Scaling Up: How Automated Manufacturing is Building the Future of Wind Energy

As the wind industry rapidly expands to meet net-zero targets, it faces significant manufacturing challenges. Turbines are growing larger and more powerful, with offshore projects demanding XXL monopiles that test the limits of current fabrication capabilities. These new designs feature diameters up to 15 meters, weights exceeding 4,000 tons, and steel thicknesses reaching 180 mm.

These massive scales, combined with a growing shortage of skilled labor, mean that traditional manufacturing methods are often too slow, labor-intensive, and unpredictable to meet the demand. This creates a production bottleneck that threatens the industry's ability to scale up effectively.

A New Blueprint: The Automated Production Line

To solve this, Pemamek has pioneered a modular, end-to-end manufacturing line concept that is fully customizable to a manufacturer's needs. The core of this offering is the PEMA production automation line, a comprehensive solution that covers every stage of tower and foundation fabrication, from plate joining and section assembly to full-section welding. The system combines heavy-duty welding automation, advanced welding processes, integrated material handling, and digitalized production control software to boost throughput and improve quality.

Key components of the PEMA production line include:

• Plate lengthening lines with integrated edge preparation and welding.
• Section assembly stations and heavy-duty roller beds for precise handling of XXL components.
• Welding platforms and column amp; boom systems equipped with advanced control software.
• Heavy-duty milling and edge preparation systems specifically tailored for thick-walled structures.

This technology is already proven in the field, with solutions delivered to major industry players such as Haizea Wind Group in Spain and Sif in the Netherlands.

Core Innovations in Welding Technology

Pemamek's solution introduces several technological advancements designed to maximize efficiency and quality, particularly in welding.

• PEMA WeldControl: This is a software system that automates complex multi-pass welding and adaptive filling. It transforms the manufacturing process by allowing operators to function as supervisors, managing multiple welds simultaneously from a single control station.
• Advanced Welding Processes: The company utilizes a highly efficient triple long stick-out process. This technique uses wire pre-heating to achieve high deposition rates, making it ideal for the large and thick tubular structures found in monopiles and towers.
• Optimized Joint Geometry: Pemamek addresses a common inefficiency related to joint geometry. Instead of traditional asymmetric X-bevels, which require more weld passes and filler material, the company uses semi-narrow or narrow groove bevels. This reduces the cross-section, which in turn cuts down on welding time, costs, and material consumption without sacrificing quality.

Building the Future of Wind Energy

Looking ahead, the demand for innovation will only increase as next-generation turbines of 15 MW and beyond become standard and floating wind technologies introduce new structural challenges. Pemamek is preparing for this future by investing in Ramp;D focused on automation, digitalization, and modularity. Real-time data analytics are being increasingly integrated into the production process, empowering operators to make faster, better-informed decisions.

Discover more about these advanced manufacturing solutions: https://www.pemamek.com/