Systematic Sewer Repair

Systematic Sewer Repair

Pioneer Achievement: Electric Drive IBAK Robotics cutters run on electricity. As a result, they are lightweight, low-noise and powerful. Unlike hydraulic or pneumatic systems, electrically driven robots do not require any noisy, heavy, energy-consuming compressors or generators. Low Operating Costs The energy balance of electric cutting and grinding robots is unique on the market: a vehicle with a cutting and grinding robot can be run for a whole day on a battery charge costing less than ten euros. The Company IBAK Robotics design and manufacture electric cutting, grinding and repair robots for sewer rehabilitation. As a pioneer of this innovative drive technology, the company has developed electric cutting and grinding systems for sewers into a marketable product. Originally, their experienced development engineers were looking for a drive technology that offers a high degree of efficiency. As a result, the cutting performance, the handling and the energy balance of IBAK Robotics cutting and grinding robots are unrivalled on the market. With their extensive range of mobile systems, vehicle outfitting and hire equipment for sewer repair, IBAK Robotics are committed to being reliable partners to their customers. A highly qualified team design, assemble and repair the systems at the Durmersheim factory and their solutions set future-oriented trends for the industry. At the same time, the company benefits from the know-how and the long years of experience of the Kiel-based parent company IBAK Helmut Hunger GmbH & Co. KG. To extend the production capacities, new premises have been built in Durmersheim. With 1200 square metres, there is ample space for the yrobotics products. In addition, the usual high quality service for all IBAK products is provided here. Thanks to the cooperation with IBAK, a competent sales and service network is available to customers all over the world. With this global network of expert contacts, the young company already lives up to its goal of customer orientation in terms of geography and professional competence. High Degree of Efficiency An outstanding feature of an electric motor is efficient conversion of energy and energy transmission. As compared to other types of drive, a considerably higher percentage of the power input is effectively used to drive the cutting tool. Low Noise Emissions After the installation of sewer pipe liners, laterals are usually reinstated during the evening or at night when traffic is low. Particularly in urban areas, inconvenience to residents due to noise pollution should be kept to a minimum. So the virtually noise-free operation of electric cutting and grinding robots not only benefits the operator but makes it easier to obtain permission for night work and increases its acceptability for example in residential areas. Good Environmental Compatibility An electric motor does not produce any harmful gases. Emissionfree operation means less strain on the environment and does not have any adverse health effects. Efficient use of resources and the low noise emissions of this drive technology also contribute to protecting the environment. 2 3

A System Solution with Modular Components The product portfolio comprises electric cutting and grinding robots for operation in mainline sewers, covering pipes with diameters of 175 to 800 mm and ovoids. The colour pan and rotate camera CutterCam was specially designed for operation with these robots and is used to supervise all rehabilitation and cutting operations. IBAK Robotics mainline sewer cutters are compatible with IBAK inspection systems and can be operated from the same control unit. The transportable Flexi- Gator system is available for cutting operations in laterals. This also runs exclusively on electricity. Thus, an AC power outlet is all that is required for cost-effective operation. The rehabilitation of connecting pipes by grouting is possible with the Reparo System which can be combined with the MultiGator basis robot for this purpose. In addition, specialist software tools geared to the requirements of the sewer industry are available. Robot Systems Cable Reel Camera Control Units Optional Accessories Portable Lateral Robot System MultiGator with Reparo-System KW 100 / KW 150 Pan and rotate colour camera CutterCam BP 3.5 + BS 7 / BS 3.5 KW 305 FlexiGator BK Winch AlliGator T 66 MiniGator ORION 2.9 Supply Unit FlexiGator IKAS evolution + IKAS Gator Software * The modular design of the IBAK system makes it possible for various IBAK inspection components (cable reels, camera tractors, cameras) to be installed as required. For further details, please refer to the leaflet on IBAK Sewer Inspection Systems. 4 5

Cutting and Grinding Robots for Mainline Sewers Precise Performance of Detailed Work The rotational speed of the tool is adjustable. In addition, the clamping cushion technology enables the robots to work without much vibration. Getting Your Bearings in the Pipe The position of the robot in the pipe is shown on a viewing direction indicator in the camera image. This is achieved by a gravitation sensor integrated in the camera. Travelling through Sections of up to 150m Clamping cushions press the wheels against the pipe wall with compressed air and ensure high traction strength of the robot so that long operating distances can be achieved. Cutter heads for all applications All materials found in sewers can be processed reliably. Cutter shaft extensions are available to access working areas that are further away and deeper down the lateral. Fast Navigation to the Working Area The robot has two axles at the top and two at the bottom of the housing. The axles can be driven separately. Adaptation to Misplaced Joints without Readjustment The centric clamping system ensures that the centre of rotation of the cutting tools is always in the middle of the pipe so that, when rotating, they follow e.g. the circumference line of the joint concerned. Pressure Monitoring to Prevent Damage to the Robot Cutting Complex Geometry in a Single Operation With the built-in rotation module, 700 rotations (left/right) are possible. The operator is given a visual warning message on the display and an alarm tone sounds to inform him if a leak is detected in the electronic installation areas. A Clear View at All Times A Sharp Focus Everywhere DN 200 to DN 800 & Ovoids For cleaning, water is supplied and the camera rotates in a matter of seconds over an integrated rubber lip and then returns automatically to its original position. (Photo on the left: before cleaning; photo on the right: after cleaning) The flexible focus not only ensures that the cutting area is in sharp focus but also provides a detailed image of e.g. the pipe wall, which is nearer to the camera. This means that rehabilitation results can be assessed and documented with convincing photo material. The robot can be optimally configured for various pipe conditions or pipe diameters with different attachments and wheel sets. 6 7

Holistic System Concept The basis of all development work is the company s desire to supply the industry with user-oriented, cost-effective solutions. To achieve this aim, a holistic approach is taken to looking at and working on the technological requirements. The compatibility and integration capacity of the system components thus achieved not only save valuable resources but also result in a system concept that covers both sectors, i.e. inspection and rehabilitation. So the customers benefit from the close cooperation between the company s divisions. Depending on the requirements, vehicles can be equipped simply with a cutting and grinding robot or a TV system or with a combined TV and cutting and grinding system. Ease of Use The robot is lowered into the manhole and retrieved again with an integrated lowering hook and a chain hoist. The robot does not have to be moved by physical strength. This not only makes the operator s work easier, but above all it is a safety aspect, as the operator does not have to go down the manhole. One Control Unit for the TV System and the Cutting Equipment The cutting and grinding robots and the camera systems are operated on a vehicle from the same control unit This makes work considerably easier for the operator because he can operate the robot, the tractor, the cable reel and the camera with the same joysticks and keyboards. Low Operating Costs A vehicle with a cutting and grinding robot can be run for a whole day on a battery charge costing less than ten euros. Combined Cutting and TV System: The TV systems can be integrated neatly into the existing architecture of the cutting and grinding vehicles. The fully automatic cable reel with integrated boom KW 305 is a useful add-on. It provides digital image transmission via fibre optic cable and holds up to 300 m of cable. This is paid off and wound on in synchronisation with the speed of the camera tractor. Space-Saving No heavy, bulky generators or compressors are necessary to produce the required energy. Power is supplied to the cutting equipment preferably by a lithium-ion battery integrated into the vehicle. It is charged either from an external power source or by the integrated 24 volt alternator when the vehicle engine is running. 8 9

AlliGator The AlliGator is the largest electric cutting and grinding robot from IBAK Robotics for mainline sewers and provides high-performance operation in pipes with diameters of up to 800 mm. Specifications AlliGator Operating range Mainline sewers Pipe diameters 230 to 600 mm (optionally 800 mm) Dimensions / Weight Length* 1160 mm Surrounding diameter ø 228 mm Weight 69 kg Operation BS 3.5, BS 7 Hybrid cable length 100 m or 150 m Tractor Motors 4 electric motors Power 300 Watts Max. speed 15 m/min Rotating module, rotating elbows 700 Height adjustment for lifting/lowering unit 195 mm Traction Clamping cushions with compressed air, 8 driven wheels Cutting Motor Type Brushless 3-phase electric drive, watercooled Voltage 48 V Power 2500 Watts Max. speed 10,000 rpm Comfort & Safety Centre of rotation of cutting tool Centered in the pipe Vent system Lowering hook with chain hoist Pressure monitoring of electronic installation areas Camera Camera type CutterCam Lighting LED Special features Cleaning function, position sensor, autofocus, automatic shutter Accessories Wheels and wheel attachments Various sizes (up to DN 800), spacers, ovoid pipe attachments Cutter head suspension (4th axle) IBAK software IKAS Gator *from the cutting motor to the folding joint 10 11

MiniGator The MiniGator is a cutting and grinding robot for mainline sewers with diameters of 175 to 350 mm. Operation in pipes with larger diameters of up to DN 600 is possible with an extension kit. Specifications MiniGator Operating range Mainline sewers Pipe diameters 175 to 350 mm (optionally 600 mm) Dimensions / Weight Length* 1000 mm Surrounding diameter ø 172 mm Weight 45 kg Operation BS 3.5, BS7 Hybrid cable length 100 m or 150 m Tractor Motors 4 electric motors Power 400 Watts Max. speed 15 m/min Rotating module, rotating elbows 700 Height adjustment for lifting/lowering unit 125 mm Traction Clamping cushions with compressed air, 8 driven wheels Cutting Motor Type Brushless 3-phase electric drive, water-cooled Voltage 48 V Power 2000 Watts Max. speed 10,000 rpm Comfort & Safety Centre of rotation of cutting tool Centered in the pipe Vent system Lowering hook with chain hoist Pressure monitoring of electronic installation areas Camera Camera type CutterCam Lighting LED Special features Cleaning function, position sensor, autofocus, automatic shutter Accessories Wheels and wheel attachments Various sizes (up to DN 600), spacers, ovoid pipe attachments Cutter head suspension (4th axle) IBAK software IKAS Gator *from the cutting motor to the folding joint 12 13

FlexiGator Specifications FlexiGator The FlexiGator system is of modular design and thus easily transportable. The bend-capable FlexiGator is used in DN 100 to DN 150 pipes (optionally DN 200) and is therefore particularly suitable for laterals. The FlexiGator system can be disassembled into its individual modules to facilitate easy transport. Operating range Laterals Pipe diameters 100 to 150 mm (optionally 200 mm) Dimensions / Weight Length* 1200 mm Surrounding diameter ø 80 mm Weight 7 kg Operation Control box Hybrid cable length 60 m System Components Control unit Splash-proof Cable reel With 60 metres of cable Supply unit With water supply, electronics, etc. Robot FlexiGator Mobility Propulsion function 50 mm Rotation function 540 Lowering/lifting angle 35 Cutting motor Type Brushless 3-phase electric drive, water-cooled Voltage 24 V Power 300 Watts Max. speed 13,500 rpm Camera Camera type Colour pan and rotate camera: view of cutting area Fixed colour camera: view straight ahead and view of cutting area Lighting LED Special features Both cameras with cleaning function 14 15

MultiGator Specifications MultiGator The MultiGator is a flexible, electric basis robot and rehabilitation components such as the Reparo System grouting unit for connecting pipes can be connected to it. Operating range Specifications FlexiGator Mainline sewers Pipe diameters 250 to 600 mm Dimensions / Weight Length* 1150 mm Surrounding diameter ø 228 mm Weight 62 kg Operation BS 3.5, BS7 Hybrid cable length 100 m or 150 m Tractor Motors 4 electric motors Power 300 Watts Max. speed 15 m/min Rotating module, rotating elbows 700 Traction Clamping cushions with compressed air, 8 driven wheels Comfort & Safety Vent system Lowering hook with chain hoist Pressure monitoring of electronic installation areas Articulated joint Camera Camera type CutterCam Lighting LED Special features Cleaning function, position sensor, autofocus, automatic shutter Accessories Wheels and wheel attachments Rehabilitation components IBAK software Various sizes for extension to DN 600, ovoid pipe attachments Reparo System IKAS Gator 16 17

The Reparo-System The Reparo System is designed for rehabilitation and bonding of laterals in DN 250 to DN 600 pipes in combination with the MultiGator basis robot. With the grouting system, holes can be filled with material. The robot can carry up to 3 litres of grouting resin in a cartridge. Operating Procedure The Reparo system is installed on the MultiGator and is positioned at the entrance of the lateral under camera observation. First the shield and then the silicon plug for the lateral pipe is pressed against the pipe wall with compressed air. The shield and plug pressures can be adjusted independently of each other and can be read out and controlled at any time via a digital pressure indicator. To fill the defect with material, resin is pressed out of the cartridge through the opening in the grouting shield into the intermediate cavities that are to be filled up. The injection pressure can also be adjusted individually. With the controlled application of warmth, the resin sets quickly and in the intended manner. Process Monitoring The entire positioning and grouting procedure can be observed with three cameras. Two of the video images can be transmitted simultaneously to the monitors. As a bus system is used, the operator continually receives feed-back from the sewer (e.g. about the temperature development), so that the rehabilitation process can be continually controlled and supervised. The articulated joints facilitate the introduction and handling of the system in the sewer. Due to its modular design, the combined Multigator-Reparo unit can be operated from the same system as IBAK Robotics cutting and grinding robots. The Advantages at a Glance: The bus system continually provides information on the progress of the grouting procedure (feed-back from the sewer). A relatively large amount of material can be transported by the system. The protection of all hoses and leads ensures high system reliability. High speed of operation through minimised immobilisation times (rapid curing and temperature control). Separate and therefore targeted air control directly on the unit. Best possible process control with optimum camera surveillance. Easy introduction into the sewer thanks to folding joints. Free choice of the resin to be used (with DIBt approval). Connection to existing cutting and grinding systems is possible. 18 19

CutterCam The development of IBAK Robotics products profits from the expertise in the field of camera technology that exists in Kiel. Know-how and stimuli from sewer camera inspection have a profitable effect on the rehabilitation division, so that the Mini-, Alli- and MultiGator cutting and grinding robots are all equipped with a camera in line with the latest IBAK standards. Sharp Focus Everywhere The CutterCam is equipped with a flexible focus so that areas at various distances can be brought into sharp focus as required. During the cutting process, the camera is focused on the cutting tool in the working area. However, for instance, the pipe wall, which is nearer to the camera, can also be shown in detail with the Cutter- Cam. This means that the repair results can be surveyed and professionally documented and the extent and quality of the performed rehabilitation work can be evidenced with convincing photo material. This valuable data can be supplemented with comments on the performed measures and stored systematically with the IBAK IKAS Gator software. Photo on the left: before cleaning Photo on the right: after cleaning Getting Your Bearings in the Pipe The position of the robot in the pipe is shown on a direction of view indicator in the camera image. This is achieved by a gravitation sensor integrated in the camera. In addition, the generous pan range and LED lighting provide a spacious view and illumination of the working area. A Clear View at All Times The camera lens and the LED lighting can be cleaned rapidly with water during operation in the pipe so that there is always a clear view in spite of the cutting dust produced. At the press of a button, the camera rotates in a matter of seconds over an integrated rubber lip and then returns automatically to its original position. Unlike vulnerable wipers installed in an exposed position, this mechanism is specially designed for operation in sewers. Specifications CutterCam Camera type* Cutter camera, two-wire Operating range* DN 200 upwards Dimensions/Weight* Ø 58 mm / length 100 mm / weight approx. 430 g Pushrod operation No Tractor operation Upright image No, but position sensor Correctly-oriented image No Zoom No F (aperture) 01:02.00 f (focal distance) (mm) 03.08.15 Lighting 4 white power LEDs Light sensitivity (lux) 0.025 lux (F 1.2, 1/50 s) Luminous flux (Lumen) 440 lm Protection class IP 68 to DIN 40050 Permissible ambient temperature Operation 0 C +40 C, storage -30 C +70 C Test pressure for leak test 1.0 bar Pressure monitoring Integrated pressure sensor 1) Diaphragm function Fixed shutter, automatic electronic shutter, remote-controlled Pan range +160 /-135 Cleaning function Automatic wipe function Angle of aperture 68 diagonal View field +105 /-160 Rotation angle No Focus function/ range Manual 1 cm, remote-controlled, autofocus Sensor (inches) 1/4 CMOS TV standard NTSC or PAL Horizontal resolution 420 lines PAL Integrated laser ** Explosion protection No Integrated detector transmitter No Combinable with IBAK Robotics MiniGator/ AlliGator/MultiGator IBAK Robotics FlexiGator No IBAK control units BS 3.5, BS 7 1) LCD indicator and alarm in the control unit * when mounted on robot ** under preparation 20 21

KW100 / KW150 BS 3.5 / BS 7 The KW 100 and the KW 150 are motor-driven cable reels and hold 100 or 150 metres of hybrid cable. Only a single cable is required to operate electric cutting robots. The cable has a diameter of 28 mm and is guided by a trapezoidal threaded spindle. It contains the electric conductors and the air and water lines to ensure optimum supply to the AlliGator, MiniGator and MultiGator. The cable reel can be operated optionally from the operator s section in the vehicle or with a remote control unit. The cable winch module is powered via an electric drive unit equipped with a metre counter, speed control and an electric switchbox. Two integrated water pumps and water tanks supply water to the cutting motor cooling system and the camera cleaning device. Specifications KW 100 / KW 150 Product classification Max. cable length KW150: 150 m Width x height x depth (mm) KW150: 600x1025x1500 Weight KW150: 290 kg (incl. cable) Length measurement Motor-driven Cable level wind function Remote control Emergency stop Cable reel KW100: 100 m KW100: 600x830x1100 KW150: 600x1025x1500 KW100: 600x830x1100 ja KW100: 240 kg (incl. cable) The IBAK BS 3.5 and the BS 7 are control units for IBAK Robotics cutting and grinding systems and IBAK inspection systems for fixed installation in a vehicle. These central control and operating units consist of an ergonomically designed control console, a 19 rack and a keyboard. All current IBAK Robotics cutting and grinding robots and IBAK camera tractors, cable reels and cameras can be operated from them and all connected components are automatically identified by the system. The robot, the camera tractor and the camera are operated in a userfriendly manner with the two joysticks. The touchscreen integrated into the control console also offers the user numerous settings and operating possibilities such as an information menu where all assembled components that have been identified by the system are displayed on a colour display. In addition, various features such as the brightness of the lighting, various functions of the robot, the camera and the camera tractor and other system-relevant options can be controlled. Damage descriptions, descriptions of rehabilitation measures, symbols and comments entered via the keyboard can be overlaid in the video image with the integrated data display generator. It is also possible to connect video recording devices. Spoken comments can be entered by means of the microphone integrated into the control console. The audio output saves these voice memos in synchronisation to the video. With these control systems plus the PC, the rehabilitation process can be professionally planned and documented via the IBAK software. All cutting operations can be assigned systematically to the appropriate sewer sections and can be backed up with video and photo material with the IBAK-designed software tools IKAS Evolution and IKAS Gator. Combinable with IBAK Robotics robots MiniGator, AlliGator, MultiGator IBAK control systems BS 3.5, BS 7 22 23

IBAK Robotics GmbH Schlosserstr. 22 76448 Durmersheim Germany Tel +49 (0) 7245 91670-0 Fax +49 (0) 7245 91670-29 Web www.ibak-robotics.de Mail info@ibak-robotics.de AlliGator, MultiGator, MiniGator und FlexiGator are registered trademarks of IBAK Robotics GmbH. This document may contain errors and is subject to changes 150126_Robotics_Produkte_21x21_EN