In 2022, the Italian heavy element manufacturer Cimolai made a strategic investment in a PEMA robotic welding station, marking a significant step towards enhancing efficiency and repeatability in bridge and beam manufacturing.
“We work with very large elements, with lengths ranging from 12 to 15 meters, heights from 2 to 3 meters, and weights up to 40 tons,” explains Daniele Ottorogo, responsible for robotics systems at Cimolai Group’s Polcenigo production site in Italy.
Known for its expertise in heavy steel elements for varied industries, such as industrial and civil construction, Cimolai recognized the need to streamline its manufacturing processes to ensure better efficiency and welding quality. Thus, in 2022, the PEMA robotic welding station was installed at the Polcenigo factory.
At the Polcenigo site, Cimolai manufactures its largest structures: bridges and beams.
“The robotic welding station does not take breaks and enables us to schedule unmanned shifts or breaks, while the machine handles the job. We can now confidently say that 99 out of 100 welds are consistently perfect,” Ottorogo emphasizes.
The significance of offline programming
For every manufacturer, gaining a competitive edge requires optimizing cycle times. Especially with heavy workpieces, cycle times can extend to several hours due to multiple passes, handling, and turning in between.
To optimize cycle times, especially with heavy workpieces, Ottorogo highlights the significance of offline programming. PEMA WeldContol allows for the creation and simulation of welding paths and sequences, enabling precise results without the need for the actual robot or workpiece to be present.
“The ease of offline programming enables us to create very long welds, up to 13 meters continuously, as well as large welds requiring multi-pass welding. We are now confident to say that 99 out of 100 welds are perfect and equal with each other,” Ottorogo adds.
PEMA WeldContol offline programming allows the creation and simulation of welding paths and sequences without the need for the actual robot or workpiece to be present. By digitally modeling the robotic welding environment, including fixtures and workpieces, the operator can fine-tune parameters such as speed, torch angle, and weld path to achieve precise results. Furthermore, the program creates a simulation to avoid any collisions.
“Once the correct welding parameters for a joint are set, I can make for example 10 welds, and they all are perfectly equal.” Ottorogo continues, “We have now the advantage of minimizing defects caused by human error. The robot always operates the same way.”
We work with very large elements, with lengths ranging from 12 to 15 meters, heights from 2 to 3 meters, and weights up to 40 t.
DANIELE OTTOROGO Responsible for robotics systems at Cimolai Group’s Polcenigo production site in Italy.
Rapid implementation of the robot welding station
To ensure a seamless experience in acquiring a robot welding station, Pemamek offers an extensive service model that spans from initial design to factory tests, installation, training, and support. Ottorogo sees the biggest value of collaboration in the extensive services as a part of delivery.
“We greatly appreciate the fact that we had the factory acceptance test at Pemamek’s site before receiving the machine here in Polcenigo. After the installation phase and final acceptance test, we received the operator and offline programming training. These have allowed us to work independently right from the start”, Ottorogo adds.
Robotic welding brings several advantages to heavy manufacturing, including increased safety and cost efficiency. According to Ottorogo, repeatability and consistent quality have been some of the most important benefits for Cimolai by far.
“I can say that there is complete satisfaction with choosing Pemamek as a supplier. We are pleased, and I’m sure we continue to work in the future”, summarizes Ottorogo.
