Precision Welding Automation Boosts Boiler Production in Ireland

Client Profile

In September 2024, a boiler manufacturer in Ireland faced mounting challenges in their welding operations. With increasing demand for high-quality containers, their reliance on manual welding processes became a critical bottleneck. The company sought an automation partner to address three distinct yet interconnected production challenges.

Challenge 1: Inconsistent Circumferential & Socket Weld

The client’s existing process for welding circumferential seams and socket weld relied on manual MIG welding with rotating rollers. This approach presented several pain points:

• Unstable weld bead appearance with frequent undercut and porosity
• Pass rates fluctuating between 65–80%, leading to costly rework
• High dependence on skilled welders, with training cycles disrupted by staff turnover
• Production delays during peak periods due to labor-intensive processes

Our Solution

Deployed a 2-meter reach robotic welding cell featuring:

• Articulated robot with ±0.05mm repeatability
• Positioner with dynamic speed matching for consistent torch angles
• Integrated vision tracking system compensating for part variations
• Optimized MIG welding process parameters for carbon steel vessels

Outcomes

• Achieved uniform weld profiles meeting ASME Section IX visual standards
• Stabilized pass rates at 97–98% across production batches
• One robotic cell replaced 4–5 manual stations with 24/7 operation capability

Challenge 2: Longitudinal Seam Integrity Issues

For straight seam welding, the client used manual TIG welding which caused:

• Frequent leaks in pressure testing (15% failure rate)
• Slow deposition rates (1.2m/hr) creating production bottlenecks

Our Solution

Implemented a dedicated longitudinal seam welding system with:

• Custom-designed carriage mechanism for precise torch guidance
• Automated wire feeding & gas shielding management
• Closed-loop heat input control

Outcomes

• Near-perfect 99.8% pressure test pass rate
• Production speed increased to 3.5m/hr with consistent quality

Challenge 3: Large-Diameter Vessel Fabrication

For vessels exceeding 2 meters diameter, manual welding was physically impractical due to:

• Accessibility constraints for welders
• Impossibility of maintaining consistent torch angles

Our Solution

Developed a custom SAW (Submerged Arc Welding) system featuring:

• Boom-mounted welding head with adaptive height control
• Real-time monitoring interface for operator oversight
• Automated flux recovery and recycling

Outcomes

• Enabled fabrication of large-scale vessels previously unattainable manually
• Eliminated weld defects caused by accessibility constraints

About Aixsen

At Aixsen, we deliver end-to-end industrial automation systems designed for demanding manufacturing environments.

We deliver precision laser cutting, robotic arc welding, and intelligent material handling solutions—designed as standalone systems or integrated lines, fully engineered around your specific process, quality requirements, and output targets.