Electric transmission system processing solution

The development of the energy, oil, and petrochemical industries has led to an increasing demand for large-sized steel structures with high thickness and harsh working conditions. From wind power towers, power plant structures; equipment support frames, pipe racks, skids, and technology modules; to steel structures serving oil and petrochemical projects, each product group sets strict requirements for manufacturing accuracy, load-bearing capacity, welding joint quality, and operational stability.

In particular, many components in this field use thick steel plates, large sizes, long welding lengths, and high load-bearing weld ratios. Therefore, manufacturing quality depends not only on individual equipment but also on the ability to synchronously control the entire process from material preparation, cutting and edge preparation, assembly, welding, surface treatment to production data management.

Weldcom provides an ecosystem of solutions serving the production of steel structures in the energy and oil and gas industries in that direction, combining processing equipment, high-productivity welding technology, robots, and automation to simultaneously meet the requirements of quality, output, and project schedule.

Diverse structure production for various energy sub-sectors

Unlike production lines specializing in a group of highly repetitive components, the energy and oil and gas sectors include many different types of structures in terms of size, cross-section, and manufacturing methods: heavy beams and columns, box structures, equipment support frames, pipe racks, skids, structural modules, tubular structures, and auxiliary steel components.

Specifically, in the wind power sector, large-diameter tubular components require specialized welding equipment, adaptability to the workpiece diameter, and stable control of long welds. Bruco has developed specialized welding gantries for handling tubular workpieces with diameters from 4,000 to 14,000 mm.

Therefore, Weldcom's solution is built with flexibility in workpiece size, material thickness, component profile, and welding technology, helping businesses organize the production of multiple product groups on the same technological platform.

Precise processing of thick steel plates and standardizing connections from the start

For energy and oil and gas structures, the quality of the weld depends greatly on the precision of the workpiece and the connection preparation process. Dimensional deviations, bevel angles, or assembly gaps from the cutting stage will increase adjustment time, filler metal volume, welding deformation, and processing workload in subsequent stages.

Weldcom provides steel plate processing solutions from CNC cutting to high-power laser cutting, serving thick and ultra-thick materials. Bevel cutting head configurations support various edge types V, I, X, Y, K, with bevel angles up to 45°, combined with machine vision alignment and automatic deviation compensation.

Accurate control of the geometry and edge connection from the start helps stabilize the assembly process, control weld gaps, and lay the foundation for subsequent automatic welding technologies.

High-productivity welding technology for large structures and thick steel

Welding is one of the stages that determine the productivity of energy and oil and gas structure manufacturing plants. Heavy beams, box structures, and thick components often concentrate a large volume of filler metal, while the requirements for penetration, weld shape, and input heat control are increasingly high.

Weldcom deploys automatic SAW solutions, Tandem SAW, Triple Arc, and Tandem ICE suitable for each structural group. Tandem ICE combines current-carrying welding wire with cold wire feeding to increase speed and deposition productivity while maintaining low line energy.

This technological direction is particularly suitable for components with long welds, large cross-sections, and high thickness, where the challenge is not only to "weld faster" but also to balance deposition productivity, penetration, input heat, and structural deformation.

Production flow control for projects with high schedule demands

Energy and oil and gas projects often have large fabrication volumes, heavy components, multiple stages, and delivery requirements by module or assembly phase. As the scale increases, overall productivity no longer depends solely on the speed of cutting or welding machines but on the ability to coordinate processing, assembly, workpiece transportation, welding, and finishing.

Weldcom develops solutions by integrating equipment with transportation, flipping, and workpiece transfer systems, while connecting production data with SCADA/MES on suitable devices. Bruco's welding systems have integrated Ethernet/IP to support data monitoring and production management system connectivity.

This approach helps businesses better control equipment status, progress of each stage, and operational efficiency, while reducing waiting time between steps in the production line.

A technological platform for the energy and oil and gas industry

From wind power structures; power plant structures; industrial frames, beams, and modules; to structures serving oil and petrochemical industries, the production challenge converges on four main requirements: precise processing of large-sized materials and thick steel – controlling welding joint quality – enhancing manufacturing productivity – organizing efficient production flow.

Instead of focusing on a single piece of equipment, Weldcom approaches the challenge through the entire technology chain from material preparation → processing → edge connection creation → assembly → automatic/robotic welding → surface treatment → production management.

Through this, steel structure manufacturing businesses build a technological platform that meets increasingly high technical project requirements, while enhancing the ability to participate more deeply in the supply chain of the energy, wind power, oil, and petrochemical industries.