Cart solution for Zn arc-metallizing of wind towers

The principle of the automatic metallizing cart is to metallize steel tower sections for obtaining a certain anti corrosive characteristic by applying a coat of Zn/Al that acts as anodic protection. The automation system is consisting of the flowing main components:

  1. A floor mounted portal system.
  2. A cart which can be loaded with up to 6 drums containing the metallizing wire
  3. A PLC with the HMI interface
  4. 3 pcs. 600 Amp metallizing units
  5. A 3-axis manipulator arm with 3 metallizing guns deployed

The cart can be prepared with Zn/Al 85/15 wire drums (max. 6 x 250 kg) and various sizes metallizing equipment with current of up to 1800 Amp.

The cart is moving in parallel of the tower section and is driven by a serrated belt and an omega drive. The cart is supported by special polyurethane rollers and the main track is constantly cleaned by an air-knife with compressed air to avoid dust residues on the main track.

The zinc/alu coating is applied in horizontal direction along the tower section by moving the cart and rotate the tower sections step wise. The tower sections are rotated on a roller bed and firmly controlled with a












timing signal for correct rotation length. The manipulator arm will move closer to the surface during the movement of the cart parallel to the tower section. In addition, the tool head is turning so that the spray patterns always can be adjusted to be 90 degrees between the gun head and the steel surface to be metallized.

Frederik Nielsen

"Please contact me if you want to know more about our robotic cart solutions."

Frederik Nielsen Clemco Danmark A/S

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