minimized. The plate processing system is designed to prebend the leading edge
with maximum accuracy and minimum distortion, according to the company.
During the initial prebending phase, the infeed table elevates along with the
entry side support and side roll. These actions are fully synchronized to keep
the plate completely flat during the prebending phase and avoid any counter
moment that could lead to distortion.
Santoni said that this feature is very important in maintaining the integrity of
the cone rolling process. Other systems are known to lift the plate only with the
entry side roll, generating a counter bending moment that could lead to heavy
distortions on the final radius.
Once the prebend is done, the feeding process begins. The hydraulic guides
grip the plate and maintain optimized pressure and plate position through the
Once the can is about 25 percent complete, the side support elevates to hold
the can as it curves. When the can reaches the halfway point of forming the final round shape, the vertical support becomes more important as it maintains
the can’s proper shape and prevents the plate from collapsing because of its
During the final moments of the rolling process, the entry side support elevates to hook the initial rolled plate portion. This helps to keep the lead portion
of the plate roll from possibly overlapping with the last portion to be formed.
Once within the grasp of the rollers, the plate is moved in reverse to complete the alignment of the cylinder. At this point, edge alignment in preparation for tack welding can occur to ensure that the final shape and tolerances
Santoni held a demonstration of the high-productivity plate roller on the
seminar’s second day. He mentioned that rolling a cone using older “advanced
systems” might take about 10 to 15 minutes, and using a completely manual
system without accessories could take more than an hour. During the demonstration, a DAVI operator was able to position and square the plate, prebend, roll
a complete cone, and align the two leading edges in about six minutes.
Santoni has indicated that iCone© software, developed by DAVI, plays a huge
role in the success of rolling very large and heavy offshore components. (The
software can work with plate up to 140 mm [ 5. 51 in.] thick and weighing up to
80 tons.) In this case, the software automatically calculates the position of the
hydraulic guides that intermittently rotate the plate while cone forming.
The Need for New Technology
Attendees also had the chance to see Lincoln Electric’s submerged arc welding
technology that maximizes material deposition at increased production speeds
and HGG’s automated 3-D cutting systems that pull their job instructions from
building information models. Tools such as these, PEMA’s latest in heavy-duty
cylinder rotation systems for automated welding systems, and the new DAVI
plate rolling technology are going to help fabricators keep up with the bigger
and bolder designs for offshore wind towers and foundations.
“The machines of today have nothing to do with the machines of yesterday.
These past few years we have re-engineered and redesigned our complete line
of angle rolls and plate rolls,” said DAVI President Orazio Davi. “These machines
will help the fabricators with their future work.
“It should be noted, however, that achieving these results has only been possible because of tight cooperation with our most experienced end users. A deep
cooperation between machine manufacturers and end users will always be the
key for success.”
Editor-in-Chief Dan Davis can be reached at firstname.lastname@example.org.
DAVI—Promau Group, www.davi.com
HGG Group, www.hgg-group.com
PEMA Welding Automation, www.pemamek.com
Lincoln Electric, www.lincolnelectric.com