Systematic Sewer Repair

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 engi-neers 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 unri-valled 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.

The Company

Pioneer Achievement: Electric Drive

IBAK Robotics cutters run on electricity. As a result, they are light-weight, low-noise and powerful. Unlike hydraulic or pneumatic sys-tems, electrically driven robots do not require any noisy, heavy, energy-consuming compressors or generators.

Low Operating CostsThe 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.

High Degree of EfficiencyAn 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 effec-tively used to drive the cutting tool.

Low Noise EmissionsAfter the installation of sewer pipe liners, laterals are usually rein-stated during the evening or at night when traffic is low. Particu-larly 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 CompatibilityAn electric motor does not produce any harmful gases. Emission-free 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 pro-tecting the environment.

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* The modular design of the IBAK system makes it possible for various IBAK inspection com-ponents (cable reels, camera tractors, cameras) to be installed as required. For further details, please refer to the leaflet on IBAK Sewer Inspection Systems.

Control Units Optional Accessories Portable Lateral Robot System

KW 305

T 66

ORION 2.9

FlexiGator

BK

Supply Unit

FlexiGator

BP 3.5 +

BS 7 / BS 3.5

Winch

Robot Systems

IKAS evolution + IKAS Gator Software

Cable Reel Camera

Pan and rotate colour camera

CutterCam

KW 100 / KW 150

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 main-line 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.

A System Solution with Modular Components

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AlliGator

MultiGator with Reparo-System

MiniGator

Cutting Complex Geometry in a Single Operation

With the built-in rotation module, 700° rotations (left/right) are possible.

Cutting and Grinding Robots for Mainline Sewers

Cutter heads for all applicationsAll 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.

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DN 200 to DN 800 & OvoidsThe robot can be optimally configured for various pipe condi-tions or pipe diameters with different attachments and wheel sets.

Precise Performance of Detailed WorkThe rotational speed of the tool is adjustable. In addition, the clamping cushion technology enables the robots to work with-out much vibration.

A Sharp Focus EverywhereThe 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 rehabilita-tion results can be assessed and documented with convincing photo material.

A Clear View at All TimesFor cleaning, water is supplied and the camera rotates in a matter of seconds over an integrated rub-ber lip and then returns automatically to its original position. (Photo on the left: before cleaning; photo on the right: after cleaning)

Getting Your Bearings in the PipeThe 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.

Pressure Monitoring to Prevent Damage to the Robot

The operator is given a visual warning mes-sage on the display and an alarm tone sounds to inform him if a leak is detected in the elec-tronic installation areas.

Travelling through Sections of up to 150mClamping cushions press the wheels against the pipe wall with com-pressed air and ensure high traction strength of the robot so that long operating distances can be achieved.

Fast Navigation to the Working AreaThe 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.

Holistic System Concept

The basis of all development work is the company‘s desire to supply the industry with user-oriented, cost-effective solu-tions. 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.

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Low Operating CostsA vehicle with a cutting and grinding robot can be run for a whole day on a battery charge costing less than ten euros.

One Control Unit for the TV Sys-tem and the Cutting Equipment

The cutting and grinding robots and the cam-era 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 cam-era with the same joysticks and keyboards.

Ease of UseThe 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.

Combined Cutting and TV System:The TV systems can be integrated neatly into the existing archi-tecture 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 syn-chronisation with the speed of the camera tractor.

Space-SavingNo 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.

*from the cutting motor to the folding joint

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Operating range Mainline sewersPipe diameters 230 to 600 mm (optionally 800 mm)Dimensions / WeightLength* 1160 mm Surrounding diameter ø 228 mmWeight 69 kg Operation BS 3.5, BS 7 Hybrid cable length 100 m or 150 m TractorMotors 4 electric motors Power 300 Watts Max. speed 15 m/min Rotating module, rotating elbows 700° Height adjustment for lifting/lowe-ring unit

195 mm

TractionClamping cushions with compressed air, 8 driven wheels

Cutting Motor

Type Brushless 3-phase electric drive, water-cooled

Voltage 48 V Power 2500 Watts Max. speed 10,000 rpm Comfort & SafetyCentre of rotation of cutting tool Centered in the pipe Vent system YesLowering hook with chain hoist YesPressure monitoring of electronic installation areas

Yes

CameraCamera type CutterCam Lighting LED

Special featuresCleaning function, position sensor, autofocus, automatic shutter

Accessories

Wheels and wheel attachmentsVarious sizes (up to DN 800), spacers, ovoid pipe attachments

Cutter head suspension (4th axle) YesIBAK software IKAS Gator

The AlliGator is the largest electric cutting and grinding robot from IBAK Robotics for mainline sewers and provides high-performance opera-tion in pipes with diameters of up to 800 mm.

Specifications AlliGatorAlliGator

MiniGator Specifications MiniGator

*from the cutting motor to the folding joint

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Operating range Mainline sewersPipe diameters 175 to 350 mm (optionally 600 mm)Dimensions / WeightLength* 1000 mmSurrounding diameter ø 172 mmWeight 45 kgOperation BS 3.5, BS7Hybrid cable length 100 m or 150 mTractorMotors 4 electric motors Power 400 Watts Max. speed 15 m/min Rotating module, rotating elbows 700° Height adjustment for lifting/lowe-ring unit

125 mm

TractionClamping 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 & SafetyCentre of rotation of cutting tool Centered in the pipe Vent system YesLowering hook with chain hoist YesPressure monitoring of electronic installation areas

Yes

CameraCamera type CutterCam Lighting LED

Special featuresCleaning function, position sensor, autofocus, automatic shutter

Accessories

Wheels and wheel attachmentsVarious sizes (up to DN 600), spacers, ovoid pipe attachments

Cutter head suspension (4th axle) YesIBAK software IKAS Gator

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.

The FlexiGator system is of modular design and thus easily transport-able. 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.

FlexiGator

Specifications FlexiGator

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Operating range LateralsPipe diameters 100 to 150 mm (optionally 200 mm)Dimensions / WeightLength* 1200 mmSurrounding diameter ø 80 mmWeight 7 kgOperation Control boxHybrid cable length 60 mSystem Components Control unit Splash-proofCable reel With 60 metres of cable Supply unit With water supply, electronics, etc.Robot FlexiGatorMobilityPropulsion function 50 mmRotation function 540°Lowering/lifting angle 35°Cutting motorType Brushless 3-phase electric drive, water-cooledVoltage 24 V Power 300 WattsMax. speed 13,500 rpm CameraCamera 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

Specifications FlexiGator

Specifications MultiGator

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The MultiGator is a flexible, electric basis robot and rehabilitation components such as the Reparo Sys-tem grouting unit for connecting pipes can be con-nected to it.

Operating range Mainline sewersPipe diameters 250 to 600 mm Dimensions / WeightLength* 1150 mmSurrounding diameter ø 228 mmWeight 62 kgOperation BS 3.5, BS7Hybrid cable length 100 m or 150 m TractorMotors 4 electric motors Power 300 Watts Max. speed 15 m/min Rotating module, rotating elbows 700° Traction Clamping cushions with compressed air, 8 driven wheelsComfort & SafetyVent system YesLowering hook with chain hoist YesPressure monitoring of electronic installation areas

Yes

Articulated joint YesCameraCamera type CutterCam Lighting LED

Special featuresCleaning function, position sensor, autofocus, automatic shutter

AccessoriesWheels and wheel attachments Various sizes for extension to DN 600, ovoid pipe attachmentsRehabilitation components Reparo SystemIBAK software IKAS Gator

MultiGator

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The Reparo System is designed for rehabilitation and bonding of lat-erals in DN 250 to DN 600 pipes in combination with the MultiGator basis robot. With the grouting system, holes can be filled with mate-rial. The robot can carry up to 3 litres of grouting resin in a cartridge.

Operating ProcedureThe 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 con-trolled at any time via a digital pressure indicator. To fill the defect with material, resin is pressed out of the cartridge through the open-ing 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 MonitoringThe entire positioning and grouting procedure can be observed with three cameras. Two of the video images can be transmitted simulta-neously to the monitors. As a bus system is used, the operator con-tinually receives feed-back from the sewer (e.g. about the tempera-ture development), so that the rehabilitation process can be continu-ally controlled and supervised.The articulated joints facilitate the introduction and handling of the system in the sewer. Due to its modular design, the combined Mul-tigator-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.

The Reparo-System

Camera type* Cutter camera, two-wireOperating range* DN 200 upwardsDimensions/Weight* Ø 58 mm / length 100 mm / weight approx. 430 gPushrod operation NoTractor operation YesUpright image No, but position sensor Correctly-oriented image NoZoom NoF (aperture) 01:02.00f (focal distance) (mm) 03.08.15Lighting 4 white power LEDsLight sensitivity (lux) 0.025 lux (F 1.2, 1/50 s)Luminous flux (Lumen) 440 lmProtection class IP 68 to DIN 40050Permissible ambient tempe-rature

Operation 0° C–+40° C, storage -30° C–+70° C

Test pressure for leak test 1.0 barPressure monitoring Integrated pressure sensor1)

Diaphragm function Fixed shutter, automatic electronic shutter, remote-controlled

Pan range +160°/-135°Cleaning function Automatic wipe functionAngle of aperture 68° diagonalView field +105°/-160°Rotation angle NoFocus function/ range Manual 1 cm – ∞, remote-controlled, autofocusSensor (inches) 1/4“ CMOSTV standard NTSC or PALHorizontal resolution 420 lines PALIntegrated laser Yes**Explosion protection NoIntegrated detector transmitter No

Combinable withIBAK Robotics MiniGator/ AlliGator/MultiGator

Yes

IBAK Robotics FlexiGator No

IBAK control units BS 3.5, BS 7

Specifications CutterCam

1) LCD indicator and alarm in the control unit * when mounted on robot | ** under preparation

Photo on the left: before cleaningPhoto on the right: after cleaning

The development of IBAK Robotics products profits from the exper-tise 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 cut-ting and grinding robots are all equipped with a camera in line with the latest IBAK standards.

Sharp Focus EverywhereThe CutterCam is equipped with a flexible focus so that areas at various distances can be brought into sharp focus as required. Dur-ing 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 profes-sionally documented and the extent and quality of the performed rehabilitation work can be evidenced with convincing photo mate-rial. This valuable data can be supplemented with comments on the performed measures and stored systematically with the IBAK IKAS Gator software.

Getting Your Bearings in the PipeThe 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 sen-sor 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 TimesThe 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 vul-nerable wipers installed in an exposed position, this mechanism is specially designed for operation in sewers.

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CutterCam

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 con-sist of an ergonomically designed control console, a 19“ rack and a keyboard.All current IBAK Robotics cutting and grinding robots and IBAK cam-era 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 user-friendly 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 assem-bled components that have been identified by the system are dis-played 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 con-trolled. 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 synchronisa-tion 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.

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 elec-tric conductors and the air and water lines to ensure optimum sup-ply 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.

Product classification Cable reelMax. cable length KW100: 100 m

KW150: 150 m KW100: 600x830x1100 KW150: 600x1025x1500

Width x height x depth (mm) KW100: 600x830x1100KW150: 600x1025x1500 jaWeight KW100: 240 kg (incl. cable)KW150: 290 kg (incl. cable)Length measurement YesMotor-driven YesCable level wind functionRemote controlEmergency stop Yes

Combinable with

IBAK Robotics robotsMiniGator, AlliGator, MultiGator

IBAK control systems BS 3.5, BS 7

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KW100 / KW150

Specifications KW 100 / KW 150

BS 3.5 / BS 7

IBAK Robotics GmbHSchlosserstr. 2276448 Durmersheim · GermanyTel +49 (0) 7245 91670-0Fax +49 (0) 7245 91670-29Web www.ibak-robotics.deMail info@ibak-robotics.de

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AlliGator, MultiGator, MiniGator und FlexiGator are

registered trademarks of IBAK Robotics GmbH.