Tubosider, a producer of steel products for civil engineering projects including road and noise barriers, pipelines, and tunnel linings, has installed a robotic arc-welding system developed by Italian System Integrator X-Machine, using technology supplied by automation specialist Comau.
The project was designed to replace labour-intensive manual welding with a flexible robotic solution capable of handling components of different sizes.
Tubosider’s aim was to improve repeatability and precision, reduce long-term maintenance costs, and redeploy skilled workers from hazardous tasks to safer, higher-value roles.
X-Machine, which has worked with Comau on multiple industrial automation projects, built a customised turnkey system around Comau’s S-13 robot from its S-Family range. The compact robot, with a 13 kg payload and a reach of nearly 2 m, is designed to operate in confined spaces typical of steel fabrication plants. Its hollow wrist configuration protects cabling and reduces external interference, a key advantage in demanding arc-welding environments.
Artificial Intelligence plays a central role in the system. Before welding begins, the robot automatically locates the joint and compensates for any misalignment, improving accuracy and reducing defects. Welding operations are then carried out in a continuous sequence, helping to stabilise cycle times and maintain a steady production flow.
Operations are managed through a centralised control panel developed by X-Machine, which allows operators to start and supervise workflows, access digital documentation, and log activities from a single interface. Safety has been enhanced by an intelligent on-off switching system that separates human and robotic work zones, enabling parallel tasks without compromising protection.
According to Tubosider, the investment has delivered more reliable and repeatable welds, while cutting production time, energy consumption, and operating costs. Workers previously assigned to manual welding have been reassigned to less hazardous activities, supporting both safety and productivity goals.
Beyond the physical automation, the system incorporates advanced software that creates a digital twin of the welding cell. By collecting and analysing large volumes of operational data in real time, the platform allows managers to monitor performance, track overall equipment effectiveness, and adjust parameters to optimise output. Predictive diagnostics, enabled by Artificial Intelligence, identify early signs of wear or anomalies, allowing maintenance to be scheduled based on actual machine condition rather than fixed intervals.
