Grey support arms with rollers holding a long thin-walled steel shell on a PEMA station
Shell Assembly Station
PEMA Assembly and Welding Station
TW6000-100 + HD 6x4 and TW5000-25 + MD 4x4 for tubular and conical shells
The PEMA Assembly and Welding Station fits up and welds tubular and conical workpieces at one station. With a PEMA column and boom and PEMA controls, a single operator assembles and welds shells from 1500 to 6000 mm in diameter.
Manufactured byPemamek
1500–6000 mmWorkpiece diameter range
Up to 100 tComplete section weight
Up to 40 tSingle can weight
1 operatorAssembles and welds
SAWSingle or tandem twin welding head
Overview
Fit-up and welding of shells at one station
The PEMA Assembly and Welding Station is made for manufacturing tubular and conical workpieces. It integrates with a PEMA column and boom and PEMA control systems, so one operator can assemble and weld at the same station, and its fit-up technology keeps a consistent round shape even on thin-walled shells.
The PEMA TW6000-100 + HD 6x4 handles workpiece diameters of 2000 to 6000 mm, single cans of 1400 to 3000 mm length and up to 40 t, and complete sections up to 100 t. Its boom moves 6 m vertically and 4 m horizontally and carries a tandem twin SAW welding head with a camera system.
The PEMA TW5000-25 + MD 4x4 covers diameters of 1500 to 5000 mm, with support arms working at 2 to 5 m, single cans of 1200 to 3000 mm length and up to 12.5 t, and complete sections up to 25 t. It moves 4 m vertically and 4 m horizontally with a single SAW head and camera system. Both run on PEMA WeldControl 100.
Applications
Workpieces for the station
The station is built for round and conical shells that need accurate fit-up before welding.
PEMA column and boom welding a steel tank section held by support arms and blue rollers
Large steel shell held by support arms, with a welding boom reaching inside the cylinder
Submerged arc welding head with flux hoses welding a seam on top of a large steel shell
Thin-walled shells
Support arms keep a consistent circular shape during fit-up, even on thin walls.
Tanks and pressure vessels
Tank sections are assembled in a horizontal position while the station holds the cylinder shape.
Tubular sections
Cans are fitted up and joined into complete sections of up to 100 t.
Conical workpieces
Conical shells are assembled and welded on the same station as tubular parts.
Circumferential SAW seams
Single or tandem twin SAW heads on the column and boom weld the seams.
Features
Station features
- Fit-up technology for consistent roundness of shells
- Integration with PEMA column and boom and PEMA controls
- PEMA WeldControl 100 control system
- Tandem twin SAW head (TW6000-100) or single SAW head (TW5000-25)
- Camera system for weld monitoring
- Boom travel up to 6 m vertical and 4 m horizontal
Benefits
Compared with conventional assembly
One operator manages the whole assembly and welding process
Assembly and welding together for a fast production start-up
Consistent quality with no damage to the workpiece
Less dependence on cranes and extra accessories
Higher safety with less manual handling
Assembling and welding round shells?
Share your shell diameters, can lengths, weights and wall thicknesses, and our Machinery team will help you select the right PEMA assembly station.
Other Products in Robotic Welding Systems
Explore other products available within the same product category and open each page for complete technical details.
PEMA Skytrack Robot Welding Station
Compact robot welding station with a 2 t positioner, plug-and-weld setup and no special foundation.
PEMA Skyline Welding FMS
Automated flexible manufacturing system linking robot cells, manual stations and conveyors under one software.
PEMA Robotic Welding Systems
Robot welding systems from the compact Skytrack to multi-robot portals, all run on PEMA WeldControl.
PEMA VRWP Robotic Welding Portals for Shipbuilding
Vision robot welding portals for ship panels and blocks, from the compact VRWP-C to four-robot VRWP-X2.
DIG FSW Friction Stir Welding System
Static or moving gantry friction stir welding with 2, 3 or 5 axes for aluminum, copper and brass.
DIG Micropanel Welding System
Dual-robot gantry with 3D vision that welds ship micro-panels without manual programming.
DIG Block Panel Robot Welding Systems
Multi-robot gantry welding of ship blocks, micro panels, webs and bulkheads, programmed from 3D data.
DIG Narrow Gap SAW250 Welding System
Narrow gap submerged arc welding for grooves up to 250 mm deep on cylinders from Φ1200 mm.
DIG LAHW Laser-Arc Hybrid Welding System
Laser and MIG arc welding combined for deep penetration, high speed and low distortion.
DIG Column and Boom Elbow Welding System
Column and boom with a five-section articulated arm for internal welding of curved elbows.