Leussink Engineering is partnering with US company ALM Positioners to bring the benefits of accuracy and safety together with the Demmeler modular fixturing system and ALM’s positioners. The two systems combined allow users to hold and position multiple parts with one modular kit.
The Demmeler 3D workbench and welding table is a versatile jig and fixtures system for all types of welding and fabrication work. When paired with an ALM Positioner it can bring a whole new level of safety and accuracy to the workshop because the work can be held in place firmly and rotated. Positioners (which are also sometimes called manipulators) allow 360-degree rotation of parts to eliminate heavy lifting and allow for more comfortable welding.
Leussink’s Managing Director Jason Leussink explains how he went in search of a company that could supply precision positioners to his Australian-based clients.
“We’ve been working with Demmeler for nearly 30 years and have not found a local supplier who can provide the type of product our clients seek,” says Jason. “We were approached by a client who wanted to be able to hold work in place while welding. They fabricate large trailers in their workshop and by using a positioner and the Demmeler system they can achieve the ideal of down-hand welding with safety and accuracy.”
The use of a positioners such as those manufactured in the US by ALM optimises worker safety and ergonomics by letting motors and hydraulics do the heavy lifting. In many workshops, the lifting is performed using a combination of saw horses, a crane and brute force to manoeuvre a weldment into proper position. Positioners can also eliminate the need for welders or assemblers to use ladders, scaffolding or other equipment to climb on a part or lie under it.
“ALM positioners can lift parts weighing from 450kg to 56,700kg and rotate or tilt them to the desired position in seconds,” Jason adds. “Like much of our work, the pairing of Demmeler and ALM products is not an off-the-shelf product. We work with our clients to understand their requirements and develop a custom solution to fit their unique situation. We can also supply just the ALM Positioner product if that’s the best solution.”
The Demmeler system offers a high degree of precision. It allows the user to set up jigs, and clamp anywhere. This means that the same job can be repeated over and over and it comes out the same way every time.
The stoppers and clamps are set up at the start of the process, which holds the job in place for welding. Once the job is locked in, it just doesn’t move at all because it can’t. This significantly speeds up fabrication time and improves accuracy. When used in conjunction with the ALM Positioner, a job can be held firmly in place and rotated to wherever it is required.
Coupled with 3D CAD software, the Demmeler clamping system can be utilised to reproduce virtual jigs. Equipment such as 3D co-ordinate measuring machines, laser measuring systems, and optical test equipment are used for this purpose to ensure the high precision requirements of the products. This allows users to keep designs electronically and use templates over and over, meaning less storage of physical jigs that take up valuable shelf space. The use of 3D software ensures the same level of accuracy every time, which means an item can be reproduced faster and more efficiently.