DEMYKS Manipulators

DEMYKS Manipulators are multi-axis positioning and welding support solutions developed by BM Makina for heavy industry, rail and welded fabrication — a hybrid of manipulator and welding positioner systems. The system combines the lifting and movement capability of manipulators with the precise rotation and positioning advantages of welding positioners. The result delivers high precision, safety and ergonomics in the welding, assembly and maintenance of large, heavy workpieces. Since 2011, BM Makina has designed and produced this hybrid system in-house under the DEMYKS brand, developing custom configurations for each customer process.

Modular System Design (3 Modules): the DEMYKS Manipulator is a modular system designed for safe lifting, precise positioning and controlled rotation of heavy, bulky parts. It raises/lowers the part and gives the operator access to the working point at exactly the right angle. The system consists of three main modules: Vertical column & boom (manipulator module) — moves the part up and down on the Z axis and adjusts its horizontal position within the work area. Rotary table (positioner module) — rotates the part 360° around the Z axis for full access to the working point, accelerating the workflow with controlled, safe rotation. Rotary face plate (Y-axis turning module) — turns the part around the Y axis for easy access to different faces; especially valuable where multiple surfaces must be processed. With this combination, heavy workpieces can be positioned, rotated and locked on every axis during welding; the operator completes weld runs at the optimal angle without ever handling the part manually. Capacity: systems are customized per project with the required lifting, tilting and turning capacity. Movement: precise 3-axis motion including vertical lift, horizontal slew and table rotation, with optional continuous 360° rotation and optional position hold with automatic locking. Control and safety: PLC-based intelligent control, safe remote or panel control (24 V DC), thermal protection sensors, emergency stop system, inverter-controlled rotation and turning. Drive and power: electro-mechanical drive systems, 380 V three-phase supply, high-torque motor-gearbox unit, energy-efficient and quiet operation.

Rail production and maintenance workshops: welding and assembly of wagon chassis, bogies and wheelsets. Heavy industry and steel construction: rotating and welding large body parts and machine components. Energy and pressure vessel production: welding processes for pipes, tanks and boilers. Automotive and defence: manufacturing of bodies, chassis and armoured structures. Shipbuilding and industrial assembly: areas where large structures require 3-axis positioning. Heavy vehicle services: static support in truck, bus and machinery maintenance. Industrial production lines: temporary support during assembly or welding. Energy and defence: load support in heavy equipment assembly and maintenance operations.

Load capacity: increased on request per project. Height adjustment: adapts to different vehicle heights. Material: heavy-duty welded steel construction. Surface coating: industrial epoxy paint or galvanizing for corrosion protection. Base: wide-base feet with a non-slip, stable support surface. Adaptability: compatible with rail vehicles, buses, trucks and heavy machinery. Maintenance: minimal — long-term durability.

With a high-torque gear structure, vibration-free motion control and a stable steel frame, DEMYKS Manipulators deliver long service life. The modular design improves both weld quality and operator safety: positioning without manual part handling reduces accident risk and minimizes weld defects. User feedback shows that hybrid systems shorten production times and make weld quality repeatable. BM Makina has successfully commissioned these systems at Türkiye’s leading metro, tram, railway and defence industry facilities.