PEMAMEK’S INFORMATION JOURNAL 1/2004

COMPETITIVE EDGE GAINED

THROUGH AUTOMATION
EFFICIENTLY-PRODUCED TOP-QUALITY
PRODUCTS FROM LOGLIFT ARE SHIPPED
OUT DAILY TO ALL PARTS OF THE GLOBE
Loglift receives a new robot welding portal.

NEW INNOVATIONS IN ROBOTICS

The latest triumph for Pemamek Oy is the
Vision-robot system that can be employed in
such applications as preassembly lines in the
shipbuilding industry.

PRODUCTIVE LONGITUDINAL
WELDING WITH SEAMERS
Pemamek delivers production power boost
with Seamers for all welding applications on
a turn-key basis.

• POSITIONERS • ROLLERBEDS
• BOILER MANUFACTURING AUTOMATION
• WELDING AUTOMATION • SHIPYARD AUTOMATION
 COMPETITIVE EDGE
GAINED THROUGH
AUTOMATION
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
The new CNC-machining tool is for extra long components.
in production. Everything we do must
be carefully considered and automa-
ted, but at the same time personal
and refined. Today’s technology, such
ULTRA-MODERN WELDING as modern control technology and
solutions in the automation field al-
ready make it possible to create solu-
AUTOMATION FACTORY tions that can handle single-compo-
nent production efficiently and
COMPLETED flexibly.
After a year in the new premises,
we feel that our investments have
In the last two years, Pemamek has invested in building a new factory. been fruitful and the conditions for
Production at the modern facilities near Route 9 is already under way. future challenges are good. In this
journal we would like to show you
some of our customer projects and
Production was transferred to the new
we hope that it will inspire your own
premises at the beginning of last year, and
developmental plans.
government minister, Mauri Pekkarinen,
officially opened the factory in October
Greetings
2003. The opening ceremony was attended
Pekka Heikonen
by three hundred guests, including customers
and partners.

New technology in production

The new production premises cover an area
of 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- Vision-robot serves Pemamek’s own production and also
ment’s newest acquisition is a modern paint- functions as a test-bench for clients.
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-run
components 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. New paintshop inside the factory.
2

PEMA-
POSITIONERS TO
SWEDEN
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 backlash
free. 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.
TECHNOLOGY FOR
A CRANE MAKER
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 Loglift’s
process coordinator Matti Sjöberg.
When using the new station, manual
labour is only required for loading the infeed
track 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 Sjöberg.
Submerged arc welding robot in construction of crane beams.
Matti Sjöberg on the left, welder Pentti Laaksonen on the
right.
In Salo, Finland, Loglift Jonsered Cranes Oy
manufactures hydraulic timber cranes for
professional 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.
Internal longitudinal welding of a beam.
Cutting table at Loglift. Changing of the cutting grid.
3
 PEMA robot welding station in our own production.

NEW INNOVATIONS IN ROBOTICS

Vision-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.

Pemamek is specialised in robotics solutions
and has delivered dozens of applications to
customers in recent years.Today’s applications
offer the newest and most unique technology
in 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-robots
The Vision-robot system, designed for pro-
fessionals in heavy-duty machine construc-
tion, is based on machine vision. It represents
the highest level to-date of Pemamek’s 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-
4
programming or CAD-modeling are not programming solution like Vision.
required. It is also possible to weld without All Pemamek’s robot stations are deliv-
supervision.The positioning of the compo- ered in cooperation with a renowned robot
nent can be freely set, thanks to smart camera manufacturer, like Motoman or ABB. Now
technology. customers can test-run their components at
Robot programming can be done in the Pemamek facilities in Loimaa since we
Basic Makro,Vision Makro and Vision inte- have our own versatile robot station with a
grated with Design data-modelling. In addi- variety of attaching/programming applica-
tion to welding, such a robot can carry out tions.
cutting, grinding and painting.
Heavy robot stations
Pemamek’s 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 energy
sector. 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 Robot station in production, Kvaerner Masa-Yards.
LARGE DELIVERIES TO SHIPYARDS
Pemamek 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 the
deliveries contained some new technical innovations.
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.
Vosper Thornycroft – 13 m Flat Panel line.
Izar Fene and VT
One example from last year’s many deliveries
is the subassembly line at the Spanish Izar
Fene 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 roller
conveyer, 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
Kvaerner Masa-Yards,Turku – Micro panel FMC.
the panels released from them. This way
deformation of the panels can be minimised many world-renowned robot suppliers of
during different work stages and processes. the desired delivery. The Finnish shipbuilder
This tailored line is suitable for processing Kvaerner Masa-Yards focuses its production
both carbon steel and aluminium panels. know-how at the Turku shipyard, where it
has invested in a new micro panel line. This
Riva Trigoso and line is capable of producing a complete
Kvaerner Masa-Yards 3,2 x 12 m stiffened, welded and cut micro
The Italian FC Riva Trigoso shipyard invest- panel, fully automatically. The end-result is
ed in a Vision System robot-welding portal. a very accurate panel, with no need for
As proof of the competitiveness of Pema- further machining processes.
mek's solution,Vision was competing with
Izar Fene – 7 m subassembly line.
 PEMA/ESAB ID60H10 seamer.

PRODUCTIVE LONGITUDINAL WELDING

WITH SEAMERS
To 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.

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, complete
packages for different needs
Seamers 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
6
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 can
naturally also be done at the facilities of the
customer.
Global shipping
Pemamek 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.
Recently, Seamers have also been de-
livered to Spain and Russia. These were
AC/DC plasma applications that can be
easily applied to the welding of steel, stainless
steel and aluminium. The deliveries were
large; a seven-meter unit was shipped to
Spain and a six-meter one to Russia. De-
liveries also included conveyers for the han-
dling of sheets.
STRONG KNOW-HOW FOR THE ENERGY SECTOR
The 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 be
assured 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.

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

Two large membrane wall-panel welding gantries were delivered to BHEL, India.
The above-mentioned sectors of heavy
industry are ideal beneficiaries of Pemamek’s
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,
The mounting and welding lines for the
construction of windmill towers are another
of Pemamek’s 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-
and a ready-welded membrane wall panel shaped towers from cylinder-shaped compo-
of pre-defined dimensions and straightness. nents by improving the mounting and
tacking capabilities. This line has cut the
Tube-to-tube welding lines for a time required per shell from two hours to
variety of purposes 20 minutes. Excon in the Czech Republic
For over 20 years Pemamek has delivered recently acquired one.
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

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
 PEMA NEWS is an information journal of Pemamek Oy
P.O. Box 50, 32201 Loimaa, tel +358 2 760 771
fax +358 2 762 8660, www.pemamek.com
PEMA products are also sold by ESAB and ESAB's retailers, www.esab.com

PARTNERSHIP NETWORK
MAKES FULL SERVICE POSSIBLE
Pemamek’s 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.

Demonstration session at the Windmill-seminar

A modern and well-working partnership In future, similar events will be arranged

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 Pema’s
customers.
Customer seminars offer
information
One 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. During 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 be
assembled.
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.
8
when required.These events also emphasise
the position of Pemamek as a high-class
technology service provider.
New faces
In the past year a lot has happened at Pema-
mek. Since demand for the products has
remained constant, new professionals have Project manager Petri Aaltonen
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. Risto Mäkitalo has been appointed
Managing Director of Pemamek Oy. He
assumed his position in 1.5.2004.
Previously, Mr. Mäkitalo has been Vice Production manager Jyri Passila
President of Lillbacka Oy during 1990-
1998. He came to Pemamek from Raute
Oyj where he held the position of Managing
Director of the Group since 1998.
Pemamek Oy’s owner and previous
Managing Director, Mr. Pekka Heikonen,
actively continues to develop the company
as full-time Chairman of the Board.
Managing director Risto Mäkitalo