Special Purpose Machine · TIG Welding Automation
Industry 4.0 ready automated welding system designed to eliminate manual errors in tube-to-tube TIG welding. Sector-wise parameter control, auto-alignment, and cold wire feeding — engineered for heat exchangers, boilers, and pressure vessels.
Tube OD (mm)
Wall Thickness (mm)
Welding Sectors
Cycle Time Reduction
In the era of Industry 4.0, optimizing production without compromising quality is every manufacturer’s goal. Manual tube-to-tube TIG welding is highly skill-dependent and prone to defects from inconsistent heat input and filler feeding.
APS’s SPM (Special Purpose Machine) for tube-to-tube welding automates this critical process with digitally controlled parameters, auto pipe alignment, sector-wise heat control, and precision cold wire feeding — delivering flawless, repeatable welds every cycle.
| Component | Model / Type | Specification | Link |
|---|---|---|---|
| Power Source | Apollo 400 | 400A Digital Pulse TIG Welder with external parameter control capability. | View Apollo 400 → |
| Cooling Unit | 50L Water Cooling System | 50-litre tank water cooling system for continuous-duty welding operations. | — |
| Cold Wire Feeder | Pulse Wire Feeder | Pulse feeding with initial speed and retract speed controls for precise filler metal deposition. | View Cold Wire Feeder → |
| Chuck System | 250mm OD / 90mm ID | Heavy-duty chuck for secure pipe clamping throughout the welding cycle. | — |
| Proximity Sensors | Auto Position Detection | Automatically detects pipe position for alignment correction and torch distance maintenance. | — |
| Digital Control Panel | SPM Control Panel | Dedicated panel for sector parameters, weaving settings, and auto-stop configuration. | — |
| Drive Motor | 5HP Induction Motor | RV63 Gear Box (100:1) with 3:1 Helical Reducer for smooth pipe rotation. | — |
| Stepper System | Nema 34 + BH-MSD-6A | BH86 SH 118-6004 AK stepper motor with BH-MSD-6A drive for precise angular positioning. | — |
Sensor-driven auto-adjustment of inter-pipe distance reduces setup time and eliminates manual alignment errors before every weld.
5 independent welding sectors defined by angle and current. Overlap is allowed. Each sector maintains heat input for consistent fusion around the joint.
Automatically stops after completing the sum of all sector angles. Includes optional overlap sector to ensure complete joint coverage.
Digitally controlled torch weaving with configurable weave width, pause time (left/right/center), and weave speed to fill gaps precisely.
Pulse-mode wire feeding with initial speed and retract speed settings ensures controlled filler deposition without burn-back or porosity.
Apollo 400’s digital pulse TIG engine reacts to external sensor inputs in milliseconds, compensating for thermal and geometric variations in real time.
The SPM has been validated on the following test dimensions with ultrasonic weld quality inspection confirming acceptable results.
| Parameter | Root Pass | Cap Pass | Notes |
|---|---|---|---|
| Pipe OD | 38 mm | 38 mm | Within the 30–80 mm pipe diameter range. |
| Wall Thickness | 4.5 mm | 4.5 mm | Standard carbon steel pipe. |
| Bevel Angle | ~37° with straight end | — | Critical for maintaining proper root gap and fit-up. |
| Welding Process | TIG (GTAW) | TIG (GTAW) | Powered by Apollo 400 Digital Pulse TIG Welding Machine. |
| Wire Feeding | Cold Wire (Pulse Mode) | Cold Wire (Pulse Mode) | Controlled retract function at the end of each weld cycle. |
| Quality Test | Ultrasonic Test (UT) | PASS | Validated successfully during customer site acceptance testing. |
| Cycle Time Improvement | 30% Reduction | Compared to Manual Welding | Measured and verified at the installation site. |
The APS Tube-to-Tube SPM is deployed across critical industries where leak-proof, high-quality tube joints are non-negotiable.
Every PPCM system is designed and manufactured at our certified facility in Valsad, Gujarat under strict quality management.
100% designed and manufactured in-house at our own facility — giving us full control over material quality, assembly, and spare parts.
Every PPCM can be configured for specific pipe sizes, plasma sources, rail lengths, and cutting requirements of your production line.
APS provides complete installation, commissioning, and operator training for every PPCM system — including alignment and foundation guidance.
In-house manufacturing means international-standard CNC automation at genuinely competitive pricing — no middlemen, no import markup.
Dedicated service team with pan-India reach — spare parts, technical support, and service calls available across India.
| Certification / Compliance | Scope | Relevance |
|---|---|---|
| ISO 9001:2015 | Complete manufacturing facility — Valsad, Gujarat | Quality-controlled production, consistent output standards |
| IS Certified | Applicable Indian Standards for welding equipment | Compliance with BIS standards for Indian market |
| MSME Registered | Advanced Power Sources Limited | Registered Indian manufacturer — supports domestic procurement requirements |
| CE Compliance | Available for applicable export models | European conformity — available on request for export buyers |
50 kg to 10,000 kg load capacity. VFD drive, 0–120° tilt, motorised/hydraulic. For pipe, vessel, and structural welding automation.
Self-aligning and conventional welding rotators for cylindrical vessels, pipes, and tanks. Variable speed, adjustable wheel span.
Articulated welding arm systems for precise torch positioning, reach extension, and operator ergonomics in welding bays.
APS Rhino Cut plasma cutting power sources — from portable 40A hand cutters to 200A heavy-duty industrial plasma systems.
Compatible with MIG, TIG, and SAW processes for reliable, repeatable industrial performance.
Precision Tube-to-Tube Welding for strong, consistent, and leak-proof tube joints
The welding automation was successfully installed at the customer site. It has considerably reduced the cycle-time(30%) of tube to tube welding.
Weld quality test (Ultrasonic test) has been done and weld quality was observed to be good.
SPM is provided with a feature of auto-adjustment of the pipes with the help of sensor and input parameters that maintain the required distance between the pipes, significantly reducing the time required for alignment of pipes.
Pipe Dimensions:
OD: 38 mm
Thickness: 4.5 mm
End preparation:
Bevel Angle: About 37̊ with straight end
Note: Sector angles can be changed and overlap is also allowed.
The automation has an auto-stop feature and thus stops automatically after covering the angle that is sum of the angles of all the 5 sectors (Overlap Sector may be included if required).
Weaving of the torch is required to fill the gap between the pipes and achieve a proper weld. Hence, a digitally controlled weaving unit with parameters such as weave width, pause-time(left, right, center), weave speed is provided in this SPM.
Heat-input plays a major role in tube-to-tube welding and working with same parameter throughout the weld wouldn’t work. SPM is provided with features to feeds 5 different parameters (defined by the angle of the sector and current) to control and maintain weld consistency.
Note: Sector angles can be changed and overlap is also allowed.
Tube to tube welding is mainly used in heat exchangers, boilers and condensers to create leak-proof tube joints.
TIG welding is commonly used due to its precision and clean weld finish.
It ensures strong, pressure-resistant and leak-proof joints required for high-temperature industrial operations.
Yes, we offer customized welding solutions as per industrial requirements.
Designed and documented by Prit Patel(Design Engineer – APS Welding) with the guidance of Avinash Napa (Design Head and Director – APS Welding).
APS welding is always ready to help you. For Sales Enquiries:Contact: +91 9601 444 111For booking service call:Contact: +91 9601 444 222
We design and manufacture all our products and thus we know the best about our products.
We are able to offer international technology and service at optimum prices.
Our team is regularly trained for updates in service techniques and also are constantly update on knowledge and skill.
We ensure you professionally managed sales and after sales support.
Office & Manufacturing Facility:
Survey No 172/1, Paikee 2, OLD GIDC Gundlav, Valsad, Valsad District, GUJARAT – 396035. INDIA.