Machine Overview

This is a fully automated PLC based GTAW butt welding station which shall be fixed in the workshop. There will be a water cooled Torch mounted on slides arcing with the rotating job and the filler wires fed automatically in the weld pool.

The welding torches will be quick change type which shall give total flexibility to the machine. The welding parameters like current, voltage, welding speed, wire feed, step over etc will be programmable and controllable via PLC and will have overrides through a handheld remote pendant.


  • Fabricated structure on lockable wheels
  • This frame is mounted with XYZ axis, indexer, Torch, HMI, etc
  • Linear movement of 12 m
  • Drag chains for cables and hoses
  • Emergency switch on the side


  • Manual y slide for fine adjustment of center.
  • Ball screw is driven z slide for AVC and to reach sizes from 6” to 24”
  • 400W servo motor for Z slide
  • Ball screw is driven X slide for fine adjustment of joint center and for weaving and stepping in cladding mode for capping
  • 400W servo motor for X slide
  • Manual indexer for tilting the torch up to 45 deg either side for better reach on side walls.
  • Limit switches at either end of the X and Z axes.
  • Sheets to cover rail and ball screw


  • Especially “built for purpose” compact feeder
  • Grooved roller and spring-loaded bearing type.
  • Independent tensioner screw
  • Anodized aluminum body
  • Coupled with a 400w servo motor
  • Wire guide bushes on entry and exit for smooth loading of the new spool
  • Wire feeding almost in a straight line to the torch head


  • 400 amps water cooled tig torch
  • The anodized aluminum collet body
  • PVC-mounted terminal for water and gas connections
  • Quick-release coupling for PU water and gas hose pipes
  • Collet nut for torch holding


  • The PVC spool holder is fixed in an angle to avoid falling
  • Can accommodate up to 15 kg spools


  • Fully Digital Inverter Type Power Source
  • Optimized For Automated Applications: Unique Second-Generation Digital
  • System For Reproducible Welding Results of  The  Highest  Possible  Quality, Easy To Integrate Into Automated Systems
  • Heavy Duty 550 Amps With 420 Amps 100% Duty Cycle.
  • DI/DO and Ai/AO Signals to Plc.
  • 95 SQMM HOFR Cables for Positive and Negative Leads.
  • Extended Warranty Terms.
  • Ac Hot Wire Power Source for Enhancing Deposition


  • Box construction to protect motor & gearbox
  • 1.2 m x 3 tons capacity bed
  • 3 kW servo motor|1:80 heavy-duty gearbox
  • O.1 to 5 rpm
  • Tapped holes for job clamping/setting purpose
  • 3 jaw self-cantering chuck
  • Tool mark at different pcd for job truing assistance
  • Slewing ring|wheels|screw jacks
  • Cable drag chain
  • Insulated spring-loaded earthing bush


  • Long drag chain for a frame to move 6 M total length
  • Small drag chain to accommodate cables and hoses through Z axis
  • Made from premium PVC with excellent bending ability
  • Simple to fix end brackets


  • Fabricated structure on wheels
  • Scissor jack with hydraulic cylinder movement
  • Simple hand lever to operate cylinder from an oil pump
  • Mounted on wheels for linear adjustments
  • Less no of moving parts for low maintenance


  • 2 Door air-conditioned panel conforming to IP 55
  • Screwless male-female connectors on the side for field signals
  • DIN rail-mounted PLC, SMPS, Relay boards, Terminals, MCB
  • Servo drives, Isolators, Line chokes
  • Printed ferrules|printed labels, min o.5 sq mm wires, AC DC isolation
  • Front or top-mounted HMI
  • 1000 w panel A\C
  • 200 mm high covered stand
  • Cable glands for servo encoder and power cables
  • Separate earthing strip for individual earthing of each component


  • 2.5 kW capacity
  • Refrigerated cooling with a minimum of 14 DEG. settable
  • Flow and temperature interlock
  • 1-phase pump and compressor
  • Quick release coupling for water “IN” and “OUT”
  • Aluminum extrusion body
  • Water flow switch to give potential free contact
  • Working temperature up to 50 DEG. ambient


  • RYB phase indication
  • Single connection required from the customer side
  • Independent MCB for power source, chiller, control panel, hot wire unit
  • Neat routing through cable trays and drag chains


  • 10” Touch Screen HMI for Data Entry, Operations, Alarms, Data log, Display
  • Optional wireless 10” Android Tab


  • 5” wireless android-based pendant
  • Full-function buttons for various overrides
  • Essential parameter values in real-time on display
  • Unique IP address to avoid cross connection
  • Android app which can be loaded on a normal phone


  • Process: Auto Pulsed Tig
  • Min Dia : 6” Pipe
  • Max Dia : 24” Pipe
  • Max tilting of Torch: 45 deg either side
  • Max weight: 7000 kg

Functions in Manual Mode:

  • Carriage Plate “FOR“REV” movement
  • X“IN” “OUT” movements
  • Z “UP”“DOWN” movement
  • Torch tilt CW/CCW
  • Wire FOR/REV
  • Rotator CW/CCW Inching
  • Rotator 90deg inching for fast truing
  • Gas Test and flow adjust

Functions in Auto Mode:

  • Cycle Start and Down slope
  • Incr/Decr of:
    1. Current (5 Amps per touch default)
    2. Voltage (0.2 V per touch default)
    3. Rotation (10 mm/min per touch default)
    4. Wire Feed (25 mm/min per touch default)
    5. Step Distance (0.5 mm per touch default)

    • AVC ON/OFF
    • Wire ON/OFF


  • All AC Servo motors
  • Panel A/C for control panel
  • Single power connection required from customer end to our DB
  • Butt Weld and Cladding options with AVC
  • Weaving for butt welding
  • Choice of STRING or SPIRAL Bead
  • Over ride of Volt|Current|Weld Speed|Wire Feed Step distance from the Pendant.
  • Full control of Power source from PLC/HMI/PENDANT
  • Touch Retract function for fixed HF distance and consistent starts
  • Torch and wire retract on down slope
  • One touch 90 deg rotation in manual mode for quick truing of job
  • Dry run (test) mode for parameter checks
  • Separate cycle for job cooling
  • Data logging of parameters like volt, current, wire feed and welding speed
  • Real time graphical representations of essential variables including heat input
  • Correction of parameters in real time through Pendant
  • Total wire consumption (indicative) in kg on display
  • Interlocks with Water flow, Gas flow and XZ limits and indication on alarm page
  • Interlocks with Lower and Higher limits of voltage and current
  • Virtual full function pendant on HMI
  • Different pages for Alarm, Data, Display Operation and Data Log/Trend
  • XZ positions and Rotator angle & rpm on display page
  • Engineering parameters on a password protected page
  • Remote access to PLC through team viewer or similar software
  • Android based Wireless Pendant with unique IP addresses
  • Display of values of essential variables on Pendant


  • PLC: Omron
  • HMI: Exxor with WIFI facility to copy HMI on Tab
  • Servo Motor & Drive: Omron
  • SMPS: Omron
  • Isolators & terminals: Phoenix Germany
  • Motor Encoder & Power Cables: Lapp Germany
  • Enclosure: Eldon
  • Switch gears: Hager
  • Panel AC: Advanced Cooling India
  • Chiller: Advanced Cooling India
  • Torch Heads: Sap Industries/Sine Automation
  • Structure: Local, India
  • Paint: Standard PU with a coat of laquer


  • Data logger in HMI
  • One spare torch
  • One spare pendant for every 2 machines
  • Consumable torch spares for 3 months continuous operation
  • Other spares like cu tubes, connectors, flow switch, flow meter.
  • Any special feature required with respect to software
  • Tool box with necessary tools like spanners, wire cutter, alley key set, plier, hammer, measuring tape, torch light etc.
  • Welding helmet and glasses
  • 16 GB USB Pen-drive to retreive data