Customer's Challenge
Our client required In-Situ machining on a push down column structure for a wind turbine installation vessel. The primary function of these 20-meter-long push down columns is to stabilize the cargo barge, facilitating the loading of wind turbine components onto the vessel. Due to their immense size and length, it was impossible to transport them to a traditional machine shop, presenting significant logistical and space challenges.
Overview of the Push Down Column System
- The push down columns press onto the delivery barge, providing stability during wind turbine loading operations.
- The columns’ massive structure and six contact surfaces required precision machining to meet GD&T specifications, while avoiding the challenges of moving the structure offsite.
Solution
To address these tight geometric and dimensional tolerances, we engineered a customized gantry milling machine capable of machining all six surfaces of the column in a single setup.
- Co-related surfaces were machined simultaneously, ensuring precise alignment and reducing setup time.
- The entire 20-meter length of the structure was covered using four watertight, aligned setups to ensure consistency across all six surfaces.
- The API laser tracker was used to establish 32 datum pads welded onto the column, providing an accurate reference for machining.
- These datum points were crucial, setting the plane for the Easylaser geometric system, which performed in-process checks before the final finishing cuts to ensure the engineering tolerances were met.
Benefits
With our innovative machine configuration, we successfully machined all six surfaces in a single setup, significantly improving productivity. This solution reduced the time, manpower, and complexity typically required for lifting, alignment, staging, and welding, while maintaining the precise tolerances specified by the engineering drawing.
This efficient approach enabled seamless project completion, providing enhanced accuracy and reducing overall downtime for the client.
