Zeman Steel Beam Assembler
Frequently Asked Questions
How long does the data import take (from a 3D programme, for example, Tekla), and the production planning for a component with an average of 10 attachment parts?
Approx. 5 minutes per component, special elements a little longer. Semi‐automated suggestions.
How does a data import from 2D programmes (for example, AutoCAD) work?
Only the blanks (sheet metal geometries) can be imported. The position and thickness of the parts andthe definition of the mainelement (beam) must be entered again and / or newly drawn. A Suitable programme is Tekla.
What welding times and weld seam sizes does the sample beam in the machine have?
In total for 21m of weld seams a=5. Total welding time with manipulation (turning) approx. 40 min.
Can other profiles such as European (HEA, HEB) be imported and processed, for example, Russian or American Dimensions?
The rolled section profile in Iform is irrelevant. The profile data is always taken from the XML interface.
Thereby it is also possible to process sheet steel beams, corrugated web beams or also tapered beams. U‐profiles and shaped tubes with the appropriate stiffness are also possible without problems.
What accuracy can be achieved with this plant?
What about the rolling tolerances of the beam profile?
As a rule, bent or deformed beams are measured on assembly of the respective attachment components at the respective position in order to compensate for such tolerances.
We can compensate for these tolerances. In doing so, the precondition is that the tolerances do not exceed the general component tolerances of the welded elements.
In addition, it is recommended to manufacture the attacment parts which are fitted to a beam with negative tolerances. The beam itself should also be cut undersize in its length.
Is there a tool in Pro‐FIT for job distribution between master and slave robots?
The front and rear parts of the beam component are automatically divided between the master and slave (in the centre of the beam). If for production-related reasons an off setting of this division is required then it is possible manually with a simple movement of the mouse.
What welding processes do you use and is it possible to change these on the plant?
We currently use MAG 135 with solid wire 1.2mm.
Naturally, for other applications it is possible to change the size of the wire and also the wire type (for example, fluxcored wire) without a great deal of effort.
Can other attachment parts such as sheet steel be processed in the plant?
There is the possibility to fit angles with certain limit values and also cleats (small I‐profiles) as attachment parts. In addition, there is a fixture available at the beam end for special sheet metal constructions (frame corners). There is also the possibility of shaped tubes, U‐profiles and T‐pieces as attachment elements.
Can rusty materials be processed in the plant?
As a rule, yes, so long as it is welding‐related acceptable. In this case, however, a flux-cored wire welding process should always be used.
What is the maximum gap dimension between the beam and sheet metal parts?
It is possible to tack gaps up to 4mm. When welding, however, faults can occur. Such positions must be checked and possibly be re‐worked (visual weld inspection after leaving the component). The plant is equipped with a "gap detection" function and recognizes air gaps, the welding parameters are automatically correspondingly adjusted, too.
Are there service stations or similar in the plant?
For each welding robot there is a fully automatic burner cleaning station and a measurement station forcomparison with the theoretical robot tips.
In addition calibration is possible for the adjustment of the handling robot. Naturally the mechanical system is equipped with reference switches and absolute encoders in all axes. All media (such as welding wire, gas etc.) are monitored bysensors.
For a better overview during production, accompanying camera systems are installed (option).