Gantry Automat GWU Builder
Custom gantry production system for circumferential and longitudinal welding of tanks under continuous operation.
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GWU BUILDER is a custom-built industrial production system designed for circumferential and longitudinal welding of pressure and non-pressure tanks under continuous 24/7 operation. It supports SAW, MAG, TIG, Plasma and Keyhole welding technologies and combines advanced digital control with simple operation.
Due to the complexity of the system, it is supplied only as a bespoke project. The final technical configuration and feasibility are determined after detailed consultation based on the product dimensions, application requirements and customer production program.
The machine is designed for high-capacity tanks with diameters up to 5000 mm and lengths up to 25,000 mm. The maximum product weight depends on the selected roller positioners or assembly-line configuration.
The mechanical structure consists of two robust gantry towers. Their widened bases provide high stability and can carry welding power sources weighing up to 500 kg. The right tower includes an ergonomic operator station protected by a safety frame.
Both towers travel along rails using synchronized drives with a maximum speed of 4.0 m/min. An adjustable aluminum portal is installed between them and can carry one or two welding heads.
Each welding head includes precision X- and Z-axis fine adjustment with a movement range of ±100 mm. For MAG welding, an oscillation unit with a range of 20 mm to each side can also be fitted.
The final equipment is selected according to the welding technology. Wire feeders, wire reels, flux supply and flux recovery systems can be integrated directly into the welding-head support.
GWU BUILDER can be combined with CARRIER roller positioners to create a complete automated production line for large tank manufacturing.
The system can be equipped with the IRIS NICK industrial welding camera, which provides a detailed image of the weld area and is suitable for all supported welding methods, including MAG Pulse.
A second camera monitors the entire workplace from above and helps the operator determine the optimum welding position.
The control system is based on a Windows industrial computer with the HST CREATIVE user interface displayed on a 19-inch glass touchscreen.
Machine operation includes:
* touchscreen mode selection, * a proportional digital joystick, * context menus and touch gestures, * automatic weld-position control using a touch probe, * clear visualization and adjustment of welding parameters.
The production task combined longitudinal and circumferential welding of large tank sections with long travel distances, multiple welding processes and continuous operator visibility of the weld area.
The machine concept therefore had to coordinate torch movement, workpiece rotation, welding equipment and operator control without treating them as separate stations.
A single fixed welding column would not provide the described rail travel, portal span, multi-head process integration and operator station required for this production layout.
HST selected two synchronized gantry towers to support an adjustable portal and one or two welding heads while preserving longitudinal travel along the workpiece.
Fine X- and Z-axis adjustment, optional oscillation, process equipment and camera systems are integrated around the selected welding technology and production sequence.
- Stable welding conditions — The rigid twin-tower structure limits mechanical vibration transferred into the welding zone.
- Compact production footprint — The gantry arrangement combines substantial working capacity with efficient use of workshop space.
- Multi-process integration — The system can combine two welding technologies within one production concept, such as MAG and SAW.
- Controlled longitudinal travel — Synchronized rail movement positions the welding unit along the workpiece.
- Precise welding-head adjustment — Fine X- and Z-axis movement supports repeatable torch positioning and clear parameter control.
- Adaptive weld positioning — The operator can use proportional joystick control or automatic position tracking with a touch probe.
- Integrated industrial control — A touchscreen-based industrial computer brings machine movement and welding-process functions into one interface.
- Improved process visibility — Dedicated cameras provide detailed weld-area monitoring and a wider view of the workplace.
- Operator-focused workstation — The covered moving station keeps essential controls and process visibility within convenient reach.
Technical values are listed for the presented configuration. Final parameters may depend on the customer's product, application and project scope.
Working parameters
Specification group- Progress speed of the cylinder placed on pulleys *
- 0,74–369,0 cm/min
- Torque on shaft of roller positioners *
- Based on the type of positioner
- Speed of moving along the rails (Y axis)
- 0,5–450,0 cm/min
- Speed of movement the torch head (X axis) *
- 0,01–200,0 cm/min
- Speed of vertical movement the torch head (Z axis) *
- 0,01–150,0 cm/min
- Speed of horizontal movement the torch head (C axis)
- 0,01–150,0 cm/min
- Pendel of the torch *
- +/- 20 mm
- Maximum loading of the torch head by components of welding technologies
- 130 kg
- Maximum loading of pendel head by welding torch
- 5 kg
- Duty cycle **
- 24/7
The operator works from a protected moving station with touchscreen and proportional joystick control. Camera views support observation of both the weld area and the wider workplace.
The system can combine more than one welding technology within one production concept and can work with CARRIER roller positioners for tank rotation.
Coordinated travel, process control and visual monitoring support repeatable setup and clearer control of complex tank-welding operations.
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