The Challenge
Efficient and Accurate Welding of Heavy, Multi-Part Pipe Assemblies
Fabricating 3-piece pipe weldments—often over 1,000 lb—posed several key challenges:
- Automating weld joins across curved seams and compound joints
- Handling large, heavy parts without crane dependence
- Maintaining consistent & repeatable weld quality via precise positioning
- Reducing manual labor and rework in large-part welding
MWES was selected for its proven experience building robotic welding cells for complex, high-mix pipe structures and integration of multi-axis positioners.
The Solution
Dual-Station Robotic Cell Featuring Servo Positioners & Automated Torch Maintenance
MWES built a turnkey system including:
- Floor-mounted SkyHook 4-axis servo positioner to support pipes up to 14 ft in length
- Two welding zones: one for root welding and one for cap welding
- Hot-pass and cap-pass welding sequences performed via dual ABB welding robots
- Automated torch maintenance station to clean and dress tips on demand
- Recipe-based control for part size and material tracking, with load/unload station mirrored on opposite side
- Safety interlocked light curtains and integrated cell flow logic
This solution integrates robot welding, torch maintenance, and part positioning seamlessly. In summary, the system delivers a continuous, precision-supported weld workflow—achieving consistent quality without operator intervention.
The Results
Faster Cycle Times, Consistent Weld Quality & Safer Operations
The MWES pipe weld cell delivered impactful results:
- Achieved consistent, repeatable weld sequences with minimal operator oversight
- Eliminated manual weld handling on large parts, improving safety
- Reduced rework and improved first-pass weld quality via recipe control and maintenance routines
- Operated across multiple shifts with only 1–2 operators managing load/unload
By combining automated torch maintenance, precision positioners, and dual-zone welding stations, MWES enabled faster pipe fabrication, greater safety, and consistent quality in heavy-duty welding operations.
