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TOP / CASE STUDIES / A high-precision bevelling machine supporting weld quality in monopile manufacturing
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CASE 05 LINSINGER

A high-precision bevelling machine supportingweld quality in monopile manufacturing

Offshore wind and large steel structures
Bevel Preparation
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CUSTOMER
Offshore wind and large steel structures
TECHNOLOGY
Plate edge milling (a mechanical cutting bevelling machine)
PROCESS
Bevelling the edges of heavy steel plate (weld preparation)
SUPPORT
Defining the machining conditions, specification, technical coordination with the manufacturer, installation, trial running and follow-up after start-up
01

The challenge before installation

In manufacturing monopiles for offshore wind power, heavy steel plate is formed into a cylinder and the plates are then welded together to a high degree of accuracy. Bevelling — machining the plate edges to the right angle and shape before welding — is therefore a critical process.

The plate edges had previously been prepared by flame cutting, but thermal cutting tends to leave a rough surface and to produce variation in shape and dimensions. To mass-produce large-diameter, thick-walled monopiles at high quality, equipment that could machine the bevel to a more consistent accuracy was needed.

02

The equipment and technology proposed

For this we proposed LINSINGER's plate edge milling technology. It removes material from the plate edge by cutting, and can form V, X, Y and J bevels and other shapes to a high accuracy according to the welding requirements.

The LINSINGER FALCON series in particular machines all four edges of heavy plate accurately and at high speed, which suits weld preparation for offshore wind and large steel structures. Producing an angled edge by flame cutting is certainly possible, but with the LINSINGER machine the customer can consistently produce a smoother bevel face with better dimensional repeatability.

Equipment
LINSINGER FALCON series plate edge milling machine
03

Support through to installation

We took a detailed account of the plate thickness, dimensions, welding method and required bevel shapes for the monopiles the customer manufactures, and set out the machining conditions needed. We passed this on to LINSINGER and worked through the equipment specification and the machining conditions with them.

Rather than simply delivering a machine, we supported the project throughout — technical coordination with the manufacturer, installation and trial running, and follow-up after start-up — so that the machine would work reliably once built into the actual production line.

04

What changed after installation

Milling has made it possible to finish the plate edges at a consistent angle and shape, improving the quality of weld preparation. With less variation in the bevel, the welding conditions when two plates are brought together are also more stable, which leads to high-quality welds.

Fast, repeatable bevelling also contributes to the productivity needed for monopile series production. It has become one of the key machining processes supporting monopile manufacturing for offshore wind in Japan.

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