Overview
A positioner rotates or tilts the workpiece so the torch can reach every seam in the best position, typically flat or horizontal. Coordinated with a robot, the positioner moves while welding, allowing complex 3D seams.
For large fabrications we also supply column-and-boom manipulators, rotator sets and gantry systems that carry the welding head over the workpiece.
How It Works
- Choose the positioner type from part size, weight and centre of gravity
- Integrate positioner axes with the robot controller for coordinated motion
- Add servo drives for accurate speed and positioning during welding
- Fit grounding and slip rings so the weld current path is reliable
What's Included in the System
- Two-axis L-type and turn-tilt positioners
- Headstock and tailstock positioners for long parts
- Welding rotators for pipes and vessels
- Column and boom manipulators
- Gantry and track systems for extended reach
Benefits
- Better weld quality thanks to optimum torch angle
- Access to hidden seams without repositioning
- Shorter cycle time with a two-station layout
- Safer handling of heavy parts
Industry Facts & Standards
- Typical arc-on time is about 15-25% for manual welding and about 60-80% for a robotic cell, which is where most of the productivity gain comes from
- Reported output increases from robotic cells are typically in the range of two to four times
- Seam tracking and touch sensing let the robot follow real part variation instead of an ideal CAD line
- Quality documentation is built in: welding current, voltage and speed can be logged for every part
- Standards and safety: ISO 10218-1/-2 (robot safety), ISO 3834 (quality requirements for fusion welding), ISO 15614 / AWS D1.1 (procedure qualification, per customer spec).
- Figures are typical ranges from public industry sources, not Zhiyan project results.
What We Need to Prepare a Quotation
Please send us the following and we will reply with a proposal:
- Maximum part weight and dimensions
- Required rotation speed and accuracy
- Coordinated with a robot or standalone?
- Floor space and crane access
Robot Brands We Integrate for This Application
Frequently Asked Questions
Can a positioner work with any robot brand?
Yes. Positioners can run on the robot controller as an external axis or on a separate PLC drive. Zhiyan supports ABB, FANUC, KUKA, Yaskawa and other robot controllers.
What payload do I need?
Include the part, the fixture and the clamps, then leave a safety margin. Send us the part weight and centre of gravity and we will size it.