Welding Systems
State-of-the-Art Welding Systems Engineered to Your Production Needs.
Maximise your wind tower and monopile foundation manufacturing with our cutting-edge column and boom welding manipulators and multi-seam welding stations. At Key Plant Automation, we redefine industry standards by providing innovative solutions that enhance deposition rates, productivity, and arc-on time. With years of experience in the industry, we bring unparalleled expertise and knowledge to every project. Our team is dedicated to delivering solutions that meet and exceed your unique manufacturing requirements.
Increased Deposition Rates
Boost your welding efficiency and achieve higher deposition rates with our advanced welding systems. Experience faster weld speeds, reduced downtime, and ultimately, increased productivity.
Enhanced Productivity
Our systems are engineered to maximise productivity, allowing you to meet tight deadlines and scale your operations. Benefit from optimised processes that streamline your workflow and enhance overall efficiency.
Extended Arc-On Time
Minimise downtime and maximise your arc-on time with our reliable welding manipulators and seam welding systems. Our technology ensures consistent performance, reducing the need for frequent interruptions.
Column and Boom Welding Manipulators.
Are you looking to elevate your wind tower and monopile production to new heights of efficiency and quality? Look no further than Key Plant Automation’s state-of-the-art Column and Booms (C&B) designed exclusively for the renewable energy industry. Key Plant Automation specialises in designing, manufacturing, and installing tailor-made solutions as turnkey projects. Our commitment to customisation ensures that every Column and Boom is meticulously engineered to meet the unique requirements of our customers.
Long-Seam Column & Boom
Our Long-Seam C&B welding system stands out as a welding technique tailored for welding the long seam on individual cans. Operating in conjunction with a set of rotators, this method accommodates larger diameters, and additional wheels on the side provide stability during the welding process. The strategic placement of the operator by the welding head ensures continuous inspection and slag removal, contributing to the overall quality of the weld. This method offers a systematic approach, allowing one can to be welded at a time, streamlining the process.
Flange-to-Can Column & Boom
Traditionally, attaching and welding the round seam between the flange and can has been a challenging and time-consuming task on the growing line, especially when securing the flange to the initial or concluding can in a tower section. Addressing this challenge, the Flange To Can C&B welding system emerges as an optimal solution. Collaborating seamlessly with a tilt-table and a tack-table, the FTC welding system streamlines the entire welding process. (The FTC can be used without a tack-table and tilt-table, but it is not recommended). By concurrently welding both inside and outside, it significantly minimises welding time, ensuring meticulous precision and strict adherence to tolerances. The incorporation of cameras empowers operators to supervise the process from the ground, fostering improved working conditions. This innovative system plays a crucial role in boosting efficiency and overcoming the inherent difficulties associated with welding flanges.
Flange-to-Can Column & Boom
Traditionally, attaching and welding the round seam between the flange and can has been a challenging and time-consuming task on the growing line, especially when securing the flange to the initial or concluding can in a tower section. Addressing this challenge, the Flange To Can C&B welding system emerges as an optimal solution. Collaborating seamlessly with a tilt-table and a tack-table, the FTC welding system streamlines the entire welding process. (The FTC can be used without a tack-table and tilt-table, but it is not recommended). By concurrently welding both inside and outside, it significantly minimises welding time, ensuring meticulous precision and strict adherence to tolerances. The incorporation of cameras empowers operators to supervise the process from the ground, fostering improved working conditions. This innovative system plays a crucial role in boosting efficiency and overcoming the inherent difficulties associated with welding flanges.
Super Extra Heavy Duty Column & Boom
Specifically designed for welding the outside round seam on large section pieces, the SEHD C&B method finds its application in joining sections for floating foundations. The operator is strategically placed by the weld head, facilitating seamless control during the welding process. Equipped with an elevator for easy access to the weld head, this method ensures optimal working conditions. Alternatively, the SEHD C&B welding system can be adapted to utilise cameras, allowing operators to oversee the welding process from ground level. This flexibility makes SEHD C&B a versatile and efficient choice for various welding applications.
Telescopic Column & Boom
Utilising a telescopic column and boom welding system offers the advantage of space conservation on the opposite side of the column. The telescopic boom retracts and fits neatly inside the main boom arm, eliminating the need for an equivalent amount of space behind the column as in front of it.
Telescopic Column & Boom
Utilising a telescopic column and boom welding system offers the advantage of space conservation on the opposite side of the column. The telescopic boom retracts and fits neatly inside the main boom arm, eliminating the need for an equivalent amount of space behind the column as in front of it.
Focus on Operator Ergonomics
Efficiency starts with the operator, and Key Plant Automation places operator ergonomics at the forefront of design. Our Column and Boom systems feature top-of-the-class operator chairs, ensuring comfort during extended operation hours. All controls are strategically placed within easy reach, optimising workflow and reducing operator fatigue.
Precision in Welding Applications
Our manipulators are engineered to redefine automated welding processes. From inner and outer welds to circumferential and longitudinal applications, Key Plant Automation’s Column and Boom systems deliver unmatched precision. We are committed to optimising your fabrication throughput and enhancing weld production quality.
Innovative Wind Tower and Monopile Production
Choose Key Plant Automation for a future-focused approach to wind tower and monopile production. Our Column and Booms set the standard for excellence, combining cutting-edge technology, customisation, and ergonomic design to elevate your operations. Experience the difference with Key Plant Automation – where innovation meets efficiency.
Integrated Robotic Welding Solutions
Step into a new era of welding excellence as Key Plant introduces its advanced column and booms seamlessly integrated with robotic welding technology. Already partnered with a welding robot solution? No worries – Key Plant offers tailored solutions to amplify productivity and innovation. Experience precision like never before, as our integrated systems ensure meticulous accuracy in every weld, eliminating rework and delivering flawless results consistently.
Big Bag and Buffer System.
Discover the KP 1000kg Big Bag & Buffer System, an advanced solution intricately designed to meet the distinct needs of the welding industry, specifically optimised for SAW (Submerged Arc Welding) applications.
Experience a reliable, efficient, and cost-effective solution for flux handling with our innovative system, enhancing productivity and preserving the integrity of your welding processes. Step into a new era of welding with confidence as the KP 1000kg Big Bag & Buffer System promises to redefine your welding experience, offering unparalleled reliability, efficiency, and affordability.
Multi-Seam Welding Station.
Introducing an unparalleled and optimised Multi-Seam Welding Station designed for welding the outside round seam on fully tackwelded sections using SAW welding. This cutting-edge station redefines standards by offering exceptional productivity, uptime, and utility rates in the manufacturing of onshore/offshore wind towers and monopiles. The innovative cutting-edge automated solution boasts up to 4 welding heads in a single station, setting it apart as an unmatched technology.
Discover the tailored excellence of our Multi-Seam Welding Station, meticulously manufactured to align with your unique specifications and seamlessly integrate with your current production setup. Elevate your welding process with our automated and optimised solution, designed specifically for the Submerged Arc Welding (SAW) technique.
Experience unparalleled productivity, maximum uptime, and optimal utility rates with our Multi-Seam Welding Station, enhancing the efficiency of manufacturing onshore/offshore towers and monopiles. This innovative, state-of-the-art solution boasts up to four welding heads within a single station, promising a cutting-edge and streamlined approach to your welding operations.
Enhanced Daily Output
Achieve our overarching objective of increased productivity by generating a considerably higher number of products per day. 4 x the deposition rate of a standard C&B.
Tailored Precision
Engineered to meet your exact specifications, the Multi-Seam Welding Station is uniquely customised to seamlessly integrate with your existing production equipment.
Singular Operator Control
A single operator effortlessly manages and oversees the Multi-Seam Welding Station equipped with up to four welding heads.
Tailored Weldhead Solutions for Unmatched Performance
Tailor your welding experience with our customisable weldheads for Column & Booms and Multi-Seam Stations, offering a range of configurations to meet your specific needs. From x-groove and v-groove to narrow gap and various combinations like single-single or single-twin, we empower you with flexibility.
Our weldheads go beyond standard customisation by allowing individual adjustments based on your preferences. Whether it’s the type of flux recovery system, automation level on flux supply, contact nozzles, cameras, weld controls, or other specifications, we ensure that each weldhead configuration is precisely tuned to your unique requirements. Experience welding on your terms with our highly adaptable and personalised solutions.
