Welding Manipulators

Welding Manipulator – The Ultimate FAQ Guide

The welding industry has a lot of equipment and technologies to aid the process. There are welding manipulators, welding positioners, rotators, and so on.

Among those, the welding manipulator is deemed as the most efficient machinery. We’ll find out why at the end of this article.

This FAQ guide will be finding out all about welding manipulators. We’ll discuss what they are, how they differ from other equipment, how you can use them to your advantage, and the like.

What’s a Welding Manipulator?

It’s a technology that helps in the welding process by moving the welder over the workpiece.

Welding manipulators are just part of the many advancements in the welding sector.

How Does a Welding Manipulator Work?

You can understand to the fullest extent how a welding manipulator works. It’s actually simple.

Its purpose is to move the welding head closer to the workpiece; it will allow you to reach parts and areas that a welder with high skills can.

In simpler terms, it enables and enhances the welder’s lifting capability so that it reaches closer to the workpiece or the part to be welded.

What’s a Column & Boom Welding Manipulator?

It’s a type of a welding manipulator that consists of the welding boom and the column.

The column is what helps you to hold the workpiece in place, so that the welder can work on it. Welding booms are the part that helps you have complete coverage of the area being welded.

It’s a perfect machine you can use to handle any welding positions. It’s mainly used to weld on difficult parts of a particular machine or equipment.

What is a Welding Positioner?

It’s also a welding machine, which can help you automate the shifting of the workpiece.

Many people confuse weld positioners and weld manipulators, when they are actually two difference pieces of equipment.

Is Welding Positioner the Same as Welding Manipulator?

No, a welding manipulator is not the same as a welding positioner; in fact, they’re a lot different.

You would want to use a welding positioner if you want the workpiece to be kept in place. You would want to use a welding manipulator if you want to reach positions and angles that are far.

So, the welding positioner moves the workpiece, while the weld manipulator moves the weld head.

They have the same goal – to help you with your welding project.

However, they actually have different and separate functionalities and operations.

Why Should You Use a Welding Manipulator?

Welding manipulators can help you with any welding project. If you have welding projects that are difficult to complete, welding manipulators can aid and assist you.

Even the most skilled and the most talented welder would have limitations; that’s what welding manipulators are for.

Who Needs to Use a Welding Manipulator?

You would need to use a welding manipulator if you have a project that has far reach. Meaning, if there are areas that a regular welder can’t reach, using a welding manipulator can help.

In fact, in many welding projects today, almost all welders prefer using it because of its ease.

What is a Welding Boom?

It’s a machine that provides coverage of the welding area as a whole. It’s the component of a welding manipulator that allows welders to work on hard-to-reach places and angles.

Different welding booms from different companies have their own functionalities. So, you would need to know which one works for you and which doesn’t.

What is a Column & Boom Machine?

It’s’ a kind of a welding manipulator that can help you with many types of welding.

The boom is the welding arm or the welding extension hand. It reaches far places off of the workpiece, helping welders achieve complex welds easily.

The column is a machine where the boom can travel up and down, which is planted on the ground.

You can choose to use them for workpieces that are hard to large, hard to reach, and the like.

Here’s a quick video of what a column & boom welding machine is:

How Does a Column & Boom Welding Machine Function?

It functions as a type of machine that can perform the welding for you.

Even if you use a manual column & boom, welders wouldn’t have to hold the weld head. The machine is fixed on the ground via the column, and the boom is the only part moving.

Welding Boom Design and Structure

The design of the welding boom is closely related to that of a robotic arm.

It’s a machine that continuously moves the weld head closer to the surface of the workpiece. The common structure of a welding boom would include:

• Boom Arc Swing
• Rack
• Gearbox and Gearbox Base
• Boom Motor
• Cable Chain

These are the primary parts of a welding boom; if one is missing, it might not be able to work and operate.

Is a Column & Boom a Welding Positioner?

A column & boom is not a welding positioner because it doesn’t move the workpiece.

It’s considered as a welding manipulator because the boom is the one moving.

Its main function is to move the welding material to the workpiece.

Oftentimes, a welding positioner is used with a column & boom welding manipulator.

It holds the workpiece in place and does the job of positioning it.

Mechanical Parts of a Column & Boom Welding Machine

A column & boom can be divided into four (4) parts: column and boom, base, and the carriage. Each of them have their own parts.

The main mechanical parts of a column & boom machine includes:

Column

• Column & Elevation Gearbox
• Column Safety and Elevation Rack
• Limit Switches
• Brackets
• Column Strikers
• Elevation Pinion

Boom

• Motor
• Shaft
• Limit Switch
• Cable Chains
• Adjuster Plate (Gearbox)
• Feet (Gearbox)
• Boom Pinion
• Rack

Column & Boom Welding Machine Electrical Parts

Column & boom welding machines have a lot of electrical parts. But, here are parts that are the most used and sought after:

• Boom Motor Inverter
• Relay
• Terminals
• Transformer
• 1, 2, and 3 Pole Circuit Breakers
• Emergency Stop Button
• Earth Terminals
• Contactor
• Fuse Holders

The parts of a column & boom welding machine will depend on the manufacturer.

Advantages of Using a Column & Boom Welding Machine

You can gain a lot of advantages if you use a column & boom welding machine.

But, the benefits would revolve around the safety of your welders, and the efficiency of the project. The most common ones include:

• High quality of welds, including difficult and critical welds
• Flexibility and versatility of the weld
• Higher and better productivity
• Welder and staff member safety and security
• Decreased welder fatigue
• Reduced floor space
• And many more

What Workpieces Can You Work On Using a Column & Boom?

You can work on a wide variety of workpieces, especially those that are heavy and complex.

You’ll be able to work on pipes and tubes, tanks and vessels, even angular workpieces.

So long as it can impose a challenge to your welder, column & boom welding machines can help!

What Welding Can You Perform With a Column & Boom Machine?

A lot of people don’t know it, but they can perform many different welding processes using column & boom welding machines.

SAW or submerged arc welding isn’t the only welding solution, it can also include:

• Gas Tungsten Arc Welding (GTAW) or TIG Welding
• Gas Metal Arc Welding (GMAW) or MIG Welding
• Flux-Cored Arc Welding (FCAW)
• Plasma Arc Welding (PAW)

Here’s a video of the different types and kinds of welding:

Benefits of Using Welding Manipulators

Can welding manipulators really help you?

To give you some of the benefits you can get if you choose to use welding manipulators; here are some of the most common ones:

Better and Faster Productivity

Using machines can really improve your overall productivity. It can help you gain more mobility during projects and operations.

While the machines operate on the weld, you can go on and attend on other parts of the project. You can prepare the next workload, switch to a different workstation, and so on.

Safer Welding Procedures

Welding manipulators have safety kits and straps that can secure workpieces. Also, the column and boom can safely be placed and secured to fixed places.

In addition, it’s also safer for you because you can relax and watch the welding manipulator do the work.

Can Automate Your Welding Processes

Welding manipulators have been programmed to operate like how a skilled welder would.

This basically means that you can automate and develop welding processes and procedures.

Better Welding Control

Because of the computers, you will be allowed to have more control of certain factors. These factors include, but are not limited to:

• Speed of the weld
• Current
• Voltage
• Energy input and output
• Movement of goods
• And so on

Those are just some of the main benefits that welding manipulators can give you. There are a lot more and they would depend on your project’s goal and objective.

Weld Manipulators Price

The price of welding manipulators would depend on the manufacturer. Also, it would depend on whether you’ll purchase OEM or ODM products.

However, you can expect that its prices are upwards of $5,000; and that’s the general amount. You can try to find manufacturers of welding manipulators out in the market.

Anything less might not have the quality, or even the functionality that you’re looking for.

How Can I Choose the Welding Manipulator I Should Use?

Weld manipulators greatly complement the welding process.

A welding manipulator aided by a welding positioner for easier welding

That’s why you should choose the best and the most appropriate machine for your project.

But how do you choose one? To be able to successfully purchase the manipulator for your business, you need to consider the following things:

Control System of the Weld Manipulator

What type of control system does a particular welding manipulator offer?

Knowing this is important because it’ll be the system of your future machine’s control.

Adjustment of the Weld Head

Knowing how you can adjust the weld head of your manipulator is crucial. This goes head-to-head with the type of material or the output you’re looking for.

If you need to weld a structure that is over 10 feet high, you need a manipulator that will be able to reach that height.

Power Source of the Welding Machine

Did you know that choosing the right power source can help you save a lot of money?

There are inverter-based DC motors and transformers that you can take advantage of.

Since your manipulators will be activated and turned on for long hours, it is important to consider its power capacity and source.

Choosing a welding manipulator isn’t actually a difficult task, it’s something you need to be serious about because it can complement the advantages and benefits your company can have.

Are There Manual Weld Manipulators?

Yes, you can purchase manual welding manipulators in the market.

An image of what a manual or a stationary welding manipulator looks like

In fact, mechanized or automatic manipulators can be set and used as a manual manipulator, too.

Oftentimes, though, it’ll be best for you to utilize a welding positioner; especially if you have a manual welding manipulator.

This would allow your work to become easier, more flexible, and to produce better quality.

Manual Welding Manipulator vs. Automatic Welding Manipulator

Manual weld manipulators are manipulators that have stagnant weld heads.

What an automatic or a computer-controlled weld manipulator looks like

Automatic manipulators, on the other hand, are those that are controlled by a computer.

The difference lies on the movement of the beam. If your weld head needs to be moved manually, then you can consider it as a manual manipulator.

Automated welding manipulators aren’t always the best choice. In fact, manual manipulators are widely sought out in the market as well.

What is a Variable Speed Welding Positioner?

Variable speed drives, or VSDs, are devices that can alter the speed of a motor possessing fixed speed.

A welding positioner you can change the speed of, depending on your specific project

In simpler terms, it’s like a tool that can assist you in modifying how a motor functions.

Therefore, variable speed weld positioners are weld equipment in which you can change up the speed of the motor – regardless if it’s a fixed-speed motor or a regular modifiable motor.

What’s the Usual Load Capacity of a Welding Manipulator?

Load capacities of weld manipulators vary from machine to machine.

An image of a welding manipulator withstanding heavy load

There are small manipulators that can only withstand about 300 kg of force. On the other hand, there are heavy-duty weld manipulators you can purchase, that are able to withstand more than a ton of force.

Load capacities will be dependent on the size of the machine and how they’re sized.

How Do I Size a Weld Manipulator?

A worker checking and assessing a welding manipulator

You can size a weld manipulator and toggle two (2) different categories of the machine:

• Load Capacity
• Reach & Lift

Load Capacity

A welding manipulator would have varying load capacities that you can choose from.

In fact, you would need to consider all weights, such as the operator, the cross slides, welding equipment, etc.

Reach & Lift

Both the reach and the lift are distinguished by the horizontal and the vertical locations of the arc.

Moreover, there’s also minimum and maximum dimensions, depending on the range in which the weld manipulator is able to operate.

What is a 3-Axis Welding Manipulator?

3-axis refers to the number of movements a particular weld manipulator is able to make.

A 3-axis computer numerically-controlled (CNC) welding manipulator

If 2-axis weld manipulators perform two (2) movements, therefore, 3-axis machines can perform three (3).

You can use 3-axis weld manipulators for complete circumferential activities. You’ll be able to perform even the most complex of welds.

Welding Manipulator vs. Welding Positioner 

Don’t ever confuse yourself in distinguishing which is which. The manipulator and the positioner are two (2) different machines that would make your welding process easier.

A welding positioner is an auxiliary machine that moves the workpiece according to your position.

Welding manipulators, on the other hand, function reversibly. A manipulator moves the welder to the workpiece.

More often than not, you’ll need a positioner to work with a manipulator. The positioner moves the workpiece, while the manipulator would help the welding machine perform the weld.

What are Sub Arc Welding Manipulators?

They’re machines that can assist you with your submerged arc welding process.

The manipulator can position the welding head closer and deeper to the workpiece without you touching or moving it.

Is SAW the Only Solution Compatible With Welding Manipulators?

Submerged arc welding or SAW isn’t the only welding solution compatible with a manipulator. In fact, you can use it for other welding processes, too, including:

• Tungsten Inert Gas (TIG) Welding
• Metal Inert Gas (MIG) Welding
• Metal Active Gas (MAG) Welding
• And Others

Your capability will depend on the welding manipulator that you have.

Parts of a SAW Manipulator

A sub arc manipulator can have many parts and components. That would entirely depend on the manufacturer.

However, in order for a SAW manipulator to function, it would need the following:

• Weld head
• Control system
• Power source or welding machine
• Weld torch
• Travel mechanism
• Electrode material

Even if just one of these is not present, the sub arc manipulator wouldn’t be able to function. This is the complete package of what a SAW manipulator is.

Before you decide on the manipulator you’ll buy, make sure that all of these are included.

What is a Column and Boom Welding Manipulator?

It’s a type of a manipulator that consists of a “column” and a “boom” to assist a process.

The column is the pathway of the boom to move up and down. The boom is the machine that holds the oscillator, performing the weld.

You can use a column & boom manipulator to work on many different workpieces; from light, medium – to heavy workpieces.

Welding Manipulators For Sale

There are a lot of welding manipulators you can purchase in the market.

You can choose anything from cheap ones, expensive ones, those that can operate SAW, among others. Sub

Also, you can choose to rent or lease these welding manipulators. This option is best for companies that wouldn’t use manipulators for too long.

What Benefits Can Using Sub Arc Manipulators Have?

Sub arc manipulators wouldn’t be sold in the market if they didn’t have any use.

But what benefits can you get if you decide to use sub arc welding manipulators?

1. Maximized welding control (speed of wire, voltage, current and power, etc.)
2. Reduced fatigue of welders; minimized manual labor required and needed from welders
3. Safer and more secure environment
4. Increase in productivity; faster and more urgent results
5. Higher and better quality of welds

You can expect these benefits should you decide to use a sub arc manipulator.

What is a Sub Arc Manipulator Ideal For?

Sub arc manipulators cover a complex line of industries.

It can be used for the construction industry, shipyard and shipbuilding industry, pressure tanks and vessels, the petrochemical industry, and many more!

Specifications of the Weld Manipulator You Must Purchase

Before you decide on which welding manipulator to go with, you need to take note of its specs.

Here are some of the factors you need to know before purchasing a manipulator:

• Effective stroke of the vertical boom in mm
• Suitable diameter of the cylinder in mm
• Upward and downward speed of the cross boom in m per minute
• Expansion speed of the cross boom in m per minute
• Effective stroke of the cross boom in mm
• Forward and backward speed of the trolley in m per minute

These are the common specs to note before purchasing a manipulator. Knowing this can help and assist you a lot in making sure that you’ll select the best equipment for your project.

How Can a Welding Manipulator Increase Productivity?

One of the benefits of using weld manipulators is that they increase the overall productivity.

Metal Welding Closeup Photo. Welding in Action.

With a manipulator, the welder does not need to go near the workpiece any longer

Weld manipulators help increase your operation’s productivity by:

• Allowing you to control the wire speed, voltage, current, etc.
• Helping the welder relax while the machine is welding – you can designate them to other tasks
• Being able to carry out even the most complex of tasks

Is it Safe to Purchase Used Welding Equipment?

More often than not, sellers of weld manipulators would immediately disclose info about their machine.

For instance, if the machine is just slightly used, it’ll be evident; or if it’s been used for a number of times, etc.

Where Can You Get Welding Manipulators?

There are a lot of welding manipulator creators and manufacturers in the market. But, if you want to work with the best, you need to go and consider Waldun.

We here at Waldun have been providing excellent and quality welding manipulators for years. Our products have made and transformed the businesses of our clients, improving them in unimaginable ways.

Don’t settle for less when looking for a welding manipulator. Work with Waldun and expect the best and the highest quality of welding manipulators you can find in the market!