Whether in mechanical processing, energy generation or mechanical engineering, heavy pipes have to be processed, lifted or moved from one place to another in almost every industry. The components are usually made of steel, iron, cement, ceramic or even aluminum and are often considered bulky due to their weight and geometry. Until now, cranes or industrial robots were the only options for moving such pipes.

However, as the crane ropes often swing out, making precise movements difficult, and robots sometimes work very quickly, making safety fences and constant monitoring necessary, Dalmec has now designed its own handling manipulator to move large metal pipes with a maximum weight of 1,000 kilograms. The Megapartner pneumatic handling manipulator can be used in almost all branches of industry. With little effort, large, long and heavy pipes can be moved in a targeted and, above all, safe manner.

This is made possible by the use of low pressures, which significantly minimizes the risk potential - compared to devices that are operated purely hydraulically - and does not pose an environmental or fire risk, even in the event of leaks. The Megapartner also has a purely pneumatic control system that allows extremely fine positioning. "The pneumatic gripper unit gives the operator the necessary safety to be able to lift and move the desired load weight. Due to the length of the pipes, a large working stroke is also required," explains Dieter Hager, Sales Manager at Dalmec.

"When designing the pick-up devices, the operating elements were designed to be double and also pneumatically telescopic - also for ergonomic reasons." The maximum working radius is 5,000 millimetres, with a vertical stroke of up to 3,050 millimetres. The Megapartner is supplied with dry, clean, oil- and dirt-free compressed air at a working pressure of 0.8-0.95 MPa.

Moving pipes safely and precisely
To move a pipe, the manipulator grips it by the outer diameter using the specially designed pneumatic pick-up device and lifts the pipe off the roller conveyor in a horizontal position. To deposit it in a transport container, the pipe must also be swiveled by 90 degrees so that it can be set down in a vertical position. In the past, this task was usually performed by a crane, to which the pipes were attached with a load loop or a mechanical clamping device and then placed in a vertical position.

In comparison, the Megapartner allows the operator to work in a more ergonomic way, which scores particularly well in terms of work safety: "On the one hand, the low noise level of less than 73 dB allows the operator to work comfortably. Secondly, the pneumatic gripper unit has been designed to guarantee the required holding forces when swiveling and thus prevent the pipe from swinging," explains Hager. A clamping cylinder integrated into the pneumatic gripper unit, in combination with the size of the correctly dimensioned gripper jaws, ensures safe load handling.