8 Ton Welding Positioner for Defence Manufacturing in UAE

Case Study: 6

A leading defence vehicle manufacturer in the UAE required a controlled welding solution for fabricating heavy UTV underframe assemblies. The asymmetric structures needed repeatable welding positions while maintaining the requirements of qualified welding procedures. Cyclotron Automation designed and manufactured an 8 Ton Heavy Duty Welding Positioner at its Bhosari, Pune facility, then exported and commissioned the equipment in the UAE. The positioner provided controlled rotation of the offset weldment, allowing welds to be positioned consistently while simplifying handling of the heavy assembly.

The Challenge

The application presented three challenges, and only one was directly related to welding.

The first was the material and welding process. Heavy defence structures can involve high-strength structural steels where WPS compliance, heat input, interpass temperature, penetration, and weld consistency need to be controlled. Welding a significant number of joints in vertical or overhead positions introduces additional variables for the welding operator.
The second challenge was the geometry of the UTV underframe. The assumed workpiece weighed approximately 7.2 tonnes, measured around 5.5 metres long and 2.2 metres wide. It had a centre of gravity approximately 600 mm above the rotation axis with up to 500 mm eccentricity. This meant the positioner had to handle a highly asymmetric load rather than a centrally positioned 7.2 tonne component.
The third challenge was delivery. The equipment was being manufactured in India and installed in the UAE. The machine therefore needed to be tested, packed, documented, shipped, installed, and commissioned as a complete system rather than relying on repeated engineering intervention after delivery.

Cyclotron Welding Positioners from India

Cyclotron manufactures industrial welding positioners from 100 kg to 100 Tons capacity, designed for robotic/manual welding, heavy fabrication, and high-production welding environments.
Cyclotron manufactures all types of Manual/Robotic welding positioners like 1 axis, 2 axis, 3 axis, Headstock-tailstock, L Type, skyhook, etc

Our Approach

Cyclotron supplied an 8 Ton Heavy Duty Two-Axis Welding Positioner designed to rotate and tilt the complete underframe assembly.

The primary objective was repeatable positioning. The positioner brings weld joints into the flat or horizontal position wherever the component geometry permits, reducing dependence on vertical and overhead welding.

For defence fabrication, the value of this positioning is not simply faster welding. A consistent welding position gives the operator better control over penetration, bead profile, fusion, and heat input. It also helps maintain consistent conditions across repeated assemblies and supports adherence to the applicable WPS.

The positioner was sized for the actual loading condition rather than treating the 8 Ton rating as a standalone figure. The design considered the approximately 600 mm CoG height and 500 mm eccentricity of the workpiece.

Rotation is controlled through a VFD-driven system, allowing controlled starting, stopping, and rotation speed. This is important when the workpiece must be positioned accurately before welding and when maintaining controlled movement during mechanised welding operations.

The positioner also incorporates a copper earth brush assembly to provide a dedicated path for welding current. This prevents welding current from travelling through critical components such as bearings and the drive mechanism.

The result is a system designed around three requirements: controlled movement, stable positioning, and repeatable welding conditions.

Built in Pune, Commissioned in the UAE

The positioner was designed and manufactured by Cyclotron Automation at its Bhosari, Pune facility before being prepared for export to the UAE.
Before shipment, the equipment underwent factory checks covering mechanical operation, electrical functions, rotation, and load testing. Export preparation included protective packing and documentation for transportation and installation.
The equipment was then shipped to the UAE and commissioned on-site. We provided Installation support, technical documentation, troubleshooting assistance, and commissioning support as a part of the delivery process.
For an exported machine, factory testing is an important part of the process. It provides an opportunity to identify mechanical, electrical, and control issues before the equipment leaves the manufacturing facility.

The Result

These figures are a projection based on typical arc-on-time and position-of-weld improvements, not a measurement of this installation

Parameter	Projection
Downhand welding	Nearly 100% where geometry permits
Crane repositions	5 before / 0 after
Handling time saved	Approximately 3-4 hrs/unit
Weld re-inspection	Potential reduction of 30-40%

For an assumed production volume of 15 UTV underframes per month, saving approximately 3.5 handling hours per unit at a loaded labour rate of ₹1,500/hour represents approximately ₹78,750 per month in handling-related savings.

When potential reductions in grinding, handling, and inspection time are included, the projected overall benefit is approximately ₹1-1.5 lakh per month.

At an assumed equipment investment of ₹20-25 lakh, the indicative payback period is approximately 15-20 months. Actual results will depend on production volume, labour costs, welding procedures, and the customer’s existing handling process.

For defence fabrication, the larger value is consistency. Producing a weld correctly the first time can avoid the additional inspection, grinding, repair, and documentation associated with rework.

Exporting Heavy Welding Equipment?

Cyclotron Automations handles heavy welding positioner projects from engineering and factory testing in Pune through export preparation, documentation, and commissioning support. Share your workpiece drawing, weight, dimensions, and CoG details to discuss an application-specific solution.