PEMA - Column & Boom HD 4x4 Twin SAWEE-WEL-PEM-2019-00001

• Status and storage

  • Dismantled by Pematek Oy in September 2022

  • Stored in a warm, dry factory, wrapped in plastic

  • Indoor operation; ambient +5 °C to +40 °C, relative humidity 40%–80%

• Machine/system

  • PEMA Column & Boom Semi-Portal for beam welding (heavy-duty C&B welding manipulator)

  • Application: Automated submerged arc welding (SAW) of beams and other longitudinal workpieces

  • Working range: 4 m vertical × 4 m horizontal

  • Two welding arms with twin SAW heads

  • Mounted on a motorized rail carriage for welding movement

• Control

  • PEMA control panel with touch screen

  • Standard control system: PEMA WeldControl 100 (process control included)

• Included welding equipment

  • 2 × Lincoln AC/DC 1000 SD Powerwave power sources for SAW

  • 2 × Lincoln MAXsa 29 wire feeders (feed heads)

  • 2 × Ejector-type flux recovery systems integrated in welding arms

  • 2 × Pressurized air flux feeding tanks, 75 L each, heating up to 120 °C

  • 2 × Electro-mechanic joint tracking units

  • 4 × Wire feeding and reel holders (250 kg each) + additional rear reels 4 × 250 kg and 4 × 30 kg

  • 2 × Twin torch assemblies (2 × 2.4 mm)

  • Wire dimensions supported: Ø 2–4 mm; twin wire Ø 2–2.5 mm

  • PEMA pneumatic-assisted wire feeding system

• Manipulator and rail carriage

  • Two movable welding carriages with twin SAW heads

  • Rail carriage with guide roller-supported steel wheels

  • Rail width (inside-to-inside): 2350 mm

  • Traveling speed: 200–2500 mm/min

  • Side support rollers for precise movement

  • Cable management/chains for column, boom, and slide movement

• Column & boom

  • Total height from rail: approx. 6900 mm

  • Boom length: approx. 4.5 m

  • Vertical boom movement: floor up to 2000 mm

  • Motorized welding carriages with 1000 mm vertical slide

  • Horizontal movement with boom; linear guide bearings and gear-rack drives

  • Max load on slide: 120 kg

  • Power sources installed on rail carriage (fixed)

• Workpiece capacity/specification

  • Beam height: 200–2000 mm

  • Web thickness: 6–40 mm

  • Flange thickness: 6–40 mm

  • Flange width: 100–1000 mm

  • Beam length: 1.5–35 m

  • Fillet weld dimension: a = 3 mm (or per customer WPS)

• Material and joint requirements

  • Material: Carbon steel

  • Box beam: up to 1000 × 2000 mm, thickness 6–30 mm

  • T-profile: up to 800 × 1500 mm, thickness 6–40 mm

  • Fillet between web and flange for joint tracking: 10 mm

  • Beams tack welded prior to SAW

• Electrical and pneumatic requirements

  • Mains: 3 phase + (N) + PE, 400 VAC ±10%, 50 Hz ±1 Hz

  • Compressed air: 6–7 bar, DIN ISO 8573-1 class 2

  • SAW welding power supply: backup fuse 2 × 100 A; max power 2 × 55 kVA

  • PEMA semi-portal: backup fuse 1 × 35 A; max power 1 × 12.5 kVA; additional backup fuse 16 A

Additional equipment (not part of the base machine)

• PEMA BTS 5000 beam turning devices (2 pcs); electrical: backup fuse 2 × 32 A