Automated welding is now one of the cornerstones of advanced manufacturing. In sectors such as Oil & Gas, energy and heavy mechanics, where component size and geometric complexity demand absolute precision, automation has become a strategic ally to ensure quality, productivity and safety.
Within this context, Tiesse Robot presents its latest technological innovation: the 80-tonne orbital positioner, a solution designed for robotic welding of large-scale and complex-shaped metal parts.
A system designed for maximum stability and control
At the heart of the system is a two-axis positioner capable of handling and rotating components weighing up to 80 tonnes, while maintaining exceptional stability during processing.
Rotation and tilt movements are synchronised with a Kawasaki Robotics RA20N robot mounted on a three-axis Cartesian monorail (X-Y-Z), allowing dynamic control of the process and pinpoint accuracy along the entire welding path.
The result is a system capable of performing complex cladding operations using pulsed MIG technology, ensuring uninterrupted processing and impeccable repeatability.
Integrated technologies for intelligent welding
Every element of the system is designed to optimize performance: the Fronius TPS500i Pulse power source ensures high-precision synergic MIG welding.
A key role is played by the offline software developed by Tiesse Robot, which automatically manages the robot programming starting from the CAD-CAM file of the finished component. Based on the parameters set by the customer – such as excess material thickness and coating areas – the system autonomously calculates the optimal trajectories for the cladding process and automatically generates the corresponding welding paths.
The software also divides the program into multiple segments, allowing the robot to load the sequences progressively during execution - an essential feature in applications where processing can extend over weeks or even months. In this way, continuous operation, consistent accuracy and complete traceability of every stage of the process are ensured.
The equipment is completed by a methane-gas preheating system, a fume extraction unit and an adjustable platform that allows the operator to carry out visual inspections in complete safety.
Efficiency, quality and safety: the advantages of automation
The aim of this solution is to automate complex and repetitive operations, such as overlay welding on critical surfaces, while reducing cycle times and improving overall process quality. The entire robotic system has been designed and tested at Tiesse Robot’s headquarters, in full compliance with European safety and industrial automation standards. It stands as a concrete example of the integration between precision mechanics, electronic control and advanced robotics.
The 80-tonne orbital positioner is intended for production environments where robustness, reliability and process traceability are essential. It is ideally suited to sectors such as energy production, industrial plant construction, large-scale steel structures and heavy mechanical components. In all these fields, robotic welding is not merely an efficient choice, it is a true competitive advantage, reducing operating costs, ensuring consistency and repeatability, and raising safety standards for personnel.
A modular and scalable system
The same technological architecture is also available in 10- and 30-tonne versions, designed to meet the needs of manufacturers operating at different scales but sharing the same focus on precision and flexibility.
In every configuration, the principle remains unchanged: continuous processing, no downtime and complete control of the welding process.
Tiesse Robot’s “colossus” positioner embodies the company’s philosophy, creating modular, scalable solutions ready for digital interconnection. It demonstrates how robotics can evolve beyond the physical limits of traditional welding, transforming an industrial process into an intelligent system capable of adapting, learning and improving over time.