Weld pipe clamps

Process and challenges

The production of pipe clamps includes the production of individual pieces up to small series with diameters between 5 - 150 cm. Most manufactured pipe clamps have diameters of up to 100 cm. The core process consists of welding a pipe extension to a hole in the pipe clamp.

Traditional working methods

There are two traditional methods for this process:

Table setup: The pipe clamp is mounted on a table and the welding is done manually. This process must be followed by a 180° Rotation of the pipe clamp can be interrupted to turn it around. This method is susceptible to quality issues such as inclusions and unclean transitions.
Turntable assembly: An alternative method is to lock the pipe clamp on a turntable. Although this makes turning easier, larger diameters can result in cumbersome and potentially hazardous working conditions for the welder.

Workspace and challenges

The floor area used for the welding booth is 16 m² (4x4 meters), which highlights the space restrictions and challenges of working with large diameters.

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Innovative welding and clamping device for large pipe clamps

Safety-oriented construction

For processing pipe clamps with diameters of between 50 and 150 cm, we have developed a special welding and clamping device that is set up at 90°. This design prevents the rotating pipe clamp from hitting the welder while moving and thus significantly increases safety at work. Previously, the work was carried out by 2 employees - after renovation, it must be carried out by one employee alone.

‍Custom design for efficient work processes

The device is based on a standard turntable, which, however, was specially modified to meet the customer's requirements. Pipe clamps are suspended on the surface of the plate and centered by means of a rotating grain tip. A pneumatic lifting device presses the tube extension against the tip of the grain to securely fix the assembly.

‍Ergonomic benefits for welders

Height-adjustable and position-adjustable armrests allow welding to take place while sitting, which enables an ergonomic working position. Regardless of the diameter of the pipe clamp, this device allows the welder to be positioned comfortably. The construction remains fixed during welding while the entire assembly rotates along the welding torch, resulting in a significant reduction in uncomfortable working postures.

‍Space-saving solution

The overall construction of both devices is designed for efficiency and space savings, with a space requirement of just 3×3 meters (9 m²). This offers customers significant advantages in terms of the use of space in their production halls.

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