WWELDEN INDUSTRIESIndustrial Automation
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Idler Welding
Rotary Welding in Under 40 Seconds.
Simultaneous dual-torch action for balanced thermal input.
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Simultaneous dual-torch action for balanced thermal input.
Heavy-duty power sources engineered for 24/7 production.
Automatic Conveyor Idler Welding Machine
Machine overview
Experience simultaneous, uniform down-hand welding on both ends of the conveyor idler. Driven by advanced PLC control, this automated process delivers consistent weld quality every cycle, significantly reducing rework and improving structural integrity across production shifts.
Demonstration video
Operation Process
01
Load and Clamp
The idler assembly is placed on the rotary fixture and secured with pneumatic clamping for consistent, repeatable positioning.
02
Torch Positioning
The PLC activates dual-torch positioning, aligning both MIG torches with the weld joints at each end of the idler.
03
Simultaneous Rotary Welding
The idler rotates at 1–6 RPM while both torches deposit weld beads simultaneously, balancing thermal input on both ends in a single pass.
04
Cycle Complete
Torches retract, clamping is released, and the finished assembly exits the fixture ready for inspection. Next part loads immediately.
Frequently Asked Questions

The machine uses MIG/MAG welding with dual 400A torches operating simultaneously for down-hand rotary welding on both ends of the idler.

The idler rotates at 1–6 RPM, PLC-controlled, to deliver a consistent weld bead profile regardless of idler diameter.

The machine handles workpiece lengths from 200mm to 2200mm and outer diameters from 76mm to 194mm — covering the full range of standard conveyor idler sizes.

Yes. Welding both ends at the same time balances thermal input symmetrically, which minimizes the asymmetric distortion that is common in sequential single-torch welding.

Yes. The heavy-duty 400A power sources and PLC-driven automation are rated for continuous multi-shift operation without performance degradation.

Full machine data for engineering review.
Model
IW-PC
Power Input
3 phase 415V / 50 Hz
Rated Duty Cycle
60%
Rated Output Current
400 A
ModelIW-PC
Power Input3 phase 415V / 50 Hz
Rated Duty Cycle60%
Rated Output Current400 A
Welding Wire0.8 - 1.2 mm
Workpiece Length200 mm - 2200 mm
Workpiece Diameter76 mm - 194 mm
Spindle Speed1 - 6 RPM
Dimension (L x W x H) (Approximately)3600 x 700 x 1250 mm
Weight (Approximately)750 Kg
Core advantages
Simultaneous Dual-Torch ActionAdvanced PLC ControlPneumatic ClampingCentralized Welding ControlHeavy-duty 400 Amp Power Source
Best fit
•Conveyor idler assembly
•Rotary welding lines
•Uniform dual-end weld operations
Industries served
Bulk handling equipmentConveyor manufacturingFabrication lines
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Automatic Conveyor Idler Welding Machine
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