phases description wind tower production with sertom bending

PHASES DESCRIPTION OF WIND TOWER PRODUCTION

THROUGH SERTOMBENDING MACHINE

1- Plate infeeding:

The plate is put on a side rollaway supporting and then introduced into the bending rolls.In our example we suppose the plate infeeding from the right side

of the machine.

2- Plate alignment phase.

The plate is aligned through the help of

the left hydraulic side arm.

Being the plate a sector of circular ring, by the EMO machine it

can be aligned according to its

central axis in respect to the top roll.

During this first phase the right hydraulic side arm acts like a

rollaway.

3- Plate view from above.

In this drawing you can see that the circular ring sector must be aligned according to its central axis (pls. look at the drawing “EMO pre-bending wind tower left side”) and not according its left edge.

This solution reveals very advantageous in respect to a 4 rolls bending machine, because the plate position must be never rotated.If we should place the plate into the 4 rolls machine like we do by the EMO (pls. look at the drawing “RIMI 4R pre-bending wind tower left

side 1”), getting a perfect pre-bending would be impossible, because that piece of plate on the left edge of the central rolls wouldn’t be

bent and would remain straight, without pre-bending.In the drawing “RIMI 4R pre-bending wind tower left side 2” it is put in

evidence the position of the plate, necessary to perform a correct pre-bending by the 4 rolls machine.

Thereafter the plate must be rotated to allow its bending. The rotation must be done through a bridge crane, which means more time and a

further operation.

EMO pre-bending wind tower left side

4/5- First pre-bending: left side.

Directly from the alignment phase the plate is taken back through the rolls rotation, up to the centre of the top and left side rolls; at the

same time the top roll comes down pressing and bending the plate, getting the pre-bending. As you can see from the drawings, the top

roll presses the very first part of the plate, leaving the remaining metal sheet always in horizontal position on the rollaway.In order to facilitate the plate sliding, the side rolls must be tilted according to

the cone angle.The EMO system reveals a great advantage in front of the 4 rolls machine, that on the contrary uses the top and central rolls to pinch the plate, while its side roll lifts the plate to perform the pre-bending; but being the plate very long, you need the bridge crane to

help the plate lifting, which means more time and a further operation.Moreover by the EMO machine you can perform the pre-bending with the tilted edge of the plate (first sector unparallel in

respect to the top roll axis), even thanks to the tilted side rolls; while by the 4 rolls machine the plate edge must be aligned to the central rolls axis to be turned always through the bridge crane to start the

bending.Look at the drawing. RIMI 4R pre-bending wind tower left side 1 and

RIMI 4R pre-bending wind tower left side 2.

RIMI 4R Pre-bending windtower left side 1

RIMI 4R Pre-bending windtower left side 2

6/7- Bending start.

To facilitate and speed up all operations, the machine is basic equipped with a Touch Panel Siemens on the control desk with

display 10.4”, showing the position of the rolls and the lateral rolls tilting. The Touch Panel helps the operator to move the rolls by a precision of ±0,2 mm, and to repeat the operations in presence of

pipes having the same dimensions.Furthermore the touch panel gives many other information, such as

the eventual presence of anomalies or alarms, diagnostic of all electro-valves, automatic lubrication program.

Once the pre-bending phase is over, you go on bending the plate rotating it clockwise.

The hydraulic left side arm with hydraulic double articulation allows the medium-big diameter pipes to be supported and to be lead up to

the hydraulic central arm.In order to get a good bending performance we suggest to close the pipe during the first step for around the 80-90% of the final diameter.

8/9- Second pre-bending on the right side of the plate.

The second pre-bending is performed in the same way of the first one, that is, while the plate ends its stroke, the top roll presses on the

last sector of the plate making the pre-bending.The lateral rolls position is the same of the first pre-bending just by

inverted positions.

10/11- Second bending

Rotating the pipe anticlockwise we will be able to get it closed.Obviously the two side arms with double articulation and the central

arm keep on supporting the plate.

12/13-Calibration phase

This phase is very important because it helps the internal platetensions to stabilize, granting a good tolerance on the diameter and avoiding after the pipe welding process to calibrate it once again in

the machine.The calibration phase occurs rotating the pipe again clockwise.

Altogether the pipe has been rotated three times from one side to the other.

We tested one can perform the bending in just a step but sometimes the pipe has a inconstant tolerance, due to the different mechanical

features of the material and to the internal tensions caused by strains. Therefore you need either to insert the pipe again into the

machine to recalibrate it or you need a long job to joint the two welded pipes.

Cone extraction

HYDRAULIC SIDE PLATE SUPPORT WITH DOUBLE ARTICOLATION

HYDRAULIC SIDE PLATE SUPPORT WITH DOUBLE ARTICOLATION

HYDRAULIC CENTRAL OVERHEAD SUPPORT FOR MAX WEIGHT OF THE PLATE 12 TON., AND MAX TUBE DIAMETER 5000 mm

CONTROL PANELARM BAR TO ALIGNMENT PLATE

MANUFACTURERS OF HEOLICS WIND TOWERS

USING SERTOM BENDING MACHINES

SPANISH

APOYOS METÁLICOSPOL. IND. ARQUINORRUTI, S/N

31809 OLAZAGUTIANAVARRAMr. INAKI

TEL. 0034/948 46 85 55MACHINE TYPE: EMO 30-30

EMO 30-30

URBASAC/ HIRIBARREN S/N

20210 LAZKAO(GUIPUZCOA)


ANROCTRA ARGAMASILLAS KM 1TOMELLOSO (CIUDAD REAL)

Mr. ANGEL RODRIGUEZTEL. 0034/926 51 14 19

MACHINE TYPE: EMO 30-25EMO 30-15

EMYPISACTRA ALBACETE KM 202230 MADRIGUERAZ

ALBACETEMr. CEBRIAN


EMO 30-30EMO 30-30

COIPER (COMONOR)POL. IND. DE CABAÑAS RARAS

24400 PONFERRADALEON

Mr. RAULTEL. 0034/987 45 33 23

MACHINE TYPE: EMO 30-25

APLACANSAAVDA. CONDE GUADALHORCE 73

33400 AVILÉSASTURIAS

Mr. CASIMIROTEL. 0034/98 55 63 898

MACHINE TYPE: EMO 30-25EMO 38-40

EMIPYSACTRA ALBACETE KM 2– 02230 MADRIGUERASTEL. 0034-967-483480


CONSTRUCCIONES METALICAS URIALDEPOL. IND. EL CAMPILLO, PAB 22 SEC. F

48509 GALLARTA (VIZCAYA)MACHINE TYPE: EMO 30-50

ITALY

PUGLIESE INDUSTRIA MECCANICA srlCONTRADA SALETTI

64041 ATESSA (CHIETI)Mr. PUGLIESE

TEL. 0039/0872-895050MACHINE TYPE: EMO 35-40

SIDERMONTAGGI SpAVIA APPIA KM. 645 74100 TARANTO

Mr. STALLOTEL. 0039/099-470 4138


ITALY

LEUCCI COSTRUZIONI SRLVIALE ENRICO FERMI, 26

72100 BRINDISIMr. DESTINO

TEL. 0039/0831-546531MACHINE TYPE: EMO 30-40

GERMANY

AMBAU GmbhROSA-LUXEMBURG STR. 4706773 GRÄFENHAINICHEN

TEL. 0049-34953-37288MR. GÖRLITZ – MR. BRÜCKNER


U.S.A.

HIRSCHFELDTEXAS

MR.TEL.


phases description wind tower production with sertom bending

Documents