Wind energy is one of the main pillars of the energy transition. In the face of growing demand for clean energy sources, investments in wind farms – both onshore and offshore – are gaining momentum.
Wind towers are huge structures. They can be over 200 meters high and weigh hundreds of tonnes. Their production must meet strict technical and quality standards. Without compromise. That is why control at every stage of the process – from sheet metal cutting to final assembly – is important. And metrology is at the heart of this control.
Challenges in wind tower production
Tower production is a complex engineering process. It consists of many steps: cutting, rolling, welding, machining, assembling. PROram engineers work together with E-Towers, a tower manufacturer.
PROram offers precise large-scale measurements, even in difficult hall conditions, which is crucial for ensuring the quality of wind tower production. Any error, even a millimetre one, can turn into a serious construction problem.
The most common challenges are:
- Welding deformations – these must be detected and corrected.
- Segment eccentricity – a very important issue – causes difficulties in tower assembly.
- Difficulty of measurement – traditional measuring tools fail with elements several meters long.
That is why modern, digital technologies and measuring tools work well in such an environment. They are fast, accurate and repeatable.
The role of metrology
Modern metrology is a strategic technology that goes beyond traditional dimensional control and plays a key role in optimising the entire wind tower production process.
Why?
Firstly, it allows for ongoing quality control. 3D measurements make it possible to check whether the components conform to the design at every stage. This helps to quickly detect and correct errors before the components move on to the next stage of the production process.
Secondly, it increases efficiency. 3D scanning provides a complete map of the object. We can analyse deviations, compare geometries and automate reporting.
Thirdly, it ensures safety. The accuracy of a construction has a direct impact on its durability and resistance to wind loads. With these dimensions, deviations that may seem small can actually lead to serious consequences.
And last but not least, it meets the requirements of the quality assurance system. Customers expect the product to meet all standards. Metrology provides this data in a transparent and reliable way.
How PROram supports wind towers manufacturers
At PROram, metrology is one of the three pillars of the business. The team of specialists supports customers in industrial projects, including the most demanding ones, such as offshore structures, both wind and oil & gas.
- ProScan is an advanced 3D measurement and scanning service that enables precise mapping of the geometry of large-size components. To minimize the risk of errors and speeding up the production process.
The experience of the PROram team guarantees high-quality scanning and data processing.
- ProQ-QC is comprehensive support in the field of quality documentation, including verification of compliance with ISO GPS, GD&T standards and preparation of reports for customers and auditors. It guarantees a smooth passage of audits and meeting customer requirements.
- PoP – Pool of Professionals gives you access to selected engineers, quality controllers, welding inspectors and technicians. This provides support at every stage of production and optimizing processes. PROram gives you access to selected specialists – for inspections, consultancy or as permanent support for your production team.
Customer benefits
Cooperation with PROram brings concrete benefits:
- Reduction of errors – thanks to early detection of non-conformities, which translates into lower production costs and minimised waste.
- Time savings – thanks to fast analysis and automated reporting, which allows for a shorter production cycle.
- Improved quality and safety – confirmed by precise measurements, which guarantees the durability and reliability of wind tower structures.
- Compliance with standards
Wind turbine production is one example of where we prove the effectiveness of modern industrial metrology methods in quality assurance systems.
