8/8/2019 Pema News 2004 En

1/8

POSITIONERS ROLLERBEDS

BOILER MANUFACTURING AUTOMATION

WELDING AUTOMATION SHIPYARD AUTOMATION

PEMAMEKS INFORMATION JOURNAL 1/2004

COMPETITIVE EDGE GAINEDTHROUGH AUTOMATION

EFFICIENTLY-PRODUCED TOP-QUALITYPRODUCTS FROM LOGLIFT ARE SHIPPED

OUT DAILY TO ALL PARTS OF THE GLOBELoglift receives a new robot welding portal.

NEW INNOVATIONS IN ROBOTICSThe latest triumph for Pemamek Oy is theVision-robot system that can be employed insuch applications as preassembly lines in theshipbuilding industry.

PRODUCTIVE LONGITUDINALWELDING WITH SEAMERSPemamek delivers production power boost

with Seamers for all welding applications ona turn-key basis.

8/8/2019 Pema News 2004 En

2/8

Production was transferred to the new

premises at the beginning of last year, and

government minister, Mauri Pekkarinen,

officially opened the factory in October

2003. The opening ceremony was attended

by three hundred guests, including customers

and partners.

New technology in production

The new production premises cover an areaof over 7,500 m2 of which 6,000 m2 is for

production and 1,500 m2 for office space.

These large premises contain much state-

of-the-art production technology. An 8-

meter CNC-machining tool was acquired

by the machining department for processing

extra-long components. The finishing depart-

ments newest acquisition is a modern paint-

shop that can also use water-soluable paints.

The Vision-robot System represents fresh

investment in robotics. In addition to our

own production, the robot also serves the

needs of customers, who can test-runcomponents on it.

This combination of new premises and

new technology boosts production at the

factory. Today Pemamek Oy is clearly one

of the most modern welding automation

factories in the world.

ULTRA-MODERN WELDINGAUTOMATION FACTORYCOMPLETEDIn the last two years, Pemamek has invested in building a new factory.

Production at the modern facilities near Route 9 is already under way.

COMPETITIVE EDGEGAINED THROUGHAUTOMATION

Changes in the world economy are

picking up pace and the race is getting

tougher in global markets. In this

strong current of change, we Euro-

peans must take care of our own

development.

Our enterprises must invest in the

enhancement of our own competitiv-

ity; we need better and more refined

products. Our clients require attention

and we should take care of them on

a more personal level. This requires

specialisation, focus and investments

in production. Everything we do must

be carefully considered and automa-

ted, but at the same time personal

and refined. Todays technology, such

as modern control technology and

solutions in the automation field al-

ready make it possible to create solu-

tions that can handle single-compo-

nent production efficiently and

flexibly.

After a year in the new premises,

we feel that our investments havebeen fruitful and the conditions for

future challenges are good. In this

journal we would like to show you

some of our customer projects and

we hope that it will inspire your own

developmental plans.

Greetings

Pekka Heikonen

The new CNC-machining tool is for extra long components.

N ew paintshop inside the factory.

Vision-robot serves Pemameks own production and also

functions as a test-bench for clients.

2

8/8/2019 Pema News 2004 En

3/8

TECHNOLOGY FORA CRANE MAKERPEMA-

POSITIONERS TOSWEDEN

In the last few years, Pemamek has

renovated the entire basic model line

for positioners and rollerbeds. These

renovations are aimed at improving

such issues as work force safety and

productivity. The fine appearance of

our products is one of the main rea-

sons for our current impressive

growth. Pemamek usually delivers

positioners and rollerbeds as standard

basic models, but sometimes custom-

ers wish to have some special modi-

fications to better suit their needs.

Recently two 15-tonne head-

and tailstocks were delivered to

Kvaerner Kamfab Ab in Karlstadt,

Sweden. When we planned this

machine, the special needs of a

company that produces equipment

and lines for heavy industry were

carefully taken into consideration.

These positioners are equipped

with special jigs and they have a larger

height adjustment range than the

basic model. The rotation is backlashfree. A control unit for the equipment

is also supplied. These features enable

it to be controlled by such means as

a welding robot.

Kamfab reports that using the new

positioner, enhanced by a welding

portal, a 40% time saving has been

achieved. This shows how well-

planned investments in the right

equipment can give a company a

competitive advantage.

In Salo, Finland, Loglift Jonsered Cranes Oy

manufactures hydraulic timber cranes forprofessional use. Its market area is global.

The company employs about 200 people.

Production is divided into cranes for forest

tractors, timber trucks and industry. Loglift

is a Europe-wide market leader in manufac-

turing timber cranes.

Loglift is a long-time customer of Pema-

mek Oy. Over the years, Loglift has been

supplied with a variety of positioners, cutting

tables and welding robots for submerged

arc and MAG-welding.

For the past fourteen years, Loglift has been

using a robot-welding portal with a mecha-

nised positioner that was used for the welding

of crane beams. This station will be replaced

in the summer with a new automated FMS-

type welding portal equipped with un

manned control.

Because of positive experiences gained with

the previous welding portal, the new one was also

ordered from Pemamek. Smart technology brings

in flexibility and usability, points out Loglifts

process coordinator Matti Sjberg.

When using the new station, manual

labour is only required for loading the infeedtrack and unloading the outfeed track. Every-

thing that happens to the component in

between, including positioning and welding,

is fully automated.

For years Pemamek has been one of our

suppliers. The equipment has always been in-

place and adequate and we are satisfied with its

operation, says Matti Sjberg.

Internal longitudinal welding of a beam.

Cutting table at Loglift. Changing of the cutting grid.

3

Submerged arcwelding robot in construction of crane beams.

Matti Sjberg on the left, welder Pentti Laaksonen on the

right.

8/8/2019 Pema News 2004 En

4/8

Pemamek is specialised in robotics solutions

and has delivered dozens of applications to

customers in recent years. Todays applications

offer the newest and most unique technologyin the world. The central themes in these

applications are the development of usability

and improvement of the duty cycle in an

actual working environment. A completely

new feature of this technology is the easy-

to-use programming of the robotics. The

foremost product in the range is the Vision-

system.

Vision-robotsThe Vision-robot system, designed for pro-

fessionals in heavy-duty machine construc-

tion, is based on machine vision. It representsthe highest level to-date of Pemameks strong

mechanisation automation traditions.

Flexibility and user-friendliness are the

main features of the Vision-system that can

be programmed to aid in automated welding.

Ease of programming is a time-saver; offline-

programming or CAD-modeling are not

required. It is also possible to weld without

supervision. The positioning of the compo-

nent can be freely set, thanks to smart cameratechnology.

R obot programming can be done in

Basic Makro, Vision Makro and Vision inte-

grated with Design data-modelling. In addi-

tion to welding, such a robot can carry out

cutting, grinding and painting.

Heavy robot stationsPemameks key products in robotics are

welding stations for components that weigh

over 10 tonnes. Here robotics play an impor-

tant role in the highly developed system,

especially in heavy workshops and the energysector. The main elements of the station are

the robot rail, the robot itself and a positio-

ning table controlled by the robot. The

working area of the robots can be tens and

even hundreds of square meters. Many areas

of industry could greatly benefit from a

programming solution like Vision.

All Pemameks robot stations are deliv-

ered in cooperation with a renowned robot

manufacturer, like Motoman or ABB. Nowcustomers can test-run their components at

the Pemamek facilities in Loimaa since we

have our own versatile robot station with a

variety of attaching/ programming applica-

tions.

NEW INNOVATIONS IN ROBOTICSVision-robotics solutions are beginning to play an important role in boosting production for companies that

need flexible and easy-to-use programming because of the shape, type and amount of their components.

Potential users are found e.g. among shipyards subassembly lines where thousands of similar but still unique

pieces are manufactured. These robotic solutions could also be used by manufacturers of large beams or

train carriages.

4

PEMA robot welding station in our own production.

R obot station in production, Kvaerner Masa-Yards.

8/8/2019 Pema News 2004 En

5/8

LARGE DELIVERIES TO SHIPYARDSPemamek continues its success as a supplier of welding- and material handling lines to shipyards. In

2003 PEMA made a number of large deliveries to shipyards in Finland, Spain, Italy and the UK. All thedeliveries contained some new technical innovations.

Iz ar Fene 7 m subassembly line.

Kvaerner Masa-Yards, Turku Micro panel FMC.

Vosper Thornycroft 13 m Flat Panel line.

Today, automation is the key to competi-

tiveness in modern shipyards' production.

Every customer has different needs in the

fields of welding and component handling.

Together with the customer, Pemamek

creates tailored solutions for a variety of

demands. This reflects Pemamek s high level

of know-how in shipbuilding production

automation.

Izar Fene and VTOne example from last years many deliveries

is the subassembly line at the Spanish IzarFene shipyard, which was equipped with a

new modular chain conveyor line. This

highly customised panel transport solution

creates a safe and flexible working environ-

ment, thanks to smart panel fastening and

smooth conveying.

In 2003 at the Vosper Thornycroft ship-

yard in Portsmouth, UK, Pema completed

the delivery of a comprehensive panel pro-

duction line, dedicated especially to the

handling and manufacturing of very thin

sheets, 3-10 mm thick. Due to the nature

of thin plates, the transportation of the panels

could not take place on a traditional rollerconveyer, but on one made up of pallets.

On the production line the panels are hoisted

up and fixed on to the pallets from under-

neath. At the very last of the ten working

stations, the pallets are again lifted up and

the panels released from them. This way

deformation of the panels can be minimised

during different work stages and processes.

This tailored line is suitable for processing

both carbon steel and aluminium panels.

Riva Trigoso andKvaerner Masa-YardsThe Italian FC Riva Trigoso shipyard invest-

ed in a Vision System robot-welding portal.

As proof of the competitiveness of Pema-

mek's solution, Vision was competing with

many world-renowned robot suppliers of

the desired delivery. The Finnish shipbuilder

Kvaerner Masa-Yards focuses its production

know-how at the Turku shipyard, where it

has invested in a new micro panel line. This

line is capable of producing a complete

3,2 x 12 m stiffened, welded and cut micro

panel, fully automatically. The end-result is

a very accurate panel, with no need for

further machining processes.

8/8/2019 Pema News 2004 En

6/8

The Seamers of Pemamek respond to the

demands of modern longitudinal welding.

The automated, PLC-controlled work cycle

swiftly produces a top-quality welding seam,

thus improving production efficiency.

It is also possible to speed up the mount-

ing of the component with auxiliary equip-

ment, such as a laser-beam targeting device

and a positioner.

Ready-tested, completepackages for different needsSeamers are manufactured at Pemamek for

a variety of needs. The ED-model line is

designed for external longitudinal welding,

with a seam length of 1,5 6 metres. For

internal longitudinal welding the ID-model

line is the answer. The seam length varies

from four to six metres, depending on the

need.

Seamers are delivered as ready-tested,

efficient packages which include the seamer,

the component conveyers and transport and

hoisting carriages for cylinders. Welding

equipment can be easily installed.

To make it easier to introduce new

equipment into production, it is possible for

the customers to run tests at the Pemamek

facility beforehand. At the same time, super-

vision and assistance is available for the

setting of production parametres. This cannaturally also be done at the facilities of the

customer.

Global shippingPemamek has delivered dozens of Seamers

all over the world. A second external longi-

tudinal Seamer ED with plasma welding

application has been delivered to Pronar in

Poland. This Seamer has two backings but

just one welding trolley. The advantage of

this kind of plasma Seamer is that the arc

can be active almost continuously; while

welding on one side of the Seamer, compo-

nent loading can be done on the other.

R ecently, Seamers have also been de-

livered to Spain and R ussia. These were

AC/ DC plasma applications that can be

easily applied to the welding of steel, stainlesssteel and aluminium. The deliveries were

large; a seven-meter unit was shipped to

Spain and a six-meter one to R ussia. De-

liveries also included conveyers for the han-

dling of sheets.

PRODUCTIVE LONGITUDINAL WELDINGWITH SEAMERSTo boost the production of longitudinal welding for sheets and cylinders in a smart way, the

solution is the Seamer. Pemamek delivers Seamers on a turn-key basis to all welding applications.

The advantages of a Seamer can be applied to MIG/MAG, plasma and submerged arc welding.

6

PEMA/ ESA B ID60H 10 seamer.

8/8/2019 Pema News 2004 En

7/8

STRONG KNOW-HOW FOR THE ENERGY SECTORThe manufacturing of power plant boilers and windmills requires much welding and component handling.

With efficient material handling and flexible conveyor lines, high productivity and arc-time can beassured in the welding of boilers. Traditionally, the windmill towers have been welded with the aid of

rollerbeds. As one tower consists of 10 to 12 shells, positioning and tacking takes up much time.

The new welding line has an 80-tonne head- and tailstock,

a mounting jig for shells and a rollerbed with a

lowering/ hoisting capability to aid in the

moving of towers.

7

The above-mentioned sectors of heavy

industry are ideal beneficiaries of Pemameks

expertise. As far as enhancing productivity

is concerned, Pemamek has invested in

material handling and material flow with

conveyor lines. A very good example of this

is a basic model welding gantry for mem-brane wall panels, equipped with six sub-

merged arc welding machines and an auto-

matic material handling line. This model is

capable of welding up to three kilometres

of seam in one 8-hour shift.

Now Pemamek can offer a whole line

for manufacturing boilers. Delivery consists

of equipment to calibrate the width of the

finbar, preparational measures for the pipes,

and a ready-welded membrane wall panel

of pre-defined dimensions and straightness.

Tube-to-tube welding lines for avariety of purposesFor over 20 years Pemamek has delivered

welding lines for boiler manufacturers. Tube-to-tube welding is one of the essential parts

in the construction of a boiler. This method

is also widely used in other process industries,

such as shipbuilding.

Generally, tube-to-tube is welded with

TIG but if necessary, MIG-welding can also

be used. Since the quality of the seam is

very important, the joints are normally

inspected using X- ray. Pemamek

manufactures tube-to-tube welding stations

as complete packages, which include con-

veyor lines and pipe stores, seam grinding

equipment and equipment for preparatory

work on the pipes (prehandling, angle of

preparation and cleaning).

Lines for welding windmills

The mounting and welding lines for theconstruction of windmill towers are another

of Pemameks fields of expertise. Over the

years, Pemamek has delivered a number of

rollerbeds to assist in the manufacturing of

windmill towers.

As an innovation, a full line has been

designed to boost the construction of cone-

shaped towers from cylinder-shaped compo-

nents by improving the mounting and

tacking capabilities. This line has cut the

time required per shell from two hours to

20 minutes. Excon in the Czech R epublic

recently acquired one.

Two large membrane wall-panel welding gantries were delivered to BHEL, India.

8/8/2019 Pema News 2004 En

8/8

PARTNERSHIP NETWORK

MAKES FULL SERVICE POSSIBLEPemameks operating principle is built around turn-key deliveries. Full service is made possible by an

extensive partnership network with leading welding corporation, ESAB, and with renowned programming

and robot manufacturers. Production is further supported by extensive use of subcontractors. In addition

to support for production, the partnership network also provides possibilities for offering peripheral

services.

PEMA NEWS is an information journal of Pemamek OyP.O. Box 50, 32201 Loimaa, tel +358 2 760 771fax +358 2 762 8660, www.pemamek.com

PEMA products are also sold by ESAB and ESAB's retailers, www.esab.com

Demonstration session at the Windmill-seminar

Production manager Jyri Passila

A modern and well-working partnership

network makes a number of good things

possible. For example, Pemamek can offer

demonstrations in welding and simulations

of production processes and layout-planning

as part of a bidding project. Different types

of production analysis and consultation

projects are also available for Pemas

customers.

Customer seminars offerinformationOne of our services is our tailored customer

seminar. An example of this took place last

year when information was exchanged and

visions updated at a windmill production

event. Dur ing the two-day event, a full-size

component of a windmill was manufactured

at our facilities in Loimaa. It was welded

and assembled in full view of an audience,

making it easy for them to understand the

high speed at which a component can beassembled.

A similar kind of event was arranged to

introduce the Vision-system. Both our own

technicians and those of our partners passed

on useful information about this innovation.

In future, similar events will be arranged

when required. These events also emphasise

the position of Pemamek as a high-class

technology service provider.

New facesIn the past year a lot has happened at Pema-

mek. Since demand for the products hasremained constant, new professionals have

been recruited. Our new Project manager

is Petri Aaltonen M.Sc. New production

manager is Jyri Passila B.Sc. The recruitment

of these specialists, strengthens the already

strong technical know-how at Pema.

Mr. R isto Mkitalo has been appointed

Managing Director of Pemamek Oy. He

assumed his position in 1.5.2004.

Previously, Mr. Mkitalo has been Vice

President of Lillbacka Oy during 1990-

1998. He came to Pemamek from R aute

Oyj where he held the position of Managing

Director of the Group since 1998.Pemamek Oys owner and previous

Managing Director, Mr. Pekka Heikonen,

actively continues to develop the company

as full-time Chairman of the Board.

8

Managing director Risto Mkitalo

Project manager Petri Aaltonen