Robotic welding
Adaptive welding is an essential part of the efficient manufacturing of heavy steel structures with variable and changing groove geometries. PEMA robot welding station with SCAN software solves the challenge for manufacturers.
In heavy manufacturing, flexibility and adaptivity are becoming essential for ensuring consistent weld quality and productivity. With the latest advancements in software, sensing technology, and robotic automation, adaptive welding enables systems to detect and respond to changing groove geometries in real time. This brings a new level of precision and reliability to welding thick, heavy, and complex structures.
case study
Faced with the challenge of ensuring weld quality, reducing repetitive strain on workers, and staying competitive in the oil and gas sector, NWP invested in advanced welding automation. They chose Pemamek for their expertise and cutting-edge scanning and adaptive welding software. This technology allows precise nozzle welding by automatically adjusting weld deposition to fit the exact contour of each vessel.
case study
Estonian contract manufacturer Harry Metall transformed its small-series production with a PEMA robotic welding station. By combining adaptive multipass welding, easy offline programming, and laser scanning, the company has reduced manual work, increased capacity and weld quality.
PEMA robot stations
The robot adjusts the welding speed, weaving parameters, torch location, and torch angle based on information from the sensor & control system. Thanks to this, you can produce flawless full penetration welds.
WeldControl SCAN software
The software automatically scans the groove data, which is displayed in the software. The operator can apply an existing multi-pass weld sequence or create a new one. The software adapts every weld pass in the sequence to the scanned groove.
Real-time laser tracking
When heat input causes parts to curve during welding, real-time laser tracking adds stability by keeping the torch aligned to the evolving seam without reprogramming or manual adjustments.
adaptive welding
Pemamek’s WeldControl 300 SCAN software is designed for adaptive welding. What makes it stand out?
Suitable for workpieces with variable groove geometries
For example:
insights from the team
Application Manager Miika Kartano collaborates with manufacturers using adaptive welding technology every week.
Adaptive welding is an automated welding process where the equipment not only performs the welding actions, but adapts in real time to changing conditions, for example variations in the joint geometry, groove shape or fit-up. It is automatic welding, where movements and welding parameters are adjusted automatically and in real time according to information from sensors.
Adaptive welding is automated welding that adjusts parameters in real time to match changing weld conditions. It delivers the greatest benefits when handling geometrically varying grooves in large, heavy structures. By automating both handling and welding, productivity and safety remain high. Adaptive capabilities also allow automated welding even when joint preparations are not perfectly precise.
Adaptive welding uses advanced software and intelligent sensing, such as laser scanning. At Pemamek, we offer this through our PEMA WeldControl 300 Scan.
Manual welding: a human welder performs the work, adapting as needed.
Mechanised/automatic welding: processes are automated but typically rely on fixed parameters and precise part preparation.
Robotic welding: use of robots to carry out welding tasks, often with pre-set paths and parameters.
Adaptive welding: builds on robotic/automated welding, adding sensors and control logic so that the system senses variations (e.g., groove geometry) and adapts parameters (welding speed, torch angle, weave, etc) accordingly.
Improved weld quality and consistency, even when part preparation is not perfect.
Ability to handle geometrically complex or variable joints (e.g., large heavy structure grooves) with less reliance on ultra-precise prep.
Increased productivity and repeatability: as automated systems take over handling and welding, the cycle times, consistency and throughput improve.
Reduced dependence on highly skilled manual welders for every task, addressing industry skills shortages.
Better safety and ergonomics: fewer human welders exposed to harsh environments, more automation of repetitive or heavy tasks.
Adaptive welding is particularly useful when:
Joints have variable or unpredictable geometry (heavy structures, large weldments, large‐scale manufacturing)
Workpiece preparation cannot guarantee ultra-tight tolerances or perfect joint fit-up.
High throughput, repeatability and quality are required (e.g., pressure vessels, large crane components, wind energy components)
Companies are facing a shortage of skilled welders or want to reduce manual welding risk/exposure.
If the answer to the following questions is yes, then adaptive welding is likely a strong option for your operation.
Do I have weld joints with variable geometry, large tolerance variation, difficult fit-ups?
Do I need high throughput and repeatable weld quality with minimal rework?
Am I facing resource constraints (skilled welders), or do I want to reduce reliance on manual welding?
Can I invest in the upfront cost and engineering time for integration, but gain long-term benefits in productivity, quality and cost?
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