LEADER 1250 is a highly versatile horizontal automatic welding machine for circumferential welding, with additional capabilities for longitudinal welding, weld cladding, and specialized screw shafts welding. It handles products up to 1250 mm in diameter and 2900 kg static load and offers advanced automation through the RCS 06 control system.
Machine design and manufacturing decisions are reviewed against the intended industrial application.
Mechanical movement, controls and operator access are considered together in the machine concept.
The welding method and workpiece requirements inform the available equipment and configuration.
HST can review the workpiece, process and production sequence before confirming a machine scope.
Product description
LEADER 1250 is a highly versatile horizontal automatic welding machine designed primarily for circumferential welding, with additional capabilities for longitudinal welding, weld cladding, and specialized screw shafts welding. The machine can provide material pre-heating prior to welding. It handles products up to 1250 mm turning diameter and 2900 kg static load. The distance between spindle flanges ranges from 3500 mm in the basic version to 10500 mm.
Its heavy-duty self-supporting steel base carries the main tower with integrated main spindle drive and control system, the opposite supporting tower, and the movable tailstock. An overhead longitudinal portal carries movable torch heads on precision roller bearings, while the tailstock travels on linear guideways along the base. Welding fume extraction can be integrated directly into the torch-head structure, and the central tower can include a cooling system for up to two welding torches.
The tailstock can have its own drive synchronized with the main spindle; both drives are backlash-free. A stepper motor drives a precision planetary gearbox and gear transmission. Both spindles use the same standardized flange for 250, 315, or 400 mm universal chucks. HST CREATIVE can also design custom clamping fixtures for specific products, either manually operated or pneumatically actuated and controlled directly by the machine.
An optional numerically controlled T axis provides motorized tailstock spindle tilting from 0 - 90°, enabling welding in specific positions and spiral weld cladding of larger plates. Tailstock clamping uses linear motion, a blocking segment, and a 125 mm pneumatic cylinder with a standard 350 mm stroke, extendable on request.
The machine can be equipped with two welding heads for two welding technologies. The heads can be installed next to each other or on a common support rod, allowing adjustment of the second head position, locked by a pneumatic-mechanical brake. Both share one servo-driven, numerically controlled X axis for longitudinal movement. This drive can also provide controlled torch oscillation (weaving) during welding. Both welding arms have their own numerically controlled Z axis with a +/- 225 mm stroke and three degrees of mechanical adjustment. A backlash-free torch support provides +/- 15 mm two-axis adjustment and 90° rotation with position locking. MIG, TIG, and PLASMA WELD torch holders are available.
The welding arm can include automatic torch tracking with an electro-mechanical sensor. A tactile probe with an internal Hall sensor detects height and lateral weld-path position, allowing automatic torch-position correction through the Z and X axes during welding.
A special screw shafts welding package enables automated welding of helical screw flights to a shaft. It combines electromagnetic torch-position monitoring, dedicated software, coordinated machine-axis motion, and an adjustable roller support for controlled product rotation. This specialized application continuously follows the helical weld path and maintains torch position, enabling continuous welding along the entire screw shaft length.
An optional independent camera system allows the operator to monitor the welding process and supports all welding methods. Camera functions are controlled through a dedicated 19-inch touchscreen and an independent control system.
The machine can also be equipped with controlled preheating up to 600°C, integrating preheating directly into the automated welding cycle. A heating torch, thermometer, and infrared temperature sensor are installed on the first welding head and managed by dedicated software. Once the preset temperature is reached, the system automatically transitions to welding mode, reducing manual intervention and maintaining consistent process conditions.
The HST CREATIVE CW 09 cold wire feeder can be fully controlled by the RCS 06 system, with adjustable feeding parameters and reverse wire feeding. The digital Remote Control Mighty Controller is available for increased operating flexibility.
The RCS 06 control system is developed for advanced welding automation and supports rotary acceleration and deceleration, welding source control with separate programming, welding power regulation, program storage, and program sequences.
LEADER 1250 is designed as one of the most comprehensive welding systems in the HST CREATIVE portfolio. Its configuration covers circumferential welding, longitudinal welding in selected applications, weld cladding of flat surfaces, spiral weld cladding, and specialized screw shaft welding. Typical applications include pressure and non-pressure vessels, machine parts, shafts, pipes, heat exchangers, fittings, and other pipe or rod products using the hollow spindle. Longitudinal welding on a copper backing bar is handled by the dedicated FINGER line. RCS 06 enables advanced welding automation across this wide range of applications.
HST service continuity
Selected HST machines can be supplied with extended service support in addition to the statutory warranty. The exact scope is always confirmed in the offer or contract.
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