Advanced Cutting Automation for Russia’s Civil Nuclear Industry
Client Profile
In November 2024, a Russian civil nuclear energy contractor faced critical challenges in manufacturing 12-meter pipeline systems. The irregular cutting patterns required for seismic-resistant piping networks pushed manual operations beyond their limits, with cascading impacts on project timelines and safety compliance.
The Challenge: When Human Precision Wasn’t Enough
The client’s pain points crystallized around three core issues:
- Geometric Complexity: Free-form cutting requirements on thick-walled pipes (18-22mm steel) resulted in ±3mm dimensional deviations – exceeding ASME BPVC tolerances.
- Weld Integrity Risks: Manual welding of irregular joints caused inconsistent penetration depths (varying 1.2-2.1mm), triggering 19% rework rates during radiographic testing.
- Production Bottlenecks: Each 12-meter pipe segment required 37 labor-hours for fit-up and rework, creating schedule overruns at their fabrication facility.
Our Solution: The Trifecta of Robotic Precision
Aixsen deployed an integrated system combining:
- STEP-certified robotic arms with 0.05mm repeatability, engineered for nuclear-grade fabrication environments
- Hybrid laser processing:
- 3kW fiber laser cutting head for beveled edges
- Scanner-based laser welding with real-time seam tracking (0.2mm positional accuracy)
- No-Teach Offline Programming:
- CAD/CAM direct import of piping ISOs
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.
