Customize Your Automated Welding System
AMET specializes in building custom automated welding systems to meet our customers’ specifications. Our advanced controls allow us the flexibility to adapt for a wide range of applications from high precision GTAW welding for aviation industry engine components to heavy-duty SAW welding of wind towers. We are able to incorporate multiple weld processes, safety equipment, real-time tolerance checking, arc viewing systems as well as a variety of sensors to constantly monitor the weld process. These capabilities can be integrated with our full line of weld fixtures or a custom weld fixture can be built.
Additional features are also possible. If you do not see the feature you are looking for in the Optional Features section please contact us. Odds are, we have created something similar. If not, we can most likely develop the feature you need.
30+ Years of welding Automation Excellence
The capacities of these systems depend upon which type of system is needed. If it is based on one of our standard fixtures, please refer to the products pages for additional information on capacities for each type of system. If you need a completely customized solution or one with additional capacities, then contact us so we can develop one to your specifications.
AMET specializes in providing completely integrated systems. These systems can be tailored to meet your needs. Any of the options listed in the Optional Features sections can be applied and integrated for a customized system. If the option you need is not in the Optional Features section, then contact us. One of our greatest strengths is the ability to build completely customized solutions. Whether it is designing a welding fixture to meet your specifications or developing new motion or monitoring software, we are confident we can create the automated welding solution for your application.
No matter which AMET solution is appropriate for your needs, our precise controls are at the center of each system we produce. All systems are equipped with servo motor driven encoder-based motion for all welding axes. Each motion axis is equipped with precision ground rails for accurate and smooth motion.
The following capabilities are standard features with all AMET control systems:
- Programmable Motion Axes: Precise velocity and position control
- Welding Power Supply: Capable of controlling and programming all weld parameters of many welding power sources directly from the weld controller
- Gas Control: Gas on/off control with manual flow controls.
- Automation Control: Up to 10 pre-weld and 10 post-weld functions are available for each weld program
"AMET has been a great partner because they are appropriately positioned to act when we need a new solution engineered or need to service an existing solution. In the end the price of a solution is negligible if it works properly, and the vendor can keep it working through their service efforts. AMET knows these things and services their customers accordingly."
- Matrix Drilling Products
"For over 15 years now I have had the privilege of working with AMET. I have personally seen how AMET Inc. industry knowledge and engineering expertise has enabled my business to increase weld quality and production and allow our clients to improve the strength and durability of their products."
- G. Wright's Welding Ltd.
"AMET’s team is exceptional to work with. They look at the provided solution as a whole – from operator interfaces to engineering requirements, they seek to understand the customer’s needs throughout the project. This results in a welding system that is robust, embraced by the workforce, and meets the rigorous requirements of Blue Origin’s vehicles and engines. We’re excited to work with AMET on our vision of millions of people living and working in space."
- Blue Origin
1. A huge benefit to our Custom Engineered Automated Welding Systems is the combination of hardware and software that is designed in house to work together.
2. The architecture used in AMET’s controls allow us to accommodate a wide range of power supplies, fixturing, safety, and automation. Many tasks can be automated, alleviating operator fatigue and increasing productivity.
3. A combination of motorized and manually adjusted axes can be implemented to facilitate the most efficient use of the automation capacities in AMET’s controls.
4. Adding camera systems to observe and record welds can be helpful when welding in remote or hard to view locations or when safety is in question.
5. AMET can integrate our Custom Engineered Automated Welding Systems in nearly any type of fixture, from small bench top lathes, to seamers, to gigantic column and booms. If your application isn’t on our website, give us a call.
6. High quality cable is used throughout each system and is cut to length in order to keep a clean look and make an efficient use of space.
7. Our advanced controls can interface with many welding power supplies. If you have a certain PS in mind for your application, ask if our controls can communicate with it. Or we can choose a supply that will work best for your budget and application.
8. Each of our Custom Engineered Automated Welding Systems is installed by our staff of experienced technicians to ensure proper setup of the custom weld system.
ARC VIEWING CAMERA
Arc Viewing Cameras can be added to a GTAW/PAW system giving the operator a view of the weld arc from a remote location. This keeps the operator in a safe location and reduces operator stress and fatigue. Additionally, the image that is shown on the monitor is magnified and shows greater detail than what could be observed without the camera. Multiple cameras may be integrated for projects where a view of the lead and trail side of the weld zone is required. Please see the Arc Viewing Camera page for additional information.
MULTIPLE PROCESS WELD HEAD
Our advanced controls allow us to integrate multiple weld processes into one weld head. Each process can be operated independently or simultaneously. For example, a TIG & Plasma weld head would feature two AVC axes (one for each torch) and either torch could operate or they can both operate simultaneously for Keyhole Plasma with a TIG trail. We offer TIG & Plasma, TIG & MIG, TIG MIG & Plasma, and SAW & MIG. Any of these combinations are available and would be completely programmable from ONE central controller. Other combinations are also available. Please contact us with any requests.
FLUX DELIVERY AND RECOVERY SYSTEM
The entire system is air-pressurized and heated to provide continuous flux delivery and recovers unused flux to help reduce costs. The system consists of a feed tank, delivery and recovery unit with 5 HP vacuum, and hopper for delivery at the weld head. The hopper is equipped with a valve to allow the operator to control the ratio of new and recovered flux delivered at the weld head.
A precision servo motor driven ball screw slide with encoder feedback provides mechanical oscillation. The oscillation motion is completely programmable including dwell time, oscillation frequency and width, and travel speed.
DATA ACQUISITION AND TOLERANCE CHECKING SOFTWARE
Data is collected and analyzed in real-time to ensure all modules are within the set tolerances. The data points can be displayed graphically on the display and can also be exported as a .csv file and viewed on a program such as Microsoft Excel. These files can be exported through one of the USB or Ethernet ports on the XM® or XPro Controller.
MULTIPLE WIRE WELD HEAD
AMET® specializes in offering custom weld heads. We offer GTAW and PAW weld heads with two wires. The wire feeders can be synced to operate simultaneously or they can be separated to operate independently. We also offer multiple wire SAW head welds. Up to 10 wire weld heads can be integrated with our control packages for applications such as cladding. Tandem or triple wire weld heads are also available for thick wall welding applications.
AMET® manufactures a full line of high precision turn tables with weight capacities from 550 to 22,100 lb (250 to 10000 kg). We also offer standard version turn tables with weight capacities from 2,200 to 132,200 lb (1000 to 60,000 kg). Each turn table faceplate includes a thru-hole for a gas purge device.
Magnetic probe is used to deflect the arc back and forth in a stirring motion for excellent sidewall tie in. The arc can also be deflected and maintained in a set position. This can be beneficial for fillet or otherwise hard-to-reach joints. Dwell time, oscillation frequency, and width are all programmable from AMET® controls. Compatible with both magnetic and non-magnetic materials.
LASER SEAM TRACKING
The XM® or XPro integrate with a laser sensor to scan and track the weld joint during welding. The laser continuously scans the joint profile and makes the necessary adjustments to ensure the torch maintains the programmed location. The scanned profile is also displayed in real-time on the operator console monitor. Seam tracking can be configured for single or multi-pass welds.
AMET® manufactures a wide range of positioners with weight capacities from 550 to 22,000 lb (250 to 10000 kg). They feature 135 degrees of motorized tilting and continuous motorized rotation. The rotation axis can be integrated with the XM® or XPro to provide programmable control for welding operations. High-precision models are also available with harmonic drive rotation for the most stringent needs. The standard configurations include a fixed base, but an elevating base is also available. Each positioner includes a thru-hole for a gas purge device.
SPIRAL PATH AND STEP-INDEX CLADDING
The vertical or horizontal axis is integrated with the rotary axis to provide precise cladding motion. We offer both Spiral Path, and Step-Index cladding options. Spiral welds begin at the bottom of the part and spiral upward until the defined height is reached. Step-Index clads in a straight line for each revolution of the part. After each revolution is completed, the torch steps upward and begins the next pass. The pitch of the spiral and the step height are programmable.
AVC FOR GTAW/PAW SYSTEM
An AVC (Arc Voltage Control) Module is added to provide the weld head with automatic arc standoff. The module provides automatic height adjustments to maintain a consistent arc voltage throughout the entire weld, including automatic adjustments on multi-pass welds.
COORDINATED MOTION MODULE
Up to four motion axes can be integrated together. This allows each axis to function and coordinate together, much like the axes of a CNC milling machine, to perform welds on unique part geometries.
CHUCK ADDED TO TOOLING
A manual chuck or gripper can be added to the headstock or tailstock of a lathe or to the faceplate of a turn table or positioner for manual part gripping/holding.
CAMERA SYSTEM (SAW)
A video camera and cross-hair laser generator are mounted to the weld head to aid in monitoring during welding operations. The video feed is displayed in real-time on the operator console monitor. The camera is also used to aid in positioning the torch(es) during setup.
VIRTUAL ALIGNMENT (TEACHING MODE)
The operator can “teach” a weld path by manually moving the weld torch along the seam and selecting points. Up to 20 points can be selected to create a circumferential, longitudinal, or combination weld path. After all of the desired points are selected, the system will retrace each one to create a custom weld path. This can be helpful if parts or materials vary or have unique joint configurations. The path can be repeated for multiple pass welds, or offsets can be applied to repeat the motions of the original path in a new location.
AMET® manufactures fit-up stations for aligning two sections prior to welding. The fit-up stations feature four (4) wheels that are controlled hydraulically. The wheels are divided into pairs A & B and C & D, and there are several options for moving them to accommodate a wide range of applications. The following motions are possible: each wheel can be moved independently (in/out from the centerline), each pair can be moved simultaneously (in/out or side-to-side), or all four wheels can be moved simultaneously. The fit-up station can also be mounted on a rail system and have motorized motion in a growing line system.
INTEGRATED PURGE/BACKING GAS
This package includes a gas union, digital solenoid, manual flow meter, and a gas line from the solenoid to the gas union for purging or backing gas capability. The digital solenoid is integrated with the XM® and XPro Controllers for programmable and manual on/off control of the gas. Programmable flow control is also available.
SYNCHRONIZED HEADSTOCK AND TAILSTOCK
This feature adds synchronized rotation between the headstock and the tailstock, so rotation begins simultaneously and then continues at the same speed. The advantage of this feature is that AMET® does not link them mechanically, but electronically. Each one is servo motor controlled with encoder feedback, so they can be clocked to different positions. This is beneficial if one end of the part is required to be welded at a 90 (or any other) degree offset of the other end.
TRAVEL CART WITH RAILS
Manipulators can be mounted to a travel cart for increased capacity. The travel carts are typically motorized, but are available as non-motorized units for our two smallest classes of manipulators. The motorized travel cart can be operated independently for positioning purposes or upgraded and used as a welding axis for longitudinal welds.
Both the horizontal and vertical boom motion can be upgraded with a servo motor and encoder for precise programmable control of the boom. The upgraded motion axis can then be used as an additional welding axis.
Includes hardware and software that allows weld programs or data to be transferred between a PC or sever and the XM® Controller wirelessly.
We integrate components into our controls for automating additional functions other than the welding process. These components include safety equipment such as automatic weld screens or curtains that are programmable to automatically open and close at the end or beginning of each weld. We can also integrate additional tooling such as automated part loading equipment.
The travel cart can be extended for mounting the weld equipment next to the manipulator to keep everything centrally located. This helps eliminate excess cabling and reduces trip hazards.
Arc initiated by touching the torch tip to the part for GTAW and PAW applications. This capability requires an AVC module.
BAR CODE PROGRAM SELECTION
Weld programs can be automatically selected by scanning a bar code associated with a specific part. This can help eliminate the incorrect program being loaded and run. Beneficial if many different parts are to be welded and operator needs to frequently switch between weld programs. Includes the bar code scanner and the necessary software to integrate with the XM® or XPro Controller.
COMPLEX INTERSECTING BORE CLADDING
Includes all of the features from the Intersecting Bore Cladding option with the addition of automatically cladding bores at off-center and off-angle intersections.
PROGRAMMABLE GAS CONTROL
Adds programmable gas flow control for GTAW and PAW applications.
AMET® offers several sensors to monitor several functions and aspects of the weld. Each one of these sensors can automatically terminate the weld program if levels exceed the set parameters. The following sensors are available:
• Humidity Sensors – measures humidity levels at the weld puddle
• Oxygen Sensors – measures oxygen levels at the weld puddle
• Water Sensors – monitors water flow for components such as torches
• Gas Sensors – monitors gas flow for shielding/backing/purging gas
STEEL HOSE MANUFACTURING
AMET has helped clients automate their welding processes for steel hose manufacturing. Seam welding is an efficient way of producing custom tubing from thin wall steel and stainless steel for use in a wide range of industrial and exhaust applications. Once welded, the tube may be outfitted with specialized end fittings or hydroformed into corrugated tube for flexible connections.
Made of heavy-duty structural steel, girders are typically manufactured and welded using single or multiple wire SAW weld processes. We provide several automated solutions for thick section welding.
Parts with intersecting bores can be welded with AMET’s welding systems. This is facilitated by our use of intelligent software matched with premium hardware.
Blowout preventers require corrosion-resistant overlays of the bores and components to ensure they can withstand harsh oil and gas environments. Our systems and controls provide an excellent solution for BOPs whether your company is the primary manufacturer or performs repairs.
TANKS / PRESSURE VESSELS
Stainless steel, or other materials, can be used to form tanks or pressure vessels of various sizes for the food and beverage or pharmaceutical industries. These vessels are typically fabricated using GTAW, PAW, or VPPAW, but with each process, AMET can provide a fully automated turnkey weld system to meet your needs.
Often constructed of stainless steel or aluminum, fuel tanks require full penetration high integrity welds to prevent leaks. AMET’s welding systems are capable of welding fuel tanks in a wide range of shapes and sizes.
AMET’s automated welding systems offer several options for welding pipe fittings such as tees, elbows, and flanges with butt or socket joint configurations.
ID and OD pipe cladding are available on our systems. We offer spiral and step-index cladding to fulfill the needs of most applications.
Oval-shaped or “racetrack” bores can be easily programmed and clad with the CMC-66 bore cladder. Additional equipment or specialized fixtures are not required to completely clad the bore from bottom to top.
OIL RIG COMPONENTS
AMET’s SAW welding systems provide the robust equipment necessary for welding components for deep sea oil rigs. Legs and other components can be welded using single or multi-wire systems.
Cylinders used for pressurized air storage such as air compressors, portable air tanks, and truck brakes. Manufacturing of these cylinders requires longitudinal and circumferential welds.
THICK WALL SECTION WELDMENT
Thick wall section welding is a common practice in many industries. Submerged arc welding is common for these types applications, and we offer single and multiple wire solutions. Our systems can be adapted for longitudinal and circumferential welding to meet your needs.
Wind towers require extensive manufacturing and welding of heavy-duty components. Each wind tower consists of multiple cans that are welded both longitudinally and circumferentially. AMET has provided several systems for the wind tower industry using the XM Controller and SAW welding process.
Valves used in the oil and gas industry often require corrosive resistant coatings on sections of the inner diameter or along the entire length. Bore cladders are used to apply the corrosive resistant metals to the ID of valves.
Circumferential welds are necessary to join the cylinder and the end cap fixture. AMET’s lathes are ideal for welding hydraulic components like these because they can be set up to accommodate a wide range of weld processes and cylinder sizes.
Ball valves require corrosion-resistant overlay for use in the oil and gas industry. Our systems are programmable to automatically clad around the opening of the ball for a completely automated solution.
Precision engine components for the aerospace industry have tight tolerances and strict quality control. Precision motion and repeatability are essential when manufacturing these components. AMET’s servo controlled axes of motion are well-suited to meet such stringent requirements.
TRACTOR TRAILER TANKERS
These tankers are used in the transportation industry to haul oil/gas, water, or other liquids. Longitudinal and circumferential welding are essential for the manufacturing of tractor trailer tanks and AMET offers a full line of weld lathes and linear seam welding systems for tank manufacturing.
Stainless steel, steel, and aluminum pipes can be welded using AMET’s systems and controls. We offer systems with manual and programmable weld head positioning along the length of the pipe.