Welding automation has been a hot topic lately, but for a good reason. It’s a way to help your welders produce more while eliminating or minimising weld defects and rework.
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Welding automation helps improve weld quality and productivity. That’s a win-win across the board. However, welding automation systems are often specialised for specific applications, requiring a thoughtful approach when picking the right systems for your shop.
Welding automation can be full or partial. For most shops, semi-automated and mechanised welding systems provide the most benefits. Empowering your welders with tools like welding tractors, positioners, or orbital welding systems helps them produce more and repeatedly achieve exceptional weld quality.
For the most part, automated welding systems ensure maximum accuracy and repeatability of the welding process. However, automation is also highly beneficial for one-off jobs because it can drastically improve weld quality and conformity to welding standards and customer specifications.
You’ll hardly find a welding product today that doesn’t require at least some form of mechanisation/automation during production. Pipes, tubes, pressure vessels, heat exchangers, sheet metal fabrication, ships, aeroplanes, cars, bridges, structural members of buildings, wall and deck panels, and many other welding jobs require some form of automation.
While you could do it all manually, the production would be too expensive and time-consuming.
If an automated system reduces rework, it also reduces the business bottlenecks, allowing a streamlined production process.
What happens if the weld on a pressure vessel has a defect? The inspector, welder, metallurgist, engineer, and even salespeople must get involved more than necessary. The true cost of a weld defect is hard to estimate, but project delays can drag on, especially with new work coming into the shop. That’s why getting it right the first time is better for everyone, and automated systems help you do just that!
Welding positioners can turn and tilt the welded part, automating the part rotation and movement during the welding process. When combined with manual or automated welding, positioners can significantly improve weld uniformity.
Positioner capacity can range from 50 kg to hundreds of tons. Besides welding, they are used for nondestructive testing, cutting, cladding, grinding, weld polishing, and other allied processes.
The most suitable application for welding positioners and turntables is pipe welding or anything round. With precise rotation speed control and a stationary welding head, you can get a perfect heat input and an outstanding weld every time, part after part. It also makes it easier to quote parts as you can quickly develop the feel for how long it takes to weld with it.
Welding positioners are also highly beneficial for cobot integrations. Cobots are a transformative technology that can significantly boost productivity and quality. But, pairing a cobot with a positioner can additionally improve results. For example, ProArc PT-150P is a system designed for cobot application, integrating cobots with the rotational power of positioners. Imagine welding structural supports on a cylinder and having to manually rotate the part each time. That leaves lots of room for error. Instead, use the ProArc PT-150 to harness the power of the cobot fully for all cylindrical welding tasks.
Turning rolls and welding rotators are perfect for weld automation on heavy pressure vessels, smaller tanks, and pipes. It’s dangerous and counterproductive to rotate large pressure vessels manually or using a forklift or similar equipment. The fastest and safest way is using turning rolls. They have multiple PU roller wheels that come in contact with the vessel’s sides and rotate it for welding or NDT.
Welding rotators can also be used for spraying as they allow controlled rotation. So, you can treat the vessel uniformly and safely access its entire surface.
Column and boom welding manipulators are the cornerstone of welding automation. They quite literally hold the welding head static or travel along the joint instead of you doing it manually.
It’s the welder’s job to use the column and boom equipment to produce sound welds, but eliminating the manual welding action drastically boosts productivity and quality.
You can use the manipulator to hold the welding head while the positioner rotates the welded piece or use a travelling beam to move the welding head over a stationary part. Large vessels and towers are usually welded using rotators and a manipulator. The vessel is rotated while the welding manipulator holds the welding head, producing a uniform weld along the circumference.
These systems can also be used for weld cladding to overlay pipes and other equipment with corrosion-resistant alloys.
We have a large selection of various welding manipulators that can be fitted to almost any industrial application.
Welding tractors carry the welding torch/head along the tracks you install to follow the joint. Tractors and carriages are the best solution for highly accurate welding and cutting of large components like storage tanks, ship hulls, and large structural steel members.
These systems are also portable, making them a perfect choice for automating welding/cutting tasks on site.
Tracks can be linear or curved to fully accommodate the weld/cut path. These systems can have excellent traction on horizontal, vertical, concave, and convex components, making them highly versatile. If you plan to weld large components made from thick steel, consider automating the process with welding tractors. Advanced tractors, like theGullco motorised systems, also give you control over the oscillation speed, width, and dwells. We stock many Gullco systems, including the Gullco KAT, for easy welding and cutting.
Orbital welding systems dramatically improve productivity, quality, and weld uniformity compared to manual pipe welding. Even the best manual pipe welder can’t consistently match the quality of orbital welding equipment.
However, the biggest benefit is just how easy it is to weld pipes with orbital welding equipment. Not only does it require far less skill, but it puts significantly less strain on the operator. Manual pipe and tube welding can be very exhausting as you hold your body in awkward and uncomfortable positions for hours on end. Orbital welding makes the job much less tiring, letting you produce perfect welds all day long.
Orbital welding applications range from petrochemical to food and pharmaceutical. If the job involves significant amounts of pipe welding, orbital is almost always the way to go.
If you are welding extra large diameter pipes, you can use a welding tractor with a circular track system to achieve a similar setup as with the orbital welding equipment.
Like orbital welding, welding lathes produce circumferential welds on pipes. However, the working principle is different. The welding lathe rotates the pipe while the welding head is stationary. You can use a single or multiple welding torches, making these systems versatile for small to medium-sized cylindrical parts.
Welding lathes are used for vacuum vessels, nuclear, defence, aerospace, and many other industries where weld precision is critical. We have an extensive line of welding lathes that can fit almost any application, including lathes from ProArc.
If you want to learn more, please visit our website Hardfacing Welding Wire.
Longitudinal arc seam welders are designed to make seam welds on storage tanks and pipes. They can produce welds with almost absolute precision and eliminate rework. Repairing a weld defect on equipment with thick walls can be very costly, making seam welders an indispensable tool for shops considering offering seam welding services.
We also provide resistance seam welders that work differently than arc welding equipment. For example, the PEI PFT resistance welder for seam welding has circular electrodes that clamp and roll two sheet metals between them, causing them to fuse due to the resistance of the current flow. They are a perfect choice for automating the production of gas tanks, vessel pipes, tubes, air-tight equipment, and other products made from sheet metal.
Westermans International has a large stock of used and new welding and cutting equipment for automated and manual applications. Everything from plasma and gas profile cutting systems to submerged arc welders, positioners, manipulators, and welding power sources. We provide individual, modular, and bespoke automatic welding solutions to help you fix specific production challenges.
Welding manipulators are mechanized devices designed to assist in positioning and manipulating welding torches or heads during welding operations. They offer controlled movement and precise positioning, allowing welders to achieve consistent and accurate welds. Welding manipulators are commonly used for welding tasks involving long or heavy workpieces, such as pipes, tanks, pressure vessels, and structural components.
When looking for a welding manipulator to improve your welding process, it's important to explore various options of welding manipulators for sale. A welding manipulator enhances precision and consistency, especially when paired with an automated system. You can find different models, including the welding head manipulator and pipe welding manipulator, each designed for specific tasks. For those in need of an automated solution, an automatic welding manipulator offers improved efficiency and quality. Whether you’re seeking a new or used welding manipulator for sale, many welding manipulator suppliers provide options to suit your production needs. Investing in weld manipulators can greatly increase productivity and accuracy in your welding operations.
NoDescriptionParameter1Vertical Stroke1-6M2Horizontal Stroke1-6M3Beam Elevating Speed600-800 mm/Min4Beam Horizontal Speed100- mm/Min5Min Height Under Boom A300-400mm6Min Distance From Center Line of Column to Front End of Boom B500-mm7Rotating Angle±180°8Trolley Moving Speedmm/Min9Trolley height300mmWelding manipulators are very useful tools for increasing the output of a given welding operation. Welding manipulators allow mechanized torch movement over a wide range of spaces. Welding manipulators eliminate much of the reliance on operator skill, as torch operation is done mechanically. The welding manipulator can be used alone or in conjunction with a workpiece positioner when complex or round parts require it. Many different welding processes can be integrated with the welding manipulator; these include, but are not limited to, submerged arc welding, gas shielded metal arc welding, and gas shielded tungsten arc welding.
With its advanced features and intuitive controls, our welding manipulator is the perfect tool for welding professionals looking to take their work to the next level. Whether you're working on small-scale projects or larger industrial applications, our manipulator is designed to make your job easier and more efficient than ever before.
Featuring a powerful motor, precision control system, and high-quality welding equipment, our manipulator is built to handle even the toughest welding jobs with ease. And with its rugged construction and durable materials, you can be sure that your welding manipulator will stand up to years of heavy use and provide reliable performance time and time again.
Ask us a question about welding robots! Whether you're a seasoned professional or just starting out in the welding industry, our manipulator is the perfect tool to help you achieve your welding goals and take your work to the next level.
Enhanced Welding Precision: Welding manipulators provide smooth and controlled movement of the welding torch, resulting in precise positioning and consistent weld quality. They eliminate human errors and variations, ensuring welds meet stringent specifications and standards.
Increased Productivity: By mechanizing the welding process, manipulators reduce the physical strain on welders and minimize the time required for repetitive movements. This leads to improved productivity, faster welding cycles, and increased output.
Versatile Applications: Welding manipulators find applications across various industries, including oil and gas, construction, manufacturing, and shipbuilding. They are particularly beneficial for welding long pipes, large structures, and components that require precise and uniform welds.
Improved Safety: Welding manipulators enhance safety by reducing the need for welders to work in hazardous or confined spaces. Operators can control the manipulator from a safe distance, minimizing the risk of injuries and exposure to welding fumes or sparks.
One button automatic operation
High quality weld deposits
Wireless remote control panel, real-time display of trolley coordinates
Welding wire broken alarm and break point detection
High productivity in manufacturing
10.2 inch colorful touch screen
Choosing a reliable JINHUA Welding Manipulator is crucial for achieving optimal welding efficiency and performance.
Quality Construction: Our welding manipulators are manufactured using robust materials and precision engineering. Even in demanding welding environments, sturdy and well-crafted manipulators ensure stability, durability, and longevity.
Customizable Configurations: We offer Welding Manipulators with customizable configurations to meet your specific welding requirements. Consider factors such as payload capacity, reach, rotation, and auxiliary functions to ensure compatibility with your workpieces and welding needs.
User-Friendly Control Device: JINHUA Welding Manipulators come with intuitive and easy-to-use control devices, allowing operators to program and adjust the movement and positioning of the welding torch with precision and efficiency.
Reliable Support and Service: By choosing the reputable JINHUA as your Welding Manipulator supplier, you gain access to reliable support, technical assistance, and maintenance services. We ensure timely assistance when needed, minimizing downtime and maximizing productivity.
With a JINHUA Welding Manipulator, you can trust in its quality, performance, and support to optimize your welding processes and enhance overall efficiency.
Welding manipulators play a vital role in enhancing welding precision, productivity, and safety. By investing in a reliable and high-quality manipulator, businesses can optimize their welding processes, achieve consistent and high-quality welds, and increase overall operational efficiency. Whether you require a manipulator for pipe welding, structural welding, or other applications, choosing the right equipment is essential.
Explore reputable suppliers that offer dependable welding manipulators for sale and experience the benefits of mechanized welding. Contact us today at to find the perfect welding manipulator that meets your specific requirements and takes your welding operations to new heights of efficiency and excellence.