SBA Technology by ZEMAN

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2 THE FUTURE IS NOW 2

3 Revolution in steel-beam fabrication ZEMAN has developed a fully automated production line for practically any type of steel beam that includes add-on parts. Possible combinations of add parts and beams SBA - The True GAME CHANGER The only way fabricators were able to assemble steel beams, anywhere in the world, was by hand. Welding of the head-plates, base-plates, connection plates and stiffeners or whatever is necessary to meet structural-design requirements are being automatically fitted and welded by SBA - a ground-breaking step for the future of steel fabrication. Old fashioned beam assembly Future of beam assembly 3

4 Working principle of SBA CAD Drawings of projects are being imported into ZEMAN s SBA software and sent to the machine. After all add-parts have been placed on the scanning table, the individual components are being automatically scanned by a 3D laser/camera system, which simultaneously compares the gathered data with the CAD drawings. Any deviation from allowed tolerances of the scanned parts will be immediately reported to the operator, who can decide, whether to proceed with the fabrication of the beam, or to replace or rework the concerned parts. This method helps to guarantee an error free assembly of each steel beam and ensures the quality control from the beginning till the end of the fabrication process. With the help of a handling robot and a welding robot, add parts are being placed at the exact position of the beam (according to CAD drawing) and mounted within a brief span of time (approx. 1 min/piece). Handling & Welding Robots in Action 4

5 Experience the Advantages of SBA System: Omit manual measuring and line marking (scribing) of welding location Automatic recognition of welding location No standstill time of robots through simultaneous work Automatic in- and outfeed of beams Minimization of labour force and labour costs Possible lack of skilled labour can be easily overcome Project-related information will be saved by the software and used for future tasks Shorter fabrication times facilitate increase in capacity at same expenditure and area Delivery of perfectly assembled beams to construction site. Shorter time to market Reliable and guaranteed quality at highest standards for all fabricated beams Easy assembly of complete construction due to high precision of fabricated beams Environmental friendly by saving energy with perfectly tuned software 5

6 SBA Production Steps: 1. Implementing CAD Drawings into ZEMAN s Pro-FIT software ZEMAN s user-friendly Pro-fit Software 2. Placing add parts on the scanning table Scanning table for add parts 6

7 SBA Production Steps: 3. Automatic feed-in of beams with the help of cross and length conveyors Auto feed-in 4. Automatic feed in and 3D scan of add parts with a laser and camera system Auto 3D scanner 7

8 SBA Production Steps: 5. Assembly starts by tack welding add parts to the beam Assembly process 6. Full welding process starts (multi pass welding possible) Two welding robots in Action 8

9 SBA Production Steps: 7. Automatic feed-out of beams with the help of conveyors and a lifting system The beam has been completely assembled and is ready for painting! SINGLE PASS / MULTI PASS WELDING IN PERFECT QUALITY 9

10 SBA Compact The SBA Compact model has been designed to increase beam assembly and welding capacity by using a minimum of space. SBA Compact is the first choice of fabricators to enter the world of automated steel beam assembly. 10

11 SBA Conti SBA Conti offers the full package of automation: Automatic In- & Outfeed of beams and add parts, for reduced handling time and quickest possible beam processing! SBA concepts highlighted by colours: 11

12 SBA Eco SBA Eco boosts fabricator s capacity output, by fully automatic welding according to CAD drawings. 12

13 Pro-FIT Software Pro-fit is an easy to use software for processing of CAD drawings with SBA: - User friendly - Only 5min work preparation - Compatible with all CAD-Programs 13

14 Functions/Options/Possibilities 3D Scanning Heavy Beam Rotators Swift Assembly Heavy Duty Handling Robot Auto Turning Station Self-Calibration & Cleaning Multilayer Welding Preheating & Plasma Cutting 14

15 FUNCTIONS/CAPABILITIES AND LIMITS OF SBA Beam sizes Height of beam 150 (200) 1100 (1500) Width of beam 80 (100) 500 Length of beam (16000/18000) min. max. Beam types H -beams 150 (200) 1100 (1500) Welded H - beams Corrugated SIN beams Rectangular /square tubes 80x80 500x500 U - profiles Others no Weight limits in kg ADD parts max. beam weight Dimensions of ADD parts Other available ADD parts (in mm) Plates 50x100x5 800 x 1400 (1800) x 60 Corner frame application Angle beams (L - profiles) 60x60x60 180x180x1400 Rectangular/square tubes 80x80x60 200x200x1400 U - profile Cleats (H - beam) Timbering style structure not available at the moment T - parts (pre-welded parts) Welding seams Automatic tack weld generating (programming) automatic set by profit but changeable by operator Close-up welds (spot welds) Curved welding (radi) Automatic re-orientation of the weld gun Fillet welds single layer a3 a6 Fillet welds multi layer a8 a15 V - welds single layer a4 a6 V - welds multi layer a8 a10 Full penetration welds no Gap detection/- compensation Automatic seam tracking system (AWC) Part2Part welding Vertical welds (up - welding) only tackwelding Plasma cuts Copying Beam holes not available at the moment Bevel cut at the rear side of beam Chamfer located cross in the beam no Pre-heating Head-/footplate Other accessories (assembly parts) no heat against bending of accessories partially heat against bending of beam no Auto measurements and tolerance compensation Others Auto centring/averaging Auto fillet detecting (fillet welds) Auto groove dedecting V - type welds Holes at accessories as reference for assembly Auto pushing method in different directions during Assembly-/ assembly production (managed tolerances by the handling robot) Beam always measured at assembly pos +/- 1mm Zero-point offset of main beam (changeable by operator if needed) Master/Slave job splitter (in case of 2 Robot version) Free definition of gripper tool positions on accessories (if needed) automatic and flexible Turning devices open-top (free of barriers) Clamping beam clamped in all directions Number of different sizes of gripper tools 3 Work preparation software (programming of production) all necessary parameters and options; change- and programmable 15

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