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

The Seco energy site will offer a range of video and written content that focuses on the issues faced by manufacturers serving the power generation and wind energy industries. Visitors will be provided with information on the latest trends, new process and product innovations, and real world examples of highly successful energy applications.

The site will feature an intuitive layout that lets users quickly and easily identify and view content of interest. Menu navigation is by an interactive model featuring a power plant and windmill.

“The energy market has remained incredibly robust, even throughout the global economic issues faced over the past several years,” says Don Graham, Manager – Turning Products & Education Services of Seco Tools. “It’s an industry that continues to see significant innovation and competitiveness. The new energy site will provide manufacturers with a valuable resource for following the industry’s latest developments.”

Seco Tools
www.secotools.com/energy.

Caption

Windpower Engineering & Development

The Siemens energy efficient building will be used to assemble nacelles.

Siemens Energy has been awarded LEED (Leadership in Energy and Environmental Design) Gold Certification for its recently opened wind-turbine-nacelle assembly plant in Hutchinson, Kansas, for its environmentally responsible design and efficient operations. The 300,000-square-foot facility is Siemens’ first LEED Gold certified production facility in the U.S. It also holds the distinction of being the first LEED Gold new construction/industrial site in the state of Kansas. The certification program is the nationally accepted benchmark for the design, construction, and operation of high-performance, green buildings.

Siemens Real Estate facilitated the project and Gray Construction built the facility. The plant opened in December 2010 and produces nacelles for the company’s 2.3-MW and 3.0-MW wind turbines. The factory achieved Gold certification for energy use, lighting, water, and material use, as well as incorporating a variety of other sustainable strategies.

Highlights:

• Insulation resulting in minimal heat loss in the winter and minimal air conditioning (AC) losses in the summer
• No CFC or HCFC (Hydro chlorofluorocarbons) refrigerants used in AC systems
• Intelligent water management, 48.7% better than Energy Policy Act baseline
• Daylight provided through skylights (75% of all regular occupied areas)
• “Sage Glass” system controls solar heat gain (reducing energy consumption), blocks glare, and increases day lighting potential
• Use of low-emitting materials in sealants, adhesives, paints, carpet, wood and finishes
• During construction avoided 50% of construction waste from disposal; use of recycled and regional materials

Siemens
www.siemens.com/energy

Windpower Engineering & Development

This basic workshop is slated for December 1, 2011 at the Hilton Windsor, 277 Riverside Dr, West Windsor, Ontario, Canada. The Great Lakes Wind Network will also participate in the workshop.

This basic workshop is slated for December 1, 2011 at the Hilton Windsor, 277 Riverside Dr, West Windsor, Ontario, Canada. The Great Lakes Wind Network will also participate in the workshop. Developers say it will cover the bases for manufacturers and service providers interested in exploring market diversification into one of the fastest growing markets. Questions answered will include:

• How extensive is this industry and what are the trends?
• What is the FIT program in Ontario and how do you capitalize on it?
• What components and systems make up a wind turbine?
• What is the supply chain structure for wind turbine parts?
• What are the mandatory requirements for this industry?
• Beyond manufacturing, what else is needed?
• Where does a company get more information fast?

Do you operate a factory in Ontario that has the capability to produce power electronics, control systems, hydraulics, fasteners, brakes, blades, nacelles, or supplemental equipment for the wind industry such as ladders, elevators, hoists, fire suppression, lighting, or meteorological equipment? Do you operate a foundry, forge. machine shop, or fabricating plant? Do you provide support services including engineering, construction, legal or financial services? If so, the wind industry may be an overlooked opportunity.
Register at www.xagenergy.com

Windpower Engineering & Development