.025mm) and 0.0003 in./ft  (0.025 mm/m) respectively. This system operates independently from the fully-integrated thermal compensator.

Soraluce America Inc.
www.soraluce-america.com

Windpower Engineering & Development

PC-based Quadra-Check Metrology software provides advanced functions for inspection measurement machines.

The latest version of the PC-based Quadra-Check Metrology software provides advanced functions for inspection measurement machines. This software makes it possible to perform 2D and 3D measuring tasks in the field of metrology when standard DRO products will not suffice. Labeled the IK5000 V2.96, this inspection package builds on the original Metronics Quadra-Check QC5000 software by introducing new capability such as 3D Profiling that can provide measurement and graphic evaluation of 3D contours using multi-sensor and tactile measuring machines. This new option, used for profile measurements, imports a 3D CAD file (either STEP or IGES) and compare it with the actual measured part.

Part Programming improvements were added to support compensation for the thermal behavior of products that shrink or expand during the manufacturing. This will let users write a single inspection program for measuring parts with materials having a known growth or shrink rate throughout the manufacturing process.

Improvements were also added to existing Radial and Palletize methods of automatic part programming routines. These methods help users when there are common features or parts that repeat angularly, around a datum, or based on a palletized grid layout. On video-based Inspection machines, these improvements will retain specific video tool sizes and positions needed for these measurements, and then repeat them based on the angle they are located around the datum or in reference to a linear layout. The new Palletize grid functions will also let the user graphically select which parts in the grid are required for measurement, and only run the program in those locations.

The IK5000 version 2.96.0 runs on PCs using Windows 7 (32bit) operating systems as well as Windows XP and Vista.

Heidenhain
www.heidenhain.us

Windpower Engineering & Development

Seco says its High Feed 2 cutters reach maximum removal rates through a combination of strength and number of teeth versus diameter.

A High Feed 2 line of small diameter high feed milling tools focuses on bringing high levels of productivity and reliability to modern CNC machines. High feed rates and small depths of cut let the cutters handle a variety of applications, including pocketing, ramping, helical interpolation, facing, contouring, slotting and plunging. Cutting diameters range from 0.625 to 1.25 in.

The line includes a range of PVD and CVD insert grades for hard steels up to 62 HRc and a variety of chip groove and flat geometries to tackle several different materials, including superalloys. The chip groove geometries also allow for soft cutting in steel, stainless steel, and other gummy materials.

The developer says High Feed 2 cutters achieve maximum removal rates through a combination of strength and number of teeth versus diameter. A close pitch allows fast feed rates and stable cutting performance, even in interrupted cuts. Furthermore, the well-balanced design of the cutter body and inserts allows free chip flow in copy milling, particularly when using toolholders with long overhangs.

The High Feed 2 line also provides higher security through an optimized screw and torx socket size, a maximized insert cross section and an outside radius to prevent chipping.

Seco Tools
www.secotools.com/us

Windpower Engineering & Development

Vela Gear Systems says it will have the capability to model and manufacturer gears for wind turbines.

Vela Gear Systems says it will be the cornerstone of Marion’s Green Technology Park, a newly formed cluster of sustainable businesses, comprised of three private companies and a business incubator. The real estate component of this opportunity is that the flagship business of this Green Tech Park, Vela Gear Systems (VGS) owns the 55-acre property and has been provided with $114 million in Economic Development Bonds from the city of Marion Indiana, and was awarded $11 million in federal tax credits by the U.S. Dept of Energy.

The intent is to develop the property, building four modern facilities, as a cluster of Renewable Energy focused businesses. Vela Gear Systems seeks a financial partner to credit enhance some portion of the $114 million in bonds, so the site can be developed using the bonds. VGS is a manufacturer of drive components focused on Wind Energy. This is a purpose-built U.S. manufacturer of future offshore and land-based wind-turbine drives, with diversification into mining and rail. Read an article on the founder here.

The company has an experienced team from this market, and will have operations generating revenue manufacturing large drive components and gearboxes for the petroleum industry.

Marion Indiana's Green Tech Park

GenAgain, the second company to lease a facility on this property, is a renewable business that will recycle plastic refuse from this region into a high-grade oil. GenAgain will install a proprietary processing facility, and will have pre-sales of their product prior to construction of their facility. GenAgain’s processes require heated air, which will be provided from the waste heat from VGS’ processes.

Green Energy Transport (GET), a third company to lease a facility on this property, is partnered with a Korean electric-car company. GET will import subassemblies for final assembly of an electric car, targeting utility fleet-vehicle markets. The advantage of targeting fleet vehicles, such as municipal and short range urban delivery vehicles, is that they do not require public charging stations because they return at night to a home facility for recharging. The GET team is experienced in the automotive-dealership market and will have pre-sales in place prior to construction of their facility.

The fourth to lease a facility on this property will be a “business incubator,” funded by Purdue University and local colleges. In addition, the site will have a multi-megawatt wind turbine to provide power for the businesses. Each modern building will have solar panels and use the latest ideas in sustainability. VGS says the property will be a world-class example of profitable, sustainable businesses, in a clustered development including learning institutions where there are m synergies.

Vela Gear Systems
velagear.com

Windpower Engineering & Development

“Manufacturing is changing. We urgently need strategies to share knowledge among manufacturers, suppliers, and other partners to stay competitive,” said Debbie Holton, SME director of events and industry strategy. “Mfg4 is intended to break down traditional barriers and unlock the innovation that exists within these dynamic sectors.”

With 29 straight months of growth, manufacturing is primed to help lead the country out of the recession. The Northeast is home to many of the country’s leading energy, aerospace, defense, and medical manufacturers seeking suppliers and partners with solutions that can increase productivity and reduce costs. Mfg4 (pronounced M-F-G-4) is produced in partnership with advisors from those companies – including GE Energy, Pratt & Whitney, Sikorsky and other OEMs.
With conference sessions and an exhibit floor to promote cross-industry problem- solving, Mfg4 will connect manufacturers from different disciplines and industries. This concept enables the unexpected discovery of solutions, such as a medical device manufacturer learning about advanced materials currently being used in aerospace, or for an aerospace engineer to see how a green energy company is applying advanced turbine technology.
At the heart of the Mfg4 event floor is the Insight Intersection – an area where small groups of professionals can meet to exchange information. There will be scheduled sessions and an opportunity for exhibitors to provide in-depth discussions with attendees.
The technical conference features daily keynote and breakout sessions in each of the four industries and will focus on such topics as renewable energy manufacturing, arms, medical devices and the use of composite materials in aircraft. The exposition highlights existing and emerging technologies, such as additive manufacturing, composites, micro-manufacturing and nanotechnology.
“Mfg4 is not just technology and product demonstrations,” said Paul Faughnan, technology manager for Pratt & Whitney and an Mfg4 advisor.  “It focuses on more integrated and interactive demonstrations and not just somebody cutting through aluminum at high speed because it looks cool.”
Mfg4 is targeted towards shop owners, engineers, vice presidents of engineering and manufacturing, supply chain managers and program managers. Exhibitors can apply for space at Mfg4, and will be selected based on a strategic balance of products and services that best match the needs of the audience.

Mfg4 will alternate years with EASTEC, which has been at the Eastern States Exposition in West Springfield, Mass., since 1988, returning there May 14 to16, 2013.

Mfg4
www.mfg4event.com

Windpower Engineering & Development

An RFID chip on a test part can store its serial number, part number, lot number, the build plant and production line, date of manufacture, and lots more.

Manufacturers of leak proof components can use RFID tags for part identification and information tracking. The electronic label system with standard and custom components os tailored to application requirements. Custom elements of Uson RFID tags streamline parts processing and help manage test data while cutting overall production cost.

“The potential of Uson’s custom RFID tags technology to help manufacturers get better performance from their leak detection equipment is enormous,” says Joe Pustka, a manager of Uson’s technical support team that helped pioneer the custom RFID tags.

For starts, an RFID chip residing on a test part can store serial number, part number, lot number, the build plant and production line, date of manufacture, and lots more. The custom RFID tags have been especially helpful to manufacturers of disposable parts that work together with a module or console. In these applications, when parts are connected to the console the RFID tags let it know exactly what is connected to it and what the physical parameters required for the test solution to proceed. With RFID tags such as these, any business manufacturing products that need leak testing can create smart linking to end-user consumers, ensuring that the supply chain gets each customer the product with correct specifications.”

Uson provides specifications for custom RFID tags with both its Leak Detector Express Proposal and Leak Detection Equipment Custom Application Proposal services upon request and at no charge. Uson’s no-cost training courses on state-of-the-art leak detection  include discussion of best practices for parts identification using RFID tags, bar coding, and other techniques used for more efficient production lines.

Usun
(www.uson.com)

Windpower Engineering & Development