of 8
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