en.Wedoany.com Reported - Italian plate rolling machine manufacturer Davi has introduced heavy-duty plate rolling solutions, including a three-roll variable axis system and an automated four-roll system, in response to the offshore wind industry's demand for ultra-large monopile foundations. The offshore wind sector is standardizing around ultra-large turbines exceeding 15 MW, requiring monopile foundations with diameters of 15 meters (approximately 49 feet) and steel plate thicknesses exceeding 150 mm to 170 mm (approximately 6 inches to 6.7 inches).
The core challenge facing manufacturers is how to roll steel plates of such specifications with perfect geometric tolerances, minimal straight-edge sections, and optimal cycle times, thereby reducing material waste and operational downtime risks. At extreme thicknesses, the springback and bending resistance of structural steel make it difficult for standard plate rolling machines to minimize the straight-edge sections at the plate edges, often necessitating costly trimming and rework after rolling. Additionally, the manufacturing of tapered sections for onshore and offshore wind turbine towers requires precise asymmetric force distribution. Traditional methods rely on operator experience, leading to long cycle times, high risks of plate slippage, and unstable geometric accuracy.
Davi's solutions include the MAV three-roll variable axis technology. In this series, all three rolls can tilt up to 100 mm per 3 meters of roll body length (approximately 4 inches per 10 feet), achieving geometric precision for heavy cones through a progressive point-loading mode. Both the side rolls and the top roll are fully electric and synchronized, and their planetary gearboxes allow the side rolls to approach the top roll, enabling the machine to clamp the plate at the tangent point to shorten the straight-edge sections. To prevent frame deformation under extreme bending loads, large-capacity MAV machines use a "push-push" configuration below 3,000 tons and a "pull-pull" configuration above 3,000 tons, ensuring uniform load distribution. Davi integrates heavy-duty feeding systems, including an adaptive extended feeding system and a continuous plate rotation manipulator, eliminating reliance on factory overhead cranes. For fixed foundations, MAV machines allow calibration after welding to restore roundness and meet the structural tolerances required for offshore marine environments. The system's high productivity and intelligent production line reduce plate positioning time, aligning with the fast-paced delivery schedules of offshore projects. Its control systems, iRoll eXtreme and iCone, provide real-time 3D interfaces and AI-assisted programming, automatically managing the pusher and hydraulic guides during cone rolling. A laser measurement system continuously tracks the radius from a safe distance, allowing a single operator to manage the heavy rolling process without manual templates.
Davi has a global track record of over 300 automated production lines in operation in the wind power plate rolling sector, with approximately a 70% market share in the wind energy field. All machines are designed, manufactured, and tested in Italy.
