ProNews1_05_EN.pdf - Kemppi

1/2005 EN

Kempact MIG– an outstanding compactwelding machine2005 ESSENSchweissen &Schneiden– Welding Worldprepares tomeeteWarranty – Kemppi’s newelectronic warranty system82529ContentsEditorial.......................................................................... 3Jouko Kemppi elected president of the BiathlonAssociation of Finland“We’ll produce new winners.......................................... 4Static electricity – a threat ignored ................................ 6Russia – land of opportunity........................................ 10Faces at Kemppi:Leena Tuomaala and Klaus-Dieter Hohmeier.............. 12Kempact Pulse 3000– a new category of compact pulse MIG ..................... 15Readymade package for advanced robotic welding..... 16Beyond the call of duty in Lapland.............................. 17Three way co-operation in shipyardleads to successful welds ............................................. 21Maidment Tankers – built to last.................................. 26ABB’s experience of working with Kemppi................ 28Buses manufactured in Norway are weldedusing Kemppi equipment ............................................. 31WorldSkills 2005 Helsinki a chance to displayprofessional expertise................................................... 32Mika Leirilaaksogets a feel for Formula racing.................... 35Petri Kymäläinen,welding rally driving talent ........................ 36Toni R. Ruokonen has had a goodseason on the European circuits................ 40Welding equipment alternativesfor robotic welding....................................................... 34Kemppi Oy Subsidiaries .............................................. 43Kemppi Oy Sales Offices............................................. 43Kemppi Oy customer magazine 1/2005Publisher: Kemppi Oy, P.O. Box 13, 15801 Lahti, Finland.Internet: www.kemppi.com. Telephone: +358 3 89911.Editor-in-chief: Hannu Jokela. Sub-editor: Elina Suomalainen.Photographs: Matti Viljanen and Risto Kallio.Lay-out: Tekijätiimi Oy. Subscriptions and changes of address:Kemppi Oy. Telefax: +358 3 899 428. Printed by: N-Paino, Lahti,Finland, 2005. Issued 3 times a year. ISSN 0784-2708.2

Time flies – it’s anotherEssen-year againYear 2004 was a very successful year for Kemppi. Ourbusiness was growing faster than the market, and I wouldlike to take this opportunity to thank all our customers,business partners and the Kemppi-staff for a verygood co-operation. We managed to surprise the weldingmarket again by introducing significant new productand technology developments one year before the EssenFair at the EuroBLECH Exhibition in Hannover. Thenew Kempact product family has enjoyed great sales successsince the exhibition, and there is more to come thisyear…The future looks bright, and wehave set our targets and plans until2008. As a trend setter Kemppihas often shown the directionfor the future development of welding equipment technology,and we’ll continue to do so. We have renewedour research and development activities by creating atechnology function with the responsibility of developingthe needed technology platforms and concepts for thefuture generations of Kemppi welding equipment. Theactual product development projects are from now on runin the marketing function. By doing this we can makesure that the information flow from the market to ourdevelopment process (customer feedback) andback to the market (launching of new products)is as smooth as possible.As far as our customer service is concerned,we are about to start implementinga new web-technologybased ERP-system that will facilitatea whole new range of servicesto our dealers, distributors andend-customers. All of our activitieswill follow our vision:“We want to be the preferredchoice of customers– we focus on technologyleadership, flexibility and fastreaction speed.”In September in Essen it will bepossible to experience the traditionalKemppi-way of welcoming our visitorsin the true spirit of „The Joy of Welding“.Our new products and product conceptswill demonstrate what Kemppi’s new productpromise: „100% Kemppi-Product – the Arc NeverLies“ really stands for.Looking forward to meeting you in Essen – and in themeantime please enjoy reading of the latest edition ofKemppi ProNews.Anssi RantasaloManaging DirectorKemppi Oy3

Jouko Kemppi elected president of the Biathlon Association of Finland“We’ll produce new winners”“Our target is to add the number of ourOlympic and World Championship medals.The Torino 2006 Project aimed at theTurin Olympics is well underway and thegoal is clear: get the men’s and women’srelay teams to compete at the Games.”“We must develop as a team and in thefield – that’s where the event’s power is,”says Jouko Kemppi, listing his goals.Kemppi was elected president of theFinnish Biathlon Association in late November.Kemppi Board Chairman Jouko Kemppi has been partof Biathlon Association activities for over six years. Dueto crushing debts, the Association’s finances were in badshape at the end of the 1990s. Curative measures weretaken and Finnish Minister Ilkka Suominen was chosento take the helm. Jouko Kemppi was enlisted to help developthe Association.Jouko KemppiBorn: 1946Home city: LahtiOccupation: Chairman of theBoard, Kemppi OyPersonal sports career:Finnish Business Golfchampion 1989 and 1990,runner-up 1988; NordicBusiness Golf champion1988; Finnish BiathlonChampionships +55 Series,18 th place 2003; FinnishDefence Forces 400mFreestyle Swimming, 6 th place1965.“We’ve reached our goal – the Association is debt-freefor the first time in six years,” says Kemppi happily. Hespent five years as Vice President and one year as Presidentwhen Chairman Ilkka Suominen left before his termended.Event’s strength is in the fieldFinland has a long biathlon tradition. The InternationalBiathlon Association has more than 60 member nations.Finland is among the most successful and ranks in thetop ten. So far, Finland has won 6 Olympic and 11 WorldChampionship medals. The main goal of the national associationis to increase that number.“I think our aims should be public knowledge. Medalsare a measure of success. The end of the current seasonwill show who will represent Finland at the 2006 Olympicsin Turin. The main aim is to have both the men’s andwomen’s relay teams compete at the Games.”Jouko Kemppi stresses that although the Olympic teamhas a prominent role, it’s only one part of Finland’s biathlonactivities.“We are living through a turning point because there arenot many top achievers in the biathlon. You can’t get tothe top in a year or two; succeeding in this event takespersistent effort, counted in years.”“The event’s power is in the field and cohesiveness as ateam. It starts with parents who support children’s pursuitsand sports clubs”. Jouko Kemppi says the effortmust be developed and improved, mentioning professionalevent trainers as an example.”Fourteen biathlon youths are practising flat out for theKontiolahti World Championships to be held in March2005. Their goal is to win three medals. One of the goalsalready set is to achieve success at the Vancouver Olympicsin 2010.4

Jouko Kemppi, Chairman of the Board of KemppiOy and president of the Finnish Biathlon Association, keepsfit by Nordic Walking, jogging and cross-country skiing.Tension remains from start tofinishAthletic success demands financial resources, too. Ittook six years to get the finances of the Association intoshape. New, committed sponsors have been recruited andthe event’s publicity value has been recognised.“The biathlon is an interesting event to watch. Tensionremains until the last shot is fired. In Europe, it’s amongthe most popular events in television,” Jouko Kemppistates.The company Kemppi Oy invests in co-operation withracing drivers. The link is obvious, as welding equipmentis indispensable for racing events. Co-operation with theBiathlon Association also enhances the company’s image.Especially in Central Europe, many welding professionalsfollow the biathlon, and Kemppi’s attendance atthese events has been noted.Life enriched by desire andability to help othersJouko Kemppi has made huge efforts in many sectors inpositions of trust. “It’s a natural thing for business executivesto shoulder social obligations”, he remarks, andadds “The desire and ability to help others has also enrichedmy own life.”“In the biathlon, you come up against an entirely differentworld and interesting people. I value the fact thatI can help athletes attain their goals. I’m a link in thechain, a link that mustn’t fail,” Jouko Kemppi reflects.“Working on this event also offers me an opportunity tokeep fit”, he adds with a smile.Jouko Kemppi skis and trains with the athletes. He hasalso tested his condition by competing in the Finnish BiathlonChampionship over 55 Series.“The 55+ and 65+ Series are very demanding becausethe participants are former biathlon champions. No onewho hasn’t taken part can imagine how tough the terrainis for the general series. You ski with the taste of bloodin your mouth.”“Against that, it’s really something to get to the firingrange and try to shoot as your pulse is throbbing. Afterwards,you see the athletes’ performances in an entirelynew way.”Pirjo Pöllänen5

Static electricity– a threat ignoredElectrostatic Discharge (ESD) is a phenomenon thatoccurs almost everywhere and often. At its mostpowerful, it is known as thunder – electrical chargesas high as one billion volts can be discharged betweenclouds or between clouds and the ground below aslightning or thunder. This type of electrical dischargecannot occur at normal ground-level, of course.Movement and friction generatestatic discharges of a few thousandvolts in certain conditions. For example,stroking a cat can generatethousands of volts!Electrostatic discharges are veryslowly released through insulatingmaterials and pose a serious challengeto present-day electronics.When an electronic circuit’s internalwiring measures a fraction of a micrometeracross and is only as thickas a few molecules, even imperceptiblylow electrical impulses cancause wire to burn up and damage ordestroy a circuit.Electronic appliances – welding machinesincluded – are now designedand manufactured in ways that takeinto account the ESD problem. It isonly apparent when an applianceis taken apart for servicing. At thatpoint the ground terminal is oftendisconnected and sensitive electroniccomponents can be prone to electrostaticdischarges. The best way toprotect against ESD when handlingelectronic cards or microchips is anearth connection. Materials shouldalso not build up electrostatic charge– something which is easy to prevent,but often ignored. You frequentlyhear of people who wonderwhy a new, unused electronic cardworks at first and then stops workingafterwards. The reason may well bethat some of its printed circuits weredamaged by ESD. Memory circuitsare especially sensitive. It may bethat a memory circuit damaged byESD breaks down only weeks later.It looks like a software problem butin fact it is a tiny defect in the memorycircuit itself.Protecting against ESDis simpleA simple, effective enough way toprotect against ESD is to wear anearth bracelet when handling electroniccircuits or cards. The braceletis earthed to the frame of the appliancebeing serviced. It enables staticelectricity building up in the user tobe discharged into the frame, so thatthe likelihood of a discharge damagingthe circuit is reduced. An equallyimportant shielding device is anearth pad on the workbench. Staticelectricity is discharged harmlesslyinto the pad without harming the microcircuit.As mentioned above, electrical dischargesdue to friction can run to6

thousands of volts. Today’s mostsensitive microchips and semiconductorscan be damaged by a dischargeas low as 50 volts. The trendis towards ever more sensitive technologyso protection against ESDis becoming more and more important.Many advantages can be gained byobserving a few basic procedures.For example, when handling partssusceptible to ESD you should notwear clothing manufactured with artificialfibre (nylon, for example).Artificial fibre always builds up anelectrical charge. Natural fibres aremuch safer.All Kemppi factory parts susceptibleto ESD (control cards and semiconductorsamong others) are deliveredin packaging or pouches that protectand earth the components. Packetsand pouches carry yellow ESD labels.Parts susceptible to ESD mustbe kept in their original packagingand only removed prior to installation,when the fitter has first put on abracelet designed for earth static.So take care when handling newcircuit cards and prevent potentialESD damage. Control cards can bedamaged in handling and fitting becauseof faulty ESD protection. Alwayskeep ESD in mind when servicingsusceptible parts, such as controlcards, memory circuits and semiconductors.Pekka AnttilaAfter Sales Service ManagerWear an earth bracelet when handlingelectronic cards, as does Kemppiemployee Marika Lindqvist.Parts subject to ESD are labelled assuch.7

Kempact MIG– an outstandingcompact weldingmachineThe Kempact MIG machine modelsdisplayed at the October EuroblechFair in Hannover delighted customers.Kemppi again showed that it belongsto the elite of welding machinemanufacturers worldwide, in meetingcustomer needs. The machines nowon the market are equipped with true,intelligent power source technology,user-friendly construction, and excellentwelding features using a variety offiller materials, wire diameters, and gasmixtures. Characteristics that are valuedby customers worldwide are combined asneeded in Kempact MIGs.The Arc Never LiesGood looks alone will not ensure success in the weldingmarket – welding characteristics, too, must rise tothe challenge. Kemppi has managed to develop KempactMIG machines with excellent welding features.The starting point for product development was the needfor welding to succeed whatever the materials. In general,it can be said that the Kempact MIG 2520 and2530 units were designed for unalloyed steel, with a 0.8mm wire, where they perform best. Based on user comments,these units are an unqualified success. The wireworks well for all Ar/CO 2gas mixtures as well as pureCO 2. Photo 1 shows two 0.5 mm thick Fe sheets buttjoinedwith a 0.8 mm SG3 wire and CO 2gas. CO 2exhibitsexceptionally good properties at low values becausesoft welds also work where maximum roughness is necessary.Details of welding parameters in Figure 1: wirefeed length 1.3 m/min, welding current 25 A and power14.0 V. Both 0.6 mm and 1.0 mm SG3 wires are also suitablefor welding with a range of gas options. When theratio of CO 2gas mixture is 20-25%, true spray arc weldingis not feasible with SG3 wires. This is not a problembecause Ar + 18% CO 2gas is commonly used, making aspray arc possible.8

Photo 1: Sample weldThe polarity of the welding gun can be switched to a minusvalue (DC+ –› DC-).Recommended electrode – inertgas combinations(Factory recommendation with larger fonts)Material Wire diameter Inert gasFe 0,6… 0,8…1,0 mm Ar + 8…25% CO 2and CO 2SS 0,8 … 1,0 mm Ar + 2% CO 2CuSi 3 0,8 … 1,0 mm ArCuAl 8 0,8 … 1,0 mm ArAlMg 5 1,0 … 1,2 mm ArAlSi 5 1,0 … 1,2 mm ArFe 0,8 … 0,9 mm InnershieldFe MC 0,9 … 1,0… 1,2 mm Ar + 18…25% CO 2Fe FC 0,9 … 1,0… 1,2 mm Ar + 18…25% CO 2The maximum welding current with Kempact MIGmachines is 30 V. Thus, the units enable flux-cored arcwelding with 1.2 mm wires. Sealing runs go smoothlyusing either SG3 or metal-cored wires. The weldingarc burns on CuSi 3 and CuAl 8 wires, well-known formig brazing applications, especially at low values. Thesewires are used to solder galvanised sheet metal, amongother applications.The welding properties for other materials such as aluminiumalloys and stainless steels are better than withtraditional machines. Kempact MIG machines allowthe welding of gas-less inner shield wires.Especially good for sheet metal,but also good for steel structuresKempact MIG machines are the most versatile in theirclass. The loading value of 40% ED 250 A/26.5 V is highenough to prevent thermal tripping occuring in many applications,if at all, perhaps using only the heaviest electrodes.One user described the innovations well: “Themachine is light in weight but it’s a heavy hitter.” Due tomobility and ergonomic MMT gun designs, KempactMIG machines are an excellent choice for repairing, installingand fitting out work.Pasi RaekorpiWelding Engineer9

An enterprise in Volgodonsk has weldeddomes in over 400 churches using Minarcunits.Russia – land of opportunityCustomer relationships play a key roleThe Kemppi welding machine victory parade began inRussia 27 years ago at a time when it was still the USSR.The first contract, signed in 1977, was with Avtopromimport,the foreign trade syndicate. The few thousand weldingmachines comprising the first deal were delivered tovarious Lada car service and repair shops around the SovietUnion.A cooperation agreement was signed the following yearwith Energomashexport, also a foreign trade syndicate.Former purchasing agent Sergei Vasilyev is now a distributorfor Kemppi in the Moscow area. He establishedhis import business there in 1991. Many of the ties hecreated with customers have lasted.When Russia was known as the USSR, trading was quitedifferent from the Russia of today. Deliveries were basedon bilateral trade agreements. Personal relations withcustomers were the key to trade.At that time, Kemppi was already a pioneer in tradingwith the East. In 1984, together with its Soviet counterpart,Kemppi opened a joint welding machine serviceand repair shop in Vyborg to service and repair its customers´machines. Shop manager Alexandr Ardnashnikovset up his own business in 1988. He continues to sellwelding machines as a Kemppi distributor in Russia.In the 1980s, Kemppi was the biggest foreign supplier ofwelding machines in the area of the former USSR.New trade winds blowing inRussiaToday, Russian trade is based on the same Western principlesas elsewhere in the world. The new Russia has ledto the rise of an entirely new trading generation, one thatquickly learned to use Western trading customs. Finnishenterprises no longer enjoy the benefits of bilateral tradeagreements and have not done so for a long time.The number of Kemppi distributors in Russia has grownsteadily. New ones will soon be added in Vladivostok,Rostov-on-Don, and Krasnoyarsk. As the distributor net-10

Russia’s biggest new oil field is in Nahodka in the Far East,where underwater bases for two drilling rigs in the oceanoff Sakhalin Island are being built. The welding machineson site are mainly Kemppi’s Kempomig, Minarc and Masterunits.work spreads, the availability of Kemppi products andservices improves and customers get quicker service.The increase in Kemppi’ sales and customers means thatthe presence of Kemppi’s own staff in Russia will spread.Russian customers are the most demanding in the worldtoday, and the services provided must be of top quality.The fact that law offices are open around the clock sevendays a week is very indicative. Enterprises which knowhow to adapt to the needs of customers will succeed inRussia.11

Faces at KemppiLeena Tuomaalaand Klaus-DieterHohmeier‘Our main goal is reliable delivery’, say’sLeena Tuomaala, Logistics Manager atKemppi.These goals have been met, with the deliveryreliability of welding machinesachieving 99% and sometimes even 100per cent.‘Now our greatest challenge is the implementationof a new ERP system’, saysTuomaala.Kemppi has two large logistics centres, one in Finlandand the other in Germany. Kemppi began gradually reducingstock at warehouses owned by its subsidiariesin the mid-1990s, with the current transparent systemreaching completion in 1997.‘Welding machines normally comprise several components.Previously we had to send components from onesubsidiary to another in order to meet orders, this problemhas now been solved through centralised warehousing’,describes Tuomaala.‘On average, we handle 380 dispatches per week fromboth logistics centres. These include small deliveries andcontainer shipments, and everything in between. The vastmajority of products can be forwarded on the same datethe order was received.’”Delivery reliability is a measure of logistics functionality.At Kemppi, this achieves a level of 99 or even 100per cent and has never fallen below 97 per cent’, confirmsTuomaala.Order picking lists are printed out hourly. Manuela Pirl andRenate Hartmann getting acquainted with the papers.In Finland, Kemppi’s logistics centre employs a dispatchingforeman, five logistics assistants and ten warehousestaff. In Germany there are four logistics assistants,with Patricia Köhl acting as local coordinator, andseven warehouse staff.12

Klaus-Dieter Hohmeier utilizes information technologyalready now in his work. In the future the logistics centreshifts more and more towards paperless work.Patricia Köhl and Leena Tuomaala work together a fourday-spellevery fifth week.24 hours is usually enoughAt subsidiaries, orders are entered in the Group’s sharedinformation system, while other export orders are enteredcentrally in the Finnish system. Order picking listsare printed out hourly at the logistics centre and taken tothe warehouse so that the products can be collected.‘Every welding machine and accessory is marked with abarcode. With the help of a scanner, the information canbe quickly transferred to the logistics department, whereassistants organise the shipment and draw up the necessarydispatch and export documentation.’‘In addition, we unload trucks bringing goods from Finlandseveral times a week. Quality control forms part ofour job’, affirms Klaus-Dieter Hohmeier, describing everydaywork at the German logistics centre.While shipments within Finland, Sweden, Norway, Polandand countries outside Europe are sent from Finlandcentral warehouse, welding machines to other Europeansubsidiaries including Italy, Spain and Portugal areshipped from Germany.Varied work and colleagues formsource of motivationKlaus-Dieter Hohmeier joined Kemppi’s German subsidiaryas a warehouse employee in 1986. Within sixmonthshe had become familiar with the work at thesales office: receiving orders, entering picking and dispatchlists, filling in customs documentation and customerservice.13

Leena Tuomaala and Klaus-Dieter Hohmeier”Over a three-year period, I also worked at various exhibitions,driving the Kemppi trailer in the Netherlands,Belgium, France, the Czech Republic and Poland in additionto Germany. I helped build and dismantle fairstands”, recollects Hohmeier.From 1991 he concentrated solely on warehouse work.”I enjoy the variety of my work. Co-operating smoothlywith my co-workers is also important. Kemppi has offeredme a secure future”, confirms Hohmeier.Contact persons for the German Logistics CentreLogistics Assistants by country and shipment area:Patricia Köhl: Finland, the Netherlands, ItalyManuela Pirl: Germany, Denmark, Turkey, Slovakia, theCzech RepublicRenate Hartmann: Hungary, France, parts of Spain, United ArabEmirates, Croatia, Sweden, Norway, Serbia-Montenegro, Bosnia-HerzegovinaMeral Kücükcay(on a maternity leave): parts of Spain, Great Britain, Portugal,Switzerland, Slovenia, GreeceContact persons for the Finnish Logistics CentreArja Kinnunen: Eastern Europe, China, Korea, Japan, SouthAmericaEila Koivunen: German logistics centre (warehousereplenishment), subsidiaries in CentralEurope, Spain (for shipments from Finland),KempowerMarina Koronen: Russia, CIS, the Baltic countries, Australia,Brazil, PortugalPirjo Loukeinen: India, Middle East, Far East, SouthernEuropeEila Salonen: Finland, Sweden, NorwayCats, hens and fishKlaus-Dieter Hohmeier has always valued regular workinghours, which have enabled him to spend his free timewith his family.”I have been happily married for 30 years. Our daughteris already grown-up and we have one grandchild.”The Hohmeiers live in the countryside, which fits in wellwith their hobbies:”During my free time, I dedicate myself to my pets: cats,hens and fish. When I have enough time, I potter aroundwith my model railway collection and listen to music.”New ERP system provides achallengeLeena Tuomaala began work at Kemppi as an export secretaryin 1987. Since then, her duties have always beenrelated to export and welding equipment deliveries, eventhough her job titles have changed. She became AssistantLogistics Manager in September 2001, and was appointedLogistics Manager in the beginning of 2002.”My responsibilities include everything related to logisticsin the order-delivery chain”, describes Tuomaala.”My work is very varied. Transport contracts form an essentialpart of it, as does the handling of large shipmentsrequiring special arrangements.” Leena works a four-daystretch in Germany every five weeks.Kemppi has selected a new IFS Enterprise ResourcePlanning system for the entire Group. It will be implementedin Finland during the autumn and introduced inall offices in the Group’s 11 countries in 2006. In additionto logistics, the new ERP system includes financialadministration, production, sales, marketing, documentmanagement and service management functions. Leenais a member of the related project team.”At the moment, the major challengeis to get the system up andrunning perfectly, allowing us tomove towards paperless operations.For example, pickers at logisticscentres will have a specialterminal which eliminates the needfor printing out picking lists.Pirjo PöllänenLogistics Centre is located in thesame building as Kemppi’s Germansubsidiary.14

Kempact Pulse 3000– a new categoryof compact pulseMIGKempact Pulse 3000 is Kemppi’s new compact pulseMIG welding machine, offering its users a lighter machine,excellent welding characteristics and more presetprogrammes for the required wires and gases. The designof this machine is a combination of the latest technologyand up-to-date user experiences, resulting in a 250-ampere, compact digital pulse MIG welding machineweighing just 22 kg. Its preset programmes, memory andstart-up functions guarantee the best possible characteristicsfor each application.Mobility and quality for weldingThe Kempact Pulse 3000 defines a new class of pulseMIG. A market-leading power-to-weight ratio – 250 A/ 22 kg – makes this new machine easy to move. Nowyou can easily carry a pulse MIG around, for examplein the trunk of your car. Compatibility with power generatorsguarantees smooth operation both at the workshopand in the field. The Kempact Pulse 3000 allowsyou to select the process that enables the best productivity:double-pulse, pulse MIG, synergic MIG or normalMIG/MAG. Its excellent welding characteristics arebased on arc control made possible by new technology.When you finish welding, the “snuff” function sharpensthe end of the filler wire to maximise stability when youbegin welding the next time. In addition, the 4-roll feedmechanism and the unique, optical tachometer guaranteean even and consistent wire feed delivery.Versatility and flexibilityKempact Pulse 3000 includes preset programmes requiredfor standard applications with aluminium, stainlessand normal steel, and a few programmes for specialmaterials such as CuSi. The user only needs to select thepreset programme suited to the filler material and shieldinggas directly from the menu, adjust the welding powerbased on the material used, and pull the trigger.The Kempact Pulse 3000 features 100 memory locationsin which users can store repeatedly used optimalwelding parameters, making welding faster and providingbetter quality if the welder often does the same kindof welding.Depending on the application, the user can also selectthe required start-up parameters, whether a softer startor more heat generation is required. For example, whenwelding aluminium, you can increase heat generationduring start-up by selecting the Hot Start function, andThe control paneldecrease finishing flaws with the crater filling function.The Kempact Pulse 3000 features an extensive selectionof special functions (SETUP), allowing the fine tuningof individual welding parameters.You can also switch the polarity of Kempact Pulse3000, making it suited for flux cored wires, which requirenegative polarity.Usability and productivityKempact Pulse 3000 features a Process Manager,which enables easy adjustment of welding parametersand clear panel functions.15

Readymade packagefor advanced robotic weldingMotoman and Kemppi pooled resources to meet workshopdemand for increased productivity, more uniformquality, and reduced costs. Jointly they developed apackage with everything needed for robotic arc welding.Motoman-Kemppi’sarc weldingpackage includesa feature - thepatent is pending- to automaticallycalibrate thewelding unit.The package combines a powerful,advanced power source for welding,the Kemppi Pro 4200 Evolution withMotoman’s servo-assisted wire feedunit and an air-cooled welding gunwith folding support. We have developeda unique way of calibratingtools: the Moto TAC, which automaticallycontrols robot operation,making the necessary adjustments.Underlying the package is Motoman’snewest robot model,EA1400N, specifically designed forarc welding. It includes a hose packagebuilt into the upper side of therobotic arm, making it easier to useand cutting operation time. Also thewelding gun is installed in line withthe rotating axle.Two separate versions of the packageare available: Automotive andAdvanced Welding.Carl SigfridssonProduct ManagerWelding SystemsMotoman Robotics Europe ABKempact Pulse 3000 – a new category...By using the RMT-10 remote control, (available for installationon the Kemppi PMT type MIG guns), welderscan improve their productivity by adjust power parameterson torch during welding, since they no longer need towalk back and forth between the machine and the weldedpiece. The user can also select a memory channel locationcontaining optimal welding parameters from thegun control, including preset settings for fillet and positionwelding.WeldSnake- WS 35, 6m MIG gun is a light-weight solutionfor locations where more reach is required whenwelding aluminium and stainless steel. Expensive investmentsin push-pull guns and machine suspension areno longer required, since Kempact Pulse 3000 combinedwith a WeldSnake MIG gun revolutionises the weldingof these materials.Contact your nearest Kemppi dealer to book ademonstration of the Kempact Pulse 3000.Ari PirinenAnalyst16

Kemppi’s customer promise “The Joy of Welding” was presented at the Essen welding fair in 2001.2005 ESSEN Schweissen & Schneiden– Welding World prepares to meetThe Schweissen & Schneiden Fair in Essen, Germany isnot just an exhibition, it’s a welding legend and the fair’snickname the ‘Welding Olympics’ describes the eventwell. The Schweissen & Schneiden Fair, the largest of itstype in the World, has been on the welding market calendarfor more than 50 years and every four years, equipmentusers from around the world gather to see the latestin welding technology. This year, the show is being heldfrom the 12 th to 17 th September. Time really flies fast andalthough it’s almost four years sincethe last one, it certainly feels likewe’ve just had the ‘Welding World’meeting in 2001.Kemppi has prepared itself to meetfuture needs of the welding industryand we feel it’s time to lightenup. Kemppi introduced a dominatingnew concept at Essen in 1977 -the first multi-process inverter typewelding power source in the world.Kemppi PRO was the world’s firstfully digital welding set and we areproud, that again this year, we willbe exhibiting many new digitalizedwelding machines. Excellent productsand the latest technologies arenot enough in today’s highly competitivemarket place and that is why we have reservedyet another surprise for you. Again, we think Essen is thetime and place to launch something, which creates totallynew thinking in the welding industry. This we shall doand you will be able to see it.Kemppi’s product statement ’The Arc Never Lies’ can befelt when you see for yourself our new products beingexhibited at the fair. New investment in high-speed cameratechniques is supporting our arc research work andthe results are being transferred to our products. It is allin the product and it’s certainly worth visiting the Kemppistand at Schweissen & Schneiden 2005. Our stand isto be found at our traditional location - number 230 inthe hall 2.You are very welcome to visit us inEssen, Germany and feel‘The Joy of Welding’ with Kemppi.17

MaidmentTankers– built to lastChanges in European legislation seldomprovide opportunities to improve youroffer to the customer. At MaidmentTankers in Littlehampton, Sussex,changes in the legislation effecting thedesign and specification of materials usedto build their fuel tanker bodies providedan excellent opportunity to improve ‘lifeand service life cost’ of their quality roadtanker product range. Today, MaidmentTankers are the only supplier in the UKmanufacturing Stainless Steel bodiedRoad Tankers for carrying Petroleumspirit and fuel oils.Traditionally road tankers have been broadly manufacturedfrom carbon steels with Aluminium used to a lesserdegree. The changes to Euro ADR specifications anddirectives, demanded that the construction and materialsused in tanker design be changed to accommodateimproved crash safety and road safety. The choice wasstraight forward, either increase the thickness of Steelused but render your product over weight with reducedpayload, or introduce new products manufactured fromeither Aluminium or Stainless Steel.Maidment Tankers decided to follow a project in StainlessSteel, rejecting the use of Aluminium on the groundsof shorter service life cycles and possibly more maintenancecost to the customer during service. This changein construction material of course introduced some interestingchallenges to Maidment’s fabrication department.Not only would welding process and equipment need toDerek Mihell, Mark Mihell and Les Brewer (front to back).change but also the working practice and constructiontechniques.Choosing Kemppi equipmentClearly investment was needed, particularly in the weldingtechnology. Maidment’s welding products suppliersRapid Welding Supplies were asked to assess Maidment’sneeds and recommended Kemppi PRO EVOLU-TION 4200 Pulsed Mig welding equipment with DoublePulse technology including remotely controlled KMP400W water cooled 10m push-pull welding guns.Once demonstrated by Kemppi and Rapid’s technicians,Maidments Directors carefully evaluated the financialoffer from Andrew Doe, Rapid Welding Supplies SalesManager, and ordered four machine packages to under-18

Road tanker under constructiontake the construction of the initial 10 off Stainless Steeltankers. Maidment Director Mr Derek Mihell takes upthe story; ‘The project has been a great success, weldingtimes have been reduced significantly and the equipmenthas been easy to use, particularly with the additionof the push-pull welding guns and remote ‘power triggercontrol. The remote control has allowed us to stay insidethe vessel during welding and no longer do we haveto keep climbing in and out to adjust the settings on themachines.Production of our first stainless steel tanker welded withthe Kemppi PRO Pulse equipment took place over twoyears ago now, and Les (Brewer) and Mark (Mihell)were certainly surprised by the speed of constructioncompared to the techniques previously used. As a smallKemppi PRO Evolution 4200 pulsed MIG weldingequipment at Maidmentto medium sized business we need to ensure our efficiencythrough investment like this. On this occasion the newEuro legislation has had a positive effect on both Maidment’smanufacturing efficiency and the quality and theexpected life of the Maidment Tanker product itself.John FrostKemppi UK Ltd19

ABB’s experience ofworking with KemppiABB was the first enterprise to start making robotsfor arc welding applications. That was back in 1974.The company has enjoyed a strong market positionever since. Today, ABB delivers about 1,500 robotic cellsfor arc welding each year.For several years now Kemppi hasbeen delivering power sources toABB using ABB’s own trademark.Initially the units were known asRPA but the name was switched toRPB when the “Kemppi Pro” powersource was changed into “KemppiPro Evolution”. Today,ABB markets three dif-ferent sizes: RPB 320, 420 and 520.ABB has been satisfied with the collaborationand the reliability of thepower sources.“RPB is top-notch. They are themost reliable and dependable of thepower sources we deliver.” saysDick Skarin, Product Managerat ABB AutomationTechnologies.“Naturally,we monitorthe reliabilityandavailabilityof the units very closely sincethese are factors impacting on theoperational finances of customers”,Skarin says.There is good market developmentpotential for ABB’s roboticsand the enterprise is optimisticabout 2005. While robotic cellcosts have halved over the lastten years, labour costs have risen50%. This is a key factor leadingto more development work on roboticunits. As a consequence, the profitabilityof investments has dramaticallyshifted.ABB also reveals that the enterprisehas launched a brand-new IRC5 roboticcontrol system to meet thestandards demanded of arc weldingequipment in the robotics marketfor a long time to come. Togetherwith the new IRC5 robotic system,it goes without saying that thethree power systems (RPB 320, 420and 520) will continue to be the obviouschoice for ABB customers inthe future.Göran MöneforsKemppi Sverige AB20

Service Technician Jani Vestola and Customer Care Manager Mervi Metsä working on warranty claimseWarranty – Kemppi’s newelectronic warranty systemIntroducing an improved Kemppi Channel:from March Kemppi’s extranet willfeature warranty registration and warrantyclaim processing in electronic format.During the spring of 2004, Kemppilaunched a project to streamline warrantyprocessing and offer additional servicesfor its dealers and service workshopsthrough Kemppi Channel. The warrantysystem includes registered warrantycards, dealer customer registers, warrantyclaims and the possibility to place orders.As dealers fill in warranty cards, the systemcreates personal, machine-specificcustomer registers, which dealers can utilisein their own marketing. Service workshops can alsouse this feature to offer various services to their customers.The system is protected in such a way that each usercan only see his/her own data. However, all service workshopscan check the validity of a warranty without seeingdetails as to where and from whomthe machine was bought. The order formdiffers from the old price and availabilityquery in its retrieval of the first possibledelivery date for the product.Better service forour customersHandling warranty claims was oncea slow, manual process. Its automationwill lead to faster processing, savingthe time and money of our customers,who almost certainly want their machinesback in production use as soon aspossible. Customers will no longer haveto prove date of purchase with a copy ofthe invoice or receipt; the serial number on the side ofthe machine will be sufficient to check the validity ofthe warranty. Checks are easy to perform based on the21

eWarranty – Kemppi’s new...serial number, regardless of time ofday and place of purchase. However,this requires that the warranty hasbeen properly registered. Failure toregister the warranty will oblige thedealer to verify the machine’s sellingdate in order to check the warranty’svalidity.QualityrequirementsIn 1990, Kemppi was the world’sfirst welding machine manufacturerto be granted an ISO 9001 qualitycertificate. This places certainrequirements on our quality system,and our new warranty processingsystem will help us meet theserequirements even better than before.For example, this markedly improvesmachine traceability in problemsituations, since all machinessold are registered in the eWarrantysystem. Warranty claims also providerapid and valuable informationfor our R&D and production departments,allowing us to react quicklyshould the need to change a productbecome evident and to enhanceproduct quality in order to meet ourcustomers requirements.Mervi MetsäCustomer Care Manager22

Buses manufactured in Norway arewelded using Kemppi equipmentVest-Busscar Stryn is in the beautifulSogn og Fjordane province inthe west of Norway. It has 250 employeesand is Norway’s only busmanufacturer. With the Scandinavianmarket as its focus, Vest-Busscarhas manufactured buses since 1965,continuously developing both busesand manufacturing methods.Thanks to its professional workforceand adaptation to market conditions,Vest-Busscar has won the market’sconfidence, succeeding in a sectorof constant change by focusing onproduct development.The company launched a brandnewproduct range in January 2004.The 2004 models comply with generalEuropean design and constructionnorms for buses with respect tofire and rollover safety, and provideeasier access for people with disabilities.Vest-Busscar has set its sights onbeing the leading knowledge centrefor buses in Nordic countries, supplyinga full range of products andservices for the market. The companyalso offers key after-sales servicethrough its own repair facilitiesand replacement parts stores in Oslo,Bergen, and Stryn.Huge investments have been madein production to enable the manufactureof these new bus models. Oneof several key innovations is weldingtechnique. High-alloy steels,aluminium, and black steel go intothe construction of the new vehicles.Vest- Busscar chose to work withKemppi to solve production-relatedproblems posed by welding processesand welding techniques.Right from the start, our experienceworking together shows that wemade the right decision by selectingKemppi equipment to weld high-alloymaterials and black steel.Production Manager Knut RoarSkåden is very satisfied with theproducts supplied and the associationwith Jostein Oksnes, RegionalSales Manager of Kemppi NorgeA/S.Tore BøeManaging DirectorVest-Busscar Stryn AS23

WorldSkills 2005 Helsinki– a chance to displayprofessional expertiseThis year Finland has been chosen toorganise the WorldSkills Competitionthat take place every two years. It willbe held in Helsinki Fair Centre, May 26-29, 2005. With around 800 competitorsfrom nearly 40 countries, the WorldSkillscompetition is the most extensive eventever organised in Helsinki Fair Centre. Itwill fill not only the 42 000 sq. m. of theinterior, but an additional 10 000 sq. m.of outdoor space. The number of visitorswill also exceed all previous Helsinki FairCentre attendance records, with up to150 000 people expected.Huge challengeOrganising a WorldSkills Competition is a huge challenge,not only to the Skills Finland Association, but alsoto Finnish institutions that offer professional education.These institutions are responsible for organising competitionevents – 39 in all. All but five exhibition eventswill be official skills competitions. The participants willbe the top performers under-23 years of age in their ownevents. The role of Skills Finland is to organise the eventas a whole, select the organisers for each event, and drawup all service and supply agreements. Each event organiserwill be chosen from among the top Finnish achieversin the field, an absolute requirement if a highstandard is to be achieved.Tough criteria for suppliersSince this is an international event, it places special demandson suppliers. The machines and equipment usedin competitions must be brands recognised worldwide,known for technically progressive solutions, and especiallyfor reliable performance. The product supplierschosen are indeed well-known worldwide like Volvo,Festo, Electrolux and Kemppi.But a good reputation is not enough. For the weldingcompetition, for example, competition event managerSeppo Paloluoma, of Vaasa Vocational Adult EducationCentre, and welding expert Juho Muhonen, of theIndustrial Training Centre, required welding appliancesto comply with several criteria they found essential forquality welding in their work.Kemppi as a supplierAs Kemppi employees, we can be proud that Skills Finlandselected us and our subcontractors as the sole suppliersof welding products for all events demandingwelding skills at the WorldSkills Competition.As this is an overall agreement to supply all weldingproducts, some outside our product range, we have subcontractedsuppliers who will complement Kemppi productswith products of similar quality.Our suppliers include Messer-Suomi Oy for weldinggases, Masino-Böllhoff Oy for Elga brazing consumablesand Elga Ab for all weldingconsumables.We and our subcontractors will supplythe competition with high qualityproducts which will enable us toguarantee successful competitionswherever welding or brazing activitiesare concerned.We may also be proud of the fact thatmembers of Skills Finland and othersassociated with the WorldSkills Competitionvalue Kemppi performances,products and services. Here are some24

comments and the reasons given for selecting us as weldingproducts supplier:“Kemppi is a pioneer in developing and manufacturingwelding appliances. As a family business, it naturallyconforms to ideals promoted by Skills Finland. Kemppi’sstrengths – entrepreneurship,innovation, skilled personnel, dynamism, and integrity– have made it internationally renowned. We trust thatsuch qualities will, through Kemppi, publicise the Worldsupplier and its machines and appliances meet the requirementsof professionals: cutting-edge products usingtechnical solutions that show other manufacturers theway forward for many years to come.” —Jaakko Pekkala,Technical Manager.Competition feverSince we live in the world’s most incorruptible country(Offical), I am convinced that the competitions we organ-Hans Kristensen fromNorway shows his weldingskills during the Nordicwelding championships atVaasa Vocational AdultEducation Centre in January2005. The welding machinesare the same type which willbe used in WorldSkills 2005competition in Helsinki.Championship competition even more as a forum for topprofessional performers.” —Henri Nordenswan, Administrativeand Finance Manager.“Skills Finland is honoured to have a pioneer such asKemppi as part of the main event at the 2005 WorldSkillsCompetition. It showcases the best that young, futuremasters of the profession can offer. Since only the bestappliances will do for the best performers, it is a pleasureto be able to present Finnish industrial expertise to theinternational public at the championship, and likewise tomake such top competitive performances feasible by usingleading products in the welding field.” —Henri Nordenswan,Administrative and Finance Manager.“Working together and considering each event’s specialfeatures, Skills Finland and Kemppi have built self-containedwelding appliance units that make optimum performancepossible. Not only do the units satisfy the technicalconditions of each World Championship event butthe competitors are offered the best technology availabletoday. Kemppi is the official World Championshipise will be fair without any advantage to the home country.Competitors have only a short time left to hone theirskills and prepare physically and mentally for one oftheir key life experiences to date: the WorldSkills Competition.As Kemppi employees we are doing our utmostso that Finns can prepare as well as possible and win thekey competitions: we provide the means for professionalskills to develop. We also offer the competitors trainingand the chance to participate in the qualifying rounds.I wish the organising bodies success in making the competitionsreach or exceed expectations andalso wish good luck to the competitors!Ari KangasmäkiSales DirectorKemppikoneet Oy25

Welding equipment alternativesfor robotic weldingHow are these possible?Customer needs of robotic and automatedwelding vary greatly aroundthe world. Different materials andautomated welding requirementsimpose ever greater demands onwelding processes and equipment.The industry involved and the sizeof production runs also dictate howversatile an automation solutionshould be. In the manufacture ofsmall production runs and customisedproducts, robots and automaticsmust be able to weld using severaldifferent processes while keepingsetup times as low aspossible.A typical application for a multiweldingprocess system would bewelding black and stainless steel ormetal and flux cored wire using thesame robot. More than one set ofwelding equipment is also requiredin wear surfacing welding performedduring the same work phaseas assembly welding.Differing customer needs have beentaken into account in the design ofKemppi robotics products. Weldingequipment setups can be flexiblycustomised, pushing and pullingwire feed units canbe used in the samesystem and severaldifferent welding processes can becombined with them.The Promig 540R and 520R controlunits are able to control twowire feeds, either on the same wireline or separately. Two control unitscan be connected to a single weldingpower source, which allows a singlepower source to be equipped with upto four different welding equipmentsetups or two pulling/pushing weldingequipment setups.In addition to Kemppi’s own weldingguns, the welding guns of allmajor manufacturers can be usedwith Kemppi welding machines.Their compatibility has been tested,and we are constantly adaptingnew brands and models based on theneeds of our customers.Mikko VeikkolainenCustomer Service ManagerAs many as fouralternative weldingequipment setups can be connectedto a Kemppi Pro Evolution weldingpower source.26

Mika Leirilaakso gets a feelfor Formula racingMika Leirilaakso came in twelfth on points inGermany’s Formula Renault series. Since 41drivers took part, the result is promising.“Had I not been forced to retire due to technicalhitches and accidents six times out of14, my ranking would have been even better,”Mika estimates.His best result of the season was in the Germanfinal. He was fast enough to get to 4 thplace on the grid.“The competition was undoubtedly the highpoint of my first track season. The qualifyingrounds gave me assurance after lookingat my driving closely. Pre-competition testingallowed me to get right up to speed inthe time trials, and my good starting positionhelped me finish as high as I did,” Mika explains.A total of 63 drivers took part in theFormula Renault 2000 Eurocup series. Mikacame in 20 th on overall points.A challenging and aggressive vehicleDespite his tender age, Mika Leirilaakso hasbuilt up a competitive career and deliberatelyPromising young driver MikaLeirilaakso of Lahti has drivenhis first track season in theEurocup Formula Renault2000 series and Germany’sFormula Renault series.For Leirilaakso, who earliercompeted internationally atkarting level, this season wasspent getting used to Formularacing. He’s shown that hehas enough pace to reach thetop. Next season will be reallyinteresting.“Being in the top three is arealistic goal,” Mika contends.Welding purpose-builtstructures and parts is anintegral part of motor sport. Thisprompted the Kemppi companydecision to focus sponsorshipon a sector in which weldingequipment is actually used torepair or construct the racingequipment itself.Kemppi has collaborated closelywith the Jordan Formula 1 Team,acting as Official Supplier since1998. Jordan uses Kemppi’sMastertig AC/DC weldingequipment in its production, testand race team and achieveswelded seams that hold goodunder extreme conditions.At the close of 2002, Kemppiand promising young Finnishdriver Mika Leirilaakso signed along-term sponsoring contract.In 2003, he competed in kartracing in parts of Europe as wellas Finland. He turned to FormulaRenault racing for the Europeanand German series in 2004. Thesponsorship contract was a wayfor Kemppi to add the KemppiMotor Sport link to its web site.The link features Mika reportingon his performance during thecompetition season.Additionally, Kemppi sponsoredPetri Kymäläinen and Toni R.Ruokonen last year. The formeris driving a Mitsubishi in theFinnish N-Series championship;the latter competed in Europe’sStandard Production CarChampionship, driving a Honda.The achievements of all driverssponsored by Kemppi will infuture appear on Kemppi’sMotor Sport web site.

Petri Kymäläinen, Finnish YouthSeries rally driving championin 2003, moved to the big 2+litre Group N last season withthe aim of becoming Finnishchampion in the StandardClass. The naturally aspiratedHonda engine has given way toa turbo-charged, 4-wheel driveMitsubishi Lancer Evolution 6.5.The season began promisinglywith the Arctic Lapland Rally.His speed assured him 8 thplace in the Standard Classcompetition for what is knownin Finland as the fell rally. TheFinnish Championship rallyin Kerava, intended as a testdrive, proved to be ill-fated: theseason ended when the vehiclewas written off.Petri Kymäläinen, weldingrally driving talentPetri Kymäläinen, of Myrskylä, was on theservice team of a rally-driving friend in theearly 1990s and became interested in thesport. In 1995, his experience in the navigator’sseat led to a win in the Standard Class,which kindled even greater enthusiasm.“The competition was a good scale, showingme how fast you must drive,” he recalls. Theyoung man decided to move into the adjoiningseat and press his own foot on the accelerator.The first car he owned (1996-2002) was anOpel Ascona i2000. It was fast enough toearn hima win in the 1998 F-Cup (Junior-A), a SilverMedal in the 1999 Finnish Youth Championship,5 th place in the 2001 F-Cup, and 7 thplace in the 2002 F-Cup.For the 2003 season, Kymäläinen decided tobuild a car to his own taste from start to finish.50 m of pipework inside the bodyIn 2003, the Honda Civic R-Type was the carto wait for in the N-Group. Petri Kymäläinen’svehicle arrived brand-new at Hankodock, and was transferred from there to Myrskyläto be stripped down. Adhesives, fillingand any other materials potentially detrimentalto welding or painting were removed fromthe stripped body shell using water pressureat 1000 bars. Next, all the seams in the carbody were reinforced using MIG welds at intervalsof a few centimeters. The stiffenedbody had rollbars welded to it – no boltedfastenings were used.“Counting the sum of floor trusses, front andrear overhead rollbars and rear trusses, thebody has almost 50 m of welded pipework.”Kymäläinen says. The chrome molybdenumrollbars effectively protect the body from alldirections.Mika Leirilaakso’s chiefaim is Formula 1 racing andin order to get there he isprepared to put in “110%”.Mika Leirilaakso gets a feel...set his goals years in advance. He was meantto transfer to the Formula Renault series nextseason but the promising young driver waspresented with the opportunity a year soonerthan expected.“I was looking for experience for next year.This season was my first in formula racing –it’s a whole new world compared to karting.Mika described his Tatuus vehicle as a Formula1 type, although somewhat smaller andslower than championship vehicles. It has200 horsepower and a top speed of 268 kph.Track speeds average 170-180 kph. The caraccelerates from a standing start to 100 kphin 2.5 seconds flat.“A very challenging and aggressive vehicleand instructive from the point of view of thefuture.”Youngest and least experienced in the seriesFormula Renault racing is very competitive.At 17, Leirilaakso was the youngest and leastexperienced driver in the series for this season.His team was also taking part in the seriesfor the first time.“The budget for the season was €300,000,only half that of the leading teams in the series.Due to a tight budget we didn’t get to testdrive nearly as much as we needed to - in factonly just before the last race.”“All the circuits in the series were new to us.Without test driving, the time trials were reallyhard and the car couldn’t be fine-tuned.28

High pressure washing was carried out by aprofessional company but all the seam weldingwas done by the driver himself. Kemppiwelding machines have been used onthe Kymäläinen’s farm since the 1990s.Kymäläinen’s first welding machine – andit’s still in use – was the 250 amp Kempo-mat. Next, they acquired a Kempomat 1701one-phase-machine for thin sheets. Their latestpurchase is the Kemppi Pro Inox, whichhas welding programmes for aluminium andstainless steel as well as iron.You can’t do that during the race.”“I know the car and what it can do. I didn’tknow enough about the impact of tuning. Wehad a lot of discussions with the team engineerbefore the last race, and we found outhow the car needs to be developed.” Mikastates.Championship still his goalMika Leirilaakso’s chief aim is Formula 1racing and in order to get there he is preparedto put in “110%”. He is negotiating with fourseparate teams for the coming season.“Whether I’ll drive in the Eurocup, Germanor Italian series, or perhaps all three of them,is still an open question. Being in the topthree next season is a realistic aim”, he believes.The 17-year-old looks after negotiations withteams and teamwork partners himself. In discussions,he appears to be much more maturethan others his own age.“I’ve looked after matters related to drivingsince I was 13. I’ve travelled around Finlandand elsewhere in Europe alone, and I’ve beenabroad this year more than 200 days. It hasmatured me and taught me to get along witheveryone.Pirjo Pöllänen29

Petri Kymäläinen playsfloorball and volleyball twicea week. “Ball games helpphysical fitness and reflexes,cutting reaction time.” Healso gets staying power byjogging on forest paths inthe summertime. Earlierpastimes, such as shootingand hunting, have been setaside but not forgotten.Petri Kymäläinen, welding rally...The rollbars effectively protect the body fromall directions. Nearly 50 m of rollbar waswelded into the Honda.“Kemppi Pro Inox is a good choice for peoplewho drive in rallies because all kinds ofmaterials are used to build a competitioncar,” Kymäläinen says. Down the years, hehas tested equipment made by different manufacturers:“Ease of welding, trouble-free performance,and a smooth finish shaped the choice.” Inaddition, Kemppi machines can be servicedeasily, if necessary.“We also need welding machines on thefarm,” he adds. The Kymäläinen’s 40 hectaresof arable land and 80 hectares of forestensure that there is plenty of repair and alterationwork to be done on machines. Besidesbuilding a rally car, Kymäläinen welds frontloadingbuckets, ploughs and metal structuresfor agricultural use, with professionalskill.About 800 hours of workWhile being washed, welded and painted,the Honda’s moulding preform rotated on aboom purpose-built by Kymäläinen. Expertsin the field refer to it as a grill.“Since the preform can be rotated in everydirection, I can do the work standing up.I needn’t crawl on my back under the bodyor get welding sparks in my face,” is how hedescribes it.Technology was inserted into the vehicle afterthe paintwork was completed.“Everything superfluous is stripped down tolighten the weight. For example, the aluminiumundergirding adds weight and the resultweighs roughly the same as what was therebefore.”“Many competition parts are inserted into thechassis; Kymäläinen lists shock absorbers,the stiffer-than-original clutch, and a controlunit for programming the engine. The exhaustpipes and gearbox are being rebuilt.”Kymäläinen calculates that building the Hondatook about three and a half months – over800 hours of labour. The material costs alonecame to roughly €50 000. Quite an investmentfor a hobby. You have to wonder if itwas all worthwhile.“When you build a car from start to finishyourself, you have a feel for it. A new confidencein the car is created and, if it doesn’twork, the one to blame can be found staringat you in the mirror.”The Mitsubishi Lancer Evolution aftercrashing. The rollbars are visible behind thepeeled-off doors. The experience also provedthat it’s not worth skimping on quality of workor materials when constructing rollbars.Photo: Pro Fotoklubi30

The moulding preformrotated on a special boomduring power-washing,welding and painting.It takes practice to get used to notationAfter the Finnish Youth Championship,Kymäläinen set his sights on the Group NStandard Class championship. The naturallyaspirated Honda engine has given way to theturbo-charged Mitsubishi Lancer Evolution6.5. The 4-wheel drive vehicle packs nearly300 horsepower.The 2004 season began promisingly: Petridrove well to come in eighth in the Arctic LaplandRally general competition.“It was my only successful competition thisseason. There were a lot of problems with thecar’s technology, the turbocharger in particular.”“Earlier I drove only in so-called unpublicisedcompetitions. It takes time to get usedto how to notate in competitions. It’s easy tomake notations but it takes practice to findthe right rhythm and timing.”Petri Kymäläinen decided to test the car’sperformance in the Youth Series competitionin August. The test run in the Kerava Rallycame to a halt suddenly at 100 kph and thecar was written off. The rest of the competitionseason went up in smoke.Skill alone not enoughPetri Kymäläinen has a new body for theMitsubishi and is gradually putting the cartogether. It’s well worth planing ahead at thesame time. The family farm offers a future tothe agricultural technician, but his fiery passionfor rally driving has not yet been dampened.Unfortunately, talent and skill alone arenot enough to advance on the rally circuit:“To give you an example, insurance againstdriving off the road costs €2 000 for eachcompetition. Turbocharged engines needcompetition fuel costing €6/litre. It takes alitre for each kilometer of special tests, andnearly 400 litres for a single competition,”explains Kymäläinen.“You need €100 000 for a season in the FinnishChampionship series, if you are lookingfor victory in the overall standings,” he concludes.Copy: Pirjo PöllänenPhotos: Pirjo Pöllänen and Tuomas Virén31

Toni Rasmus Ruokonen wasinvited to develop the GRMotosoport Asia team vehiclefor the 2004 season. He drovein almost every race and came9 th in the European Touring CarChampionship Independentseries, a great achievement.Toni R. Ruokonen hashad a good season on theEuropean circuitsToni Ruokonen was the first European driverto win the 2002 Asian circuit main series(ATCC). He was about to compete for itagain in 2003 when the SARS epidemic putan end to his plans. The team decided not totake part in the series because of health risks,and were too late to apply for the Europeanseries.After a year’s break, Ruokonen was invitedto participate in the European Championshipsin 2004 as part of the GR MotosportAsia team, familiar to him since 1998. Hisfirst task was to help the team tune their HondaCivic Type R vehicle to perform at its fastest.“Simon Harrison, the team’s regular driver,is good but he cannot convey how a car actuallybehaves on the circuit,” explains Ruokonen.In the end the Finn drove almost everycompetition in the series and came in ninthbased on overall points, immediately behindHarrison.Tuning varies from circuit to circuitRuokonen says the sharpest differences betweendrivers are revealed when providingdetailed feedback on the way a car handles,and the impact of various technical adjustments.“You have to know when the car is at its fastest.Good to handle and fast are not at all thesame thing. A car may feel good to handle,but the times may be no good. But a car thatis awkward to handle can still return excel-32

lent times,” Ruokonen explains.Most adjustments are made to the chassisto maximise the grip and staying power oftyres.“Tyres must last throughout the race. Fromtime to time we tune aggressively. Tyres maybe allowed to heat up if we drive only twoor three laps. They mustn’t overheat during arace, it’s like driving on ice with no studs inyour tyres. For races, you must find a compromisebetween grip and staying power.Additionally, the wheel angles, shock absorbers,springs and body roll stabilisers areadjusted.“You make different adjustments for differentcircuits because surfaces vary in eachcase. The year was a challenge to Ruokonenas his team was not at all familiar withthe race circuits. The knowledge gained duringthe year is now on file, and will be put togood use next season.Mastertig AC/DC an excellent choiceThe European Touring Car Championship isopen to factory-owned and so-called privately-owned entries, such as Toni’s.“Factory teams like Schnitzer test drive threedays a week; my team tests just three dayseach season,” says Toni, describing the difference.There is not much time for testing duringcompetition, so a very precise test plan isdrawn up in advance. Cars can do two testson the circuit, each for half an hour. The competitionis a compact stretch. It’s 50 km longand there’s only 15 minutes between startsfor repairs and tyre changes.Toni Ruokonen’s team uses a Kemppi MastertigAC/DC welding machine. He considersit an excellent choice for competition cars.“Competition driving demands a versatileand reliable unit. Many different kinds ofsteel are used when developing the car. Mastertigcan weld them all.”“As there’s only 15 minutes between starts,a welding machine must perform flawlessly.It must also be easy to use because there’sno time to learn.” Ruokonen also has a MastertigAC/DC in his own garage for the constructionof hobby cars.World championship class in 2005Toni Ruokonen has been negotiating for the2005 season. Some test runs have alreadybeen agreed.“The European Touring Car Championshipwill be a World Championship event in 2005.So far, there have only been two single-seatcar classes in the World Championship: Formula1 and Rally. There’ll be a lot more interestin the series. Many new car models – evenone from China – have already signed up.“I have good credentials because I’ve alreadydriven a season,” Ruokonen says. For him,competition driving is both a hobby and ajob. In addition he inspects and repairs ships,diving with DG Diving Group Oy.“This year, I welded under water usingKemppi equipment two or three times a weekon average,” he adds.Toni Ruokonen also runs a company, RasmusSpeed Promotion Oy, which imports andtunes control units for engines. Following hisfather’s retirement, he will also become partof Meiller Lithorex Oy, a direct marketingcompany selling print products.Pirjo Pöllänen33

17,5kgThe new Kempact product family from 17.5 kg.Full MIG welding properties. Take it easily anywhere.Works great with a generator and extra long cable.Even for the roughest conditions.For more information, please contact your Kemppi dealer or visit www.kemppi.com

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The Joy ofWeldingWelding with Kemppi just keeps you going.You're sure to always do an excellent job– at times it's downright amazing!For more information, please contact your Kemppi dealeror visit www.kemppi.com