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The Practical Reference
Guide to Positioning
This publication is designed to provide information in regard to the subject matter

covered. It is made available with the understanding that the publisher is not engaged in
the rendering of professional advice. Reliance upon the information contained in this
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of this publication. This document is not a consensus standard. Users should refer to the
applicable standards for their particular application.
550 N.W. LeJeune Road, Miami, FL 33126

The Practical Reference Guide to Positioning
Acknowledgments
Information and excerpts throughout this Guide have been adopted from The New
Handbook of Positioneering, courtesy of Koike Aronson, Inc., Arcade, NY., and additional
input provided by Pandjiris, Inc. Photographs are courtesy of Pandjiris, Inc., St. Louis,
MO.
International Standard Book Number: 978-0-87171-086-4

American Welding Society
550 N.W. LeJeune Road, Miami, FL 33126
© 2008 by American Welding Society
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Welding Society provided that the appropriate fee is paid to the Copyright Clearance Center, 222
Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet: <www.copyright.com>.
2
Basic Safety Precautions

Burn Protection. Molten metal, sparks, slag, and hot work surfaces are produced by
welding, cutting, and allied processes. These can cause burns if precautionary measures
are not used. Workers should wear protective clothing made of fire-resistant material. Pant
cuffs, open pockets, or other places on clothing that can catch and retain molten metal or
sparks should not be worn. High-top shoes or leather leggings and fire resistant gloves
should be worn. Pant legs should be worn over the outside of high-top shoes. Helmets or
hand shields that provide protection for the face, neck, and ears, and a head covering to
protect the head should be used. In addition, appropriate eye protection should be used.
Electrical Hazards. Electric shock can kill. However, it can be avoided. Live electrical
parts should not be touched. The manufacturer's instructions and recommended safe
practices should be read and understood. Faulty installation, improper grounding, and
incorrect operation and maintenance of electrical equipment are all sources of danger. All
electrical equipment and the workpiece should be grounded. The workpiece lead is not a
ground lead. It is used only to complete the welding circuit. A separate connection is
required to ground the workpiece. The workpiece should not be mistaken for a ground
connection.
Fumes and Gases. Many welding, cutting, and allied processes produce fumes and gases
which may be harmful to health. Avoid breathing the air in the fume plume directly above
the arc. Do not weld in a confined area without a ventilation system. Use point-of-welding
fume removal when welding galvanized steel, zinc, lead, cadmium, chromium,
manganese, brass, or bronze. Do not weld on piping or containers that have held
hazardous materials unless the containers have been properly made inert.
Compressed Gas Cylinders. Keep caps on cylinders when not in use. Make sure that gas
cylinders are chained to a wall or other structural support. Do not weld on cylinders.
Radiation. Arc welding may produce ultraviolet, infrared, or light radiation. Always wear
protective clothing and eye protection to protect the skin and eyes from radiation. Shield
others from light radiation from your welding operation.
Special Precautions. In the following conditions when welding aluminum alloys: (1)
High levels of fumes are produced when using the 5XXX (magnesium-bearing) aluminum
filler metals. (2) The use of argon-based shielding gas blends results in the production of
ozone, especially with 4XXX filler metals. The use of filtering masks or airline respirators
will be required if it is determined that personnel are being exposed to excessive
pollutants. Caution must also be observed in the reaction between aluminum and certain
solvents and cleaners. Consult information provided by manufacturers for the necessary
safe practices in the use of their products. AWS also recommends a personal copy of "Arc
Welding Safely", "Fire Safety in Welding and Cutting", and "Safety in Welding, Cutting,
and Allied Processes".
AWS publications may be purchased from the American Welding Society at
http://www.aws.org or by contacting the AWS at 800-854-7149.
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Intentionally Left Blank
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TABLE OF CONTENTS
Page No
Practical Reference Guide to Positioning ................................................................................. 1
Acknowledgments .................................................................................................................... 2
Basic Safety Precautions ........................................................................................................... 3
I. Introduction ...................................................................................................................... 9
II. Weldment Positioning Equipment .................................................................................... 9
A. Positioner Basics ................................................................................................... 10
1. Determining the Center of Gravity............................................................... 10
2. Finding the Center of Gravity Experimentally ............................................. 12
3. Mounting Work onto a Weldment Positioner ............................................... 14
4. Welding Chucks............................................................................................ 17
5. Work Lead Connections ............................................................................... 19
6. Floor Anchors............................................................................................... 20
B. Tilting-Rotating Positioners ................................................................................. 21
1. Selecting Positioner Capacity....................................................................... 22
2. Tilt Torque .................................................................................................... 23
3. Rotation Torque ............................................................................................ 26
4. Swing Clearance........................................................................................... 27
5. Constant and Variable Speed Positioners ..................................................... 27
6. Calculating Surface Speed............................................................................ 27
7. Speed Regulation.......................................................................................... 28
C. Powered-Elevation Positioners ............................................................................. 29
D. Drop-Center Tilting Positioners ........................................................................... 30
E. Turntable Positioners............................................................................................. 31
1. Turntable Capacity Ratings .......................................................................... 32
F. Headstock and Tailstock Positioners ..................................................................... 33
1. Large Workpiece Inertia .............................................................................. 34
2. Mounting Workpieces on Headstock and Tailstock Positioners ................. 35
3. Determining Swing Clearance ..................................................................... 38
4. Powered-Elevation Headstock and Tailstock Positioners ........................... 39
G.. Balancing Positioners ........................................................................................... 39
1. Determining Load Capacity ........................................................................ 39
2. Mounting the Work on Balancing Positioners.............................................. 41
3. Making Minor Balance Adjustments ........................................................... 41
4. Motorized Tables ......................................................................................... 42
III. Turning Rolls .................................................................................................................... 42
A. Fixed Centerline Turning Rolls ............................................................................. 43
B. Adjustable Centerline Turning Rolls..................................................................... 43
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Page No
C. Fit-Up Rolls .......................................................................................................... 44
D. Unitized-Frame Turning Rolls ............................................................................... 45
E. Tilting Turning Rolls ............................................................................................. 46
F. Sling Style Rolls ................................................................................................... 46
G. Powered and Idler Rail Cars ................................................................................. 46
H. Non-Cylindrical Work .......................................................................................... 47
I. Pipe Hold-Down Attachments .............................................................................. 47
J. Weight Capacity .................................................................................................... 48
K. Rotation Power Ratings ........................................................................................ 48
L. Tractive-Pull Ratings ............................................................................................ 48
M. Included Angle ...................................................................................................... 50
N. Traction Calculation .............................................................................................. 51
O. Selection of Turning Roll Wheel Materials .......................................................... 53
P. Alignment ............................................................................................................. 53
Q. Overturning Instability .......................................................................................... 55
R. Setting Up Turning Rolls for Multiple Sections .................................................. 57
S. Shock Loading ...................................................................................................... 59
T. Weld Joints ............................................................................................................ 59
IV. Welding Head Manipulators ............................................................................................. 59
A. Manipulator Selection ........................................................................................... 60
B. Lift ........................................................................................................................ 62
C. Lift System Safety ................................................................................................ 64
D. Reach .................................................................................................................... 64
E. Mast Rotation ........................................................................................................ 64
F. Car Travel ............................................................................................................. 65
G. Powered Motions ................................................................................................... 65
H. Manipulator Load Capacity ................................................................................... 65
I. Location and Mounting of Welding Head Manipulators ...................................... 66
J. Manipulator Equipment and Accessories ............................................................. 66
V. Side Beam and Carriage Equipment ................................................................................ 67
A. Side Beam and Carriage Equipment and Accessories .......................................... 67
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Page No
VI. Safety Considerations....................................................................................................... 69
A. Environmental Interference .................................................................................. 69
B. Fastening Loads .................................................................................................... 70
C. Avoiding Instability .............................................................................................. 70
D. Other Safe Practices ............................................................................................. 70
E. Economic Considerations ..................................................................................... 71
F. Deposition Rates ................................................................................................... 71
G. Operator Factor and Set-Up Costs ........................................................................ 71
H. Welding Skill ........................................................................................................ 71
VII. Conclusion ....................................................................................................................... 72
VIII. Bibliography .................................................................................................................... 72
IX. Safety Documents ............................................................................................................ 73
List of Tables
Table Page No.
1 Determining Traction for Selected Included Angles.................................................. 53
List of Figures
Figure Page No.
1 Center of Gravity of a Solid Cube ............................................................................. 11
2 Center of Gravity of a Cylindrical Object .................................................................. 11
3 Finding the Center of Gravity of Small Workpieces.................................................. 13
4A Finding the Center of Gravity of Large Workpieces by Balancing
them on a Pipe ........................................................................................................ 13
4B Alternate View............................................................................................................ 13
5A Finding the Center of Gravity and Weight of a Workpiece using a Hoist and Scale . 14
5B Alternate View............................................................................................................ 14
6 Effects of Tilting and Weldment Geometry on Positioner Fastener Requirements ... 16
7 Use of a Three-Jaw Self-Centering Chuck................................................................. 18
8 Calculation of Total Tilt-Load Moment Requirements .............................................. 19
9 Force of Inertia on the Base of a Positioner ............................................................... 20
10 Typical 135° Tilting-Rotating Positioner with the Table in the Flat Position ............ 21
11 Examples of 45° - 90° and 135° Tilting-Rotating Positioner..................................... 22
12 Typical Tilting-Rotating Positioner............................................................................ 24
13 Workpiece Mounted on Tilting-Rotating Positioner .................................................. 24
14 Capacity Plate Data for a Tilting-Rotating Positioner................................................ 25
15 Rotation Axis of the Positioner as the Fulcrum ......................................................... 27
16 Diagram for Determining Revolutions Per Minute.................................................... 28
17 Powered-Elevation Positioner in the 135° Tilt-Down Position.................................. 29
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Figure Page No.

18 Positioning Three Different Welds on a Spool-Shaped Workpiece
Using an Elevating Positioner ................................................................................. 30
19 Drop-Center Tilting Positioner ................................................................................... 31
20 Typical Turntable Positioner....................................................................................... 32
21 Turntable Capacity Ratings ........................................................................................ 33
22 Typical Headstock and Tailstock Positioners ............................................................. 35
23 Headstock and Tailstock Positioner Ratings for Overhanging Load Capacity........... 35
24 Effect of Rotational Inertia of Large Workpieces....................................................... 36
25 Misalignment of Headstock and Tailstock Due to Rigid Mounting of Workpiece .... 38
26 Pilot Mounting Method Overcomes Minor Misalignment ......................................... 38
27 Universal-Pin Mounting System ................................................................................ 38
28 HTS Positioners with Powered Elevation Feature...................................................... 39
29 Intersection of Tilt and Rotation Axes on Balancing Positioner ................................ 40
30 Determining Load Capacity of a Balancing Positioner .............................................. 40
31 Installation of a Counterweight .................................................................................. 42
32 Fixed Centerline Turning Rolls .................................................................................. 43
33 Adjustable Centerline Turning Rolls .......................................................................... 44
34 Vessel Turning Rolls with Adjustable Centerline....................................................... 44
35 Using Turning Rolls for Fit-U p Roll Adjustment...................................................... 45
36 Unitized-Frame Turning Rolls.................................................................................... 45
37 Rail Cars for Powered and Idler Turning Rolls .......................................................... 47
38 Turning Roll Setup for Non-Cylindrical Work ........................................................... 47
39 Tractive-Pull Ratings .................................................................................................. 49
40 Comparison of Included Angle of Workpieces........................................................... 50
41 Calculating Included Angle for Turning Rolls ........................................................... 52
42 Proper Setup for Turning Roll Alignment .................................................................. 54
43 Conditions that Cause End-Creep............................................................................... 55
44 Intentional Misalignment of Turning Rolls to Counteract End-Creep ....................... 55
45 Overturning Instability of Workpiece on Turning Rolls............................................. 56
46 Turning Roll Set Up for Workpiece with Multiple Sections ...................................... 58
47 Welding Head Manipulator and Multiple Turning Roll Alignment System............... 58
48 Bent Workpiece Supported by Multiple Turning Roll Units ...................................... 58
49 Basic Motions of a Welding Head Manipulator ......................................................... 60
50 Large Model Welding Head Manipulator ................................................................... 61
51 Welding Head Manipulator with Welding Equipment Installed on Both
Ends of the Boom.................................................................................................... 61
52 Determining Extreme arc Positions for Reach and Lift.............................................. 61
53 Determining Overall Height of a Vessel on Turning Rolls......................................... 63
54 Lift Range of a Welding-Head Manipulator ............................................................... 63
55 Determining Horizontal Boom Travel........................................................................ 64
56 Basic Side Beam and Carriage Application................................................................ 68
57 Welding Lathe............................................................................................................. 68
58 Side Beam and Carriage Application ......................................................................... 69
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I. INTRODUCTION
This Practical Reference Guide describes the basic operation of weldment positioners
and welding head manipulators and gives information on their selection and use.
Weldment positioners hold and move a workpiece into the desired positions for
welding and other related operations. Welding head manipulators hold and move the
welding head and welding torch as the weld is made. Positioners and welding head
manipulators can be used individually and in combination with each other or with other
equipment for manual, semi-automatic, mechanized, automated, or robotic welding
operations. Weldment positioners and welding head manipulators are particularly
useful to reduce operator fatigue, increase welding speed, and reduce production time
for long weld joints, circumferential joints, and thick joints that require multiple weld
passes. They can help improve productivity, reduce costs, and improve weld quality.
CAUTION: THIS DOCUMENT INCLUDES GUIDELINES FOR THE OPERATION,
SELECTION AND USE OF WELDMENT POSITIONERS AND WELDING
HEAD MANIPULATORS. CALCULATIONS OF LOADS AND FORCES
ON EQUIPMENT AND DESIGN OF MOUNTING METHODS FOR
EQUIPMENT, TOOLING, AND WORKPIECES ALWAYS SHOULD BE
DONE BY A QUALIFIED ENGINEER OR BY THE MANUFACTURER OF
THE EQUIPMENT.
II. WELDMENT POSITIONING EQUIPMENT
Positioners are mechanical devices that support and move a workpiece to the desired
position for welding and other related operations. Positioning equipment is available in
a number of configurations, depending on the motions required to properly position the
work. Weldment positioning equipment includes the following types:
Balancing positioners that are designed to permit manual movement of the
workpiece. (See section: II.G.)
Tilting-rotating positioners provide two powered axes of motion. (See section:
II.B.)
Powered elevation positioners add powered vertical motion to tilting and
rotation motions of the table. (See section: II.C.)
Drop-center tilting positioners are specially designed so that the surface of the
table is along or below the tilt axis. (See section: II.D.)
Turntable positioners have tables that rotate about a vertical axis but do not tilt.
(See section: II.E.)
Headstock and tailstock positioners provide motion to rotate a workpiece about
a horizontal axis and do not tilt. (See section: II.F.)
Turning rolls hold and turn cylindrical parts about their horizontal axis. (See
section: III.)
9
Selection of the proper type of positioning device depends on factors that are described
in the following sections of this document. These factors include the size, weight, and
complexity of the workpiece as well as the number, location, and orientation of the
weld joints. One of the first decisions to be made is how many axes of motion will be
needed to properly position the weldment. Turning rolls, turntable positioners, and
headstock and tailstock positioners provide motion about only one axis. Tilting-
rotating positioners provide two axes of motion. Three motion axes are achieved by
adding vertical motion to a tilting-rotating positioner, by combining more than one of
the basic motion devices, or by the use of fixtures and tooling.
This Practical Reference Guide also describes welding head manipulators. While
welding positioners can be used to move the workpiece, welding head manipulators
move the welding process equipment to or over the work. Two types of welding head
manipulators are included in this document:
• Welding head manipulators consist of a vertical mast and horizontal
boom to which the welding head is mounted. The manipulator provides
two, three, four, or more axes of motion and can be mounted in a fixed
position or on a traveling car.
• Welding side beams and carriages position the welding head in two axes
and provide a single axis of motion, usually straight-line motion.
A. Positioner Basics
The first decision to make when selecting a welding positioner is to determine the
number of axes of motion that are required to position the weld joints on the parts
to be welded. The next decision involves selecting the proper size and load rating
of the positioning equipment. Manufacturer’s size and capacity ratings of
positioners are based on the weight and the location of the center of gravity of the
load the positioner is designed to carry. The load includes the weldment and any
tooling or fixtures that also will be mounted on the positioner. Working within the
manufacturer’s capacity rating ensures that the positioner can not only safely
support the load, but that the motion axes are designed with the proper torque to
move the load.
(1) Determining the Center of Gravity
Knowing how to locate the center of gravity of the workpiece and
associated fixtures is necessary in order to calculate the loads and torque
requirements when selecting a positioner. The location of the center of
gravity (CG) or center of balance is important because the entire weight of
a body can be assumed to be concentrated at this location when making
engineering calculations. The center of gravity of a weldment, fixture, or
other component can be obtained from engineering drawings or calculated
by qualified personnel. If necessary, the center of gravity can be determined
experimentally using the methods described in this document.
The center of gravity of any object is located somewhere within its
dimensions. The center of gravity of a symmetrical object with uniform
density is at the geometric center of the object or on an axis of symmetry.
10
The solid cube in Figure 1 is one example. The center of gravity is at the
center of the cube and is midway between each of the faces. The center of
gravity of a hollow cube also is midway between the faces, as long as each
face weighs the same. A cylindrical object, such as that shown in Figure 2
has a center of gravity located at the geometrical center of the cylinder. The
center of gravity would not be at the geometrical center of the cylinder if
the cylinder had a dome-shaped head on one end or a structure extending
from a side.
Figure 1—Center of Gravity of a Solid Cube
Figure 2—Center of Gravity of a Cylindrical Object

The center of gravity of complex objects can be determined by dividing the
object into simple geometric shapes and calculating the center of gravity of
each of these shapes using formulas from handbooks, engineering
textbooks, or advanced 3-D modeling and engineering software. The center
of gravity of the complex object can then be determined by transferring the
center of gravity of each individual component as follows:
y = Aa1 + Bb1 + Cc1
A + B + C
11
Where
y = the distance from the x axis to the common center of gravity in in. (m)
A = the weight of shape A in lb (N)
a1 = the distance from the x axis to the center of gravity of shape A in in. (m)
B = the weight of shape B in lb (N)
b1 = the distance from the x axis to the center of gravity of shape B in in. (m)
C = the weight of shape C in lb (N)
c1 = the distance from the x axis to the center of gravity of shape C in in. (m)
Additional calculations are made to determine the location of the common
center of gravity from both the Y and Z axes in the manner outlined above.
CAUTION: DETERMINING THE WEIGHT AND LOCATION OF THE
CENTER OF GRAVITY OF WELDMENTS, TOOLING, AND
FIXTURES SHOULD BE DONE BY A QUALIFIED ENGINEER
OR OTHER QUALIFIED PERSONNEL.
(2) Finding the Center of Gravity Experimentally
The center of gravity of a workpiece can be located experimentally as well
as by calculation. The center of gravity of small workpieces can be found
by balancing them (including fixtures and attachments) on a round rod (or
pipe) as shown in Figure 3.
The center of gravity of larger workpieces can be found by balancing them
(including fixtures and attachments) on a round rod (or pipe) as shown in
Figure 4A. Draw a vertical line on the part directly above the rod. Repeat
this procedure by rotating the workpiece 90 degrees and balancing it on an
adjacent side as shown in Figure 4B. Draw another line vertically from the
rod as shown in the figure. Repeating the procedure after rotating the part
another 90 degrees results in lines on each of the three primary axes of the
part. The intersection of these three lines marks the center of gravity of the
part.
Another method that can be used to find the center of gravity of large
workpieces uses a crane or hoist. Suspend the workpiece from a hoist or
crane as shown in Figure 5A. A plumb bob from the hook of the hoist
defines a line that passes through the center of gravity. Mark this line on the
workpiece. Next, suspend the part from a second point and then a third point
and repeat the plumb bob and marking steps. A scale can be used to measure
the weight of the workpiece during one of the lifts. The center of gravity is
located at the intersection of the three lines. The lines in Figure 5 show the
results of both the balancing rod and hoist methods. Note that they indicate
the same center of gravity location for the workpiece.
12
Figure 3—Finding the Center of Gravity of Small Workpieces
Figure 4A—Finding the Center of Gravity of Large Workpieces by Balancing them

on a Pipe
Figure 4B—Alternate View
13
Figure 5A—Finding the Center of Gravity and Weight of a Workpiece using a Hoist
and Scale
Figure 5B—Alternate View
(3) Mounting Work onto a Weldment Positioner

Positioners are equipped with round or square work-tables that may have
radial slots for attaching parts or tooling. These work-tables also have pilot
holes at their centers that will accept dowels, spindles, or centering bosses.
A boss that is engaged in the pilot hole provides an easy method of
centering fixture plates and provides a “shear-stop” that prevents the fixture
from moving laterally on the table.
Two considerations must constantly be kept in mind when mounting heavy
work on a welding positioner. First, the work must be firmly attached to the
table so that it is secure as the table tilts and rotates. Second, shear stops
must be provided to prevent the workpiece from sliding on the face of the
table. Steel blocks tack welded to the table work very well as shear stops.
Another method is to use a boss engaged in the pilot hole of the table, as
described above.
14
If four bolts are tightened into four of the radial slots on the table, often both
rules for safe mounting work (strong hold down and shear stops) are
satisfied. If only two bolts are adequate, it is strongly recommend that shear
stops also be added to the table surface around the work to prevent any
possibility of the work sliding on the table. Pre-engineered holes in the
workpiece can be used to mount it to the positioner, saving production and
setup time.
One simple method of mounting a workpiece to a positioner is to weld it
directly to the table, assuming that this does not harm the work. Use tack
welds sufficiently large to handle shear stresses when the workpiece is in
the vertical tilted position. These tack welds can be ground off to remove
the work from the positioner. Positioner tables are durable and designed to
be welded to. If the table surface becomes scarred, simply fill the scars with
weld metal and dress the areas flat with a grinder. An alternative is to cover
the positioner table with a tooling plate and weld the work to this plate. The
plate can be replaced when it becomes worn or damaged.
Care must be taken when fastening a workpiece directly to the positioner
table to prevent deforming the flatness of the table. Shims may be required
to support areas of the workpiece in order to preserve the flatness of the
table.
Figure 6 illustrates the attachment of a weldment to a positioner table.
When the positioner table is horizontal (Figure 6A), the only force tending
to move the weldment would be centrifugal force due to rotation. However,
the weldment can slide as the table tilts (Figure 6B) and attachments are
required to prevent this movement. The force of gravity acting on the
weldment, parallel to the table, increases as the tilt angle increases (Figure
6C) and becomes equal to the weight of the weldment at 90° tilt. Tilting the
table more than 90° can cause the weldment to rotate about the lower
fasteners if it is not restrained by the upper fasteners (Figure 6C and Figure
6D). The two upper fasteners (F1 and F2) will be under tensile load due to
the weight and location of the center of gravity of the weldment. The
moment about the lower fastener P is the product of the weight (W) and the
horizontal distance between the center of gravity and the lower fasteners,
(x). As the tilt angle increases, the horizontal distance increases. The weight
moment is balanced by the moment of the tensile force on the upper
fasteners. Assuming the weldments in Figure 6C and Figure 6D are of equal
weight (W) but the weldment in Figure 6D is longer and narrower than the
one in Figure 6C, the force, F, can be determined by the following equation:
F = Wx/y
In both cases, x2 is greater than x1, and y2 is less than y1. Therefore, F2 is
greater than F1. Accordingly the attachments for the weldment in Figure 6D
must be stronger than for Figure 6C. All attachments should be checked to
confirm they have sufficient strength to withstand both shear and tensile
forces acting on them and a suitable safety factor added.
15
Figure 6A
Figure 6B
Figure 6C
Figure 6D
KEY TO FIGURE
W = Weight of the load, lb (N)
F1, F2 = Tensile force on the upper fasteners, lb (N)
x1 and x2 = Horizontal distance between the table face and the center of
gravity, in. (m)
P = Location of the lower fasteners
y1 and y2 = Vertical distance between the lower fasteners and the upper
fasteners, in. (m)
Figure 6—Effects of Tilting and Weldment Geometry on Positioner Fastener

Requirements (See Section II.A.3.)
16
CAUTION: MOUNTING METHODS, FASTENERS, AND TACK WELDING

SHOULD BE DESIGNED BY A QUALIFIED ENGINEER OR
DESIGNER WHO SHOULD ASSURE THAT THE MOUNTING IS
ADEQUATE FOR THE LOAD AND THE APPLICATION. THE
USER SHOULD ALWAYS FOLLOW ALL OF THE
RECOMMENDATIONS OF THE MANUFACTURER OF THE
EQUIPMENT.
(4) Welding Chucks
A welding chuck mounted onto a positioner table can provide a convenient
method of clamping and centering a workpiece. However, characteristics of
the workpiece and some basic rules for using chucks are critical to their safe
use. The shape and structure of each workpiece imparts different loading
characteristics on the chuck jaws. Also consider that the chuck can absorb
heat, expand and lose its grip on a workpiece that is preheated.
The chuck jaws must clamp the workpiece on a rigid section to minimize
the possibility of clamping failure. Clamping and centering should be
performed on the largest diameter possible. Thin sections must be held with
special jaws to overcome radial workpiece deflection while clamping.
Surface finish of the workpiece and the chuck jaws play a major role in
creating effective frictional forces needed for proper clamping. Several
different types of chuck jaws are available for effective clamping of specific
applications. As a rule of thumb, multiply the clamping force needed by two
(X2) to help overcome misalignment, workpiece inaccuracies, and surface
finish deficiencies.
Out of roundness of the workpiece can add a loading to each chuck jaw
during rotation of the part. This cyclical loading, depending on the
frequency and capacity, can create stresses that may cause jaw slippage or
clamping failure. If one revolution is needed to finish the weld, a minor
amount of slippage may be tolerated. When several rotations are required,
the workpiece can slip enough to require periodic adjustment and re-
clamping.
Overhanging and eccentric moments about the centerline of rotation must
be reviewed to determine the adequacy of workpiece clamping when using
a chuck. The moments created by an unsupported workpiece or centerline
misalignment can overcome the clamping ability of the chuck and result in
the workpiece becoming loose or coming out of the chuck.
A workpiece that is held in a chuck and is supported at another location can
become loose in the chuck due to misalignment. Figure 7 shows a three-jaw
self-centering chuck holding one end of a long workpiece. The length of the
pipe in this example requires an outboard roller support to keep the pipe
from overloading the chuck and levering itself out of the chuck jaws.
Misalignment of the chuck and the rotation centerline of the positioner will
tend to loosen the workpiece in the chuck jaws.
17
Figure 7—Use of a Three-Jaw Self-Centering Chuck

The chuck body adds weight and extends the distance to the center of
gravity of the workpiece that it holds. The weight and center of gravity
distance of the combined chuck and workpiece should be calculated to
confirm that the positioner is suitable for the job. The example in Figure 8
identifies the moments due to the weight of the workpiece and chuck with
the positioner in the 90° tilt position. Figure the moments of each item and
add them together for a total moment requirement:
Chuck: 150 lb. X (6.8 in. + 4 in.) = 1,620 lb-in. (183 Nm)
Workpiece: 180 lb X (6.8 in. + 7 in. + 25 in.) = 6,980 lb-in. (789 Nm)
Total Tilt-Load Moment Requirement: 8,600 lb-in. (972 Nm)
CAUTION: THE SELECTION OF THE PROPER CHUCK, AND MOUNTING
METHOD, AS WELL AS THE HOLDING OF THE WORK
SHOULD BE DESIGNED BY QUALIFIED PERSONNEL.
ALWAYS FOLLOW ALL MANUFACTURERS’ RECOMMENDA-
TIONS FOR THE USE OF ANY EQUIPMENT.
18
[1.27 m]
[0.102 m]
[0.636 m]
[667.2 N] [800.7 N]
[0.173 m]
Figure 8—Calculation of Total Tilt-Load Moment Requirements

(See Section II.A.4)
(5) Work Lead Connections
Welding positioners have connections for attaching the work lead from the
welding power source. Positioners are constructed with either current-
carrying bearings or sliding brushes to carry the welding current from the
work lead connections to the work table and to the weldment itself. This
precludes having to connect the work lead cable directly to the weldment
that could result in the cable becoming twisted or tangled as the table tilts
or rotates. Ensuring a good electrical connection between the weldment and
the table is another reason for securely clamping, bolting or welding the
weldment to the positioner table.
Welding current can be transmitted through sliding brushes mounted in
spring-loaded holders that bear against a surface on the rotating or tilting
element of the positioner. These brushes can be made from copper, graphite,
or copper-graphite matrix materials. Multiple brushes are used to provide
the required current carrying capacity. Proper operation of these brushes
requires that the surfaces of both the brushes and the rotating element must
be clean and free from dirt or lubricants. Brushes, brush holders, and
springs must be inspected periodically to be sure they are not worn or
damaged.
Specially designed bearings also are used in positioners to carry the welding
current to the work table. These bearings must be properly adjusted to
prevent arcing or other damage that can degrade their current carrying
ability.
Variations in arc voltage or arc length, an erratic arc, and changes in the
weld bead size and shape can be indications of problems with the welding
current circuit. The current path in the welding positioner is one area to be
checked when these problems occur. The voltage drop across the positioner
should be low (0.1V to 0.25V) and constant during welding. Any unusual
fluctuations in voltage should be investigated and corrected.
19
(6) Floor Anchors

Most positioners are designed to be stable and to stand upright even when
loaded to their full capacity. However, it is recommended that positioners
be anchored to the floor to prevent them from tipping due to some
unexpected event. For example, unexpected loads can occur when handling
long workpieces that overhang the table of the positioner. Any potential for
tipping of a positioner could be prevented by extending the floor base, but
users prefer short bases that provide maximum swing clearance.
Figure 9—Force of Inertia on the Base of a Positioner

The transfer of momentum in a moving workpiece to the positioner when
tilt movement suddenly stops can possibly cause it to tip over. Figure 9
shows the inertia force on a positioner base when the tilting workpiece is
brought to a sudden stop. The front end of the base is the fulcrum point. The
load is imposed downward. This means that the reaction load is upward at
the rear of the base of the positioner. Figure 9 illustrates that it is only
necessary to prevent the rear of the base from lifting to prevent the loaded
positioner from tipping over. Anchoring only the rear of the base has further
benefits. If the front of the base is not anchored, it can lift when the
workpiece is accidentally tilted into the floor, reducing the load on the
positioner gear train. This will not guarantee that the positioner gear train
will not be harmed, but it might prevent serious damage.
Positioners have limit switches on both the tilting and rotating axes to limit
the amount of movement of each axis. The correct procedure for handling
a large workpiece is to adjust these limit switches to stop the positioner
before the work can contact the floor.
CAUTION: THE LOCATION AND ANCHORING OF WELDING POSITIONERS
SHOULD BE PERFORMED BY QUALIFIED PERSONNEL.
ALWAYS FOLLOW ALL OF THE RECOMMENDATIONS OF THE
MANUFACTURER OF THE EQUIPMENT AND CONSULT THE
MANUFACTURER REGARDING THE SUITABILITY OF ANY
PARTICULAR APPLICATION.
20
B. Tilting-Rotating Positioners
Tilting-rotating positioners are the most common types of positioning equipment
and can support loads weighing as little as 50 lb (89 N) and as much as 4,000 tons
(3,636 M tons.). This type of positioner provides a table that rotates and tilts (see
Figure 10) and permits positioning a wide range of even complex weldments. The
table can be positioned so that the workpiece can be loaded when the table is
horizontal and then tilted for access to individual weld joints. The table also
rotates 360° to position weld joints and to provide travel along circumferential
weld joints on curved or cylindrical parts. A variable speed drive is required if
table rotation is to be used in this manner. Tilt axis drive systems are normally not
used for weld joint travel and are therefore constant speed.
Tilting-rotating positioners are produced with several tilting mechanisms,
depending on the needs of the application. The most common type can tilt the
table from a horizontal position through a 135° angle, so the table and the
mounted workpiece can tilt downward (see Figures 10 and 11). Other positioners
also tilt 135°, but these models tilt 45° and 90° from the horizontal as shown in
Figure 11. A final variation of a tilting-rotating positioner tilts 90° both ways
from the horizontal table position. The table of this type of positioner does not
rotate. Even though limited to a single 180° tilting motion, these positioners can
be used advantageously for many types of work.
Figure 10—Typical 135° Tilting-Rotating Positioner with the Table in the Flat
Position
21
Figure 11—Examples of 45°–90° and 135° Tilting-Rotating Positioners

(1) Selecting Positioner Capacity
When selecting positioning equipment, both the weight of the workpiece
and associated fixtures as well as the location of the center of gravity must
be considered to determine the loads, moments, and torque required for
each axis of motion (tilt and rotation.)
Figure 12 shows a typical tilting-rotating positioner in the 90° tilt position.
The symbol in the circle with the letters “CG” is the standard symbol used
for “center-of-gravity.” It indicates where the workpiece center of gravity is
located relative to the surface of the positioner’s table. Note that there is
another distance between the fulcrum, or tilt axis, and the surface of the
table. This distance is called the “inherent overhang” of the positioner and
is part of the design of any given machine. The inherent overhang distance
must be added to the workpiece center of gravity distance to get the total
distance that the weight of work acts through to put stress on the positioner
tilting gears. These issues are covered in more detail in the sections that
follow.
22
With an understanding of how torque ratings for positioners work, the

proper load capacity can be selected to permit the positioner to handle the
greatest torque requirement of the workpieces to be handled. The size and
model of the positioner should be based on the greatest torque requirement,
either tilt or rotation torque. Additional load capacity may be needed for
other considerations such as inertia of a moving workpiece and shocks
during loading of the positioner.
Load capacity ratings of positioning equipment are generally stated in terms
of weight and distance from the center of gravity to the surface of the table.
The load on the positioner is a combination of the weight of the workpiece
and the moment due to this weight applied at the center of gravity distance.
Positioners have torque ratings for the rotary force they provide measured
in “pounds-inches” (lb-in.) or the metric equivalent of Newton meters
(Nm). This measure is derived from the fact that a moment is created when
a weight in pounds (or Newtons) is imposed at a distance in inches (or
meters) from the center point of rotation. A simple example of moment and
torque can be seen when examining a teeter-totter. A 200 lb (889.6 N)
person on one end of the teeter-totter at 48 in. (1.2m) from the fulcrum point
would create a moment of 9,600 lb-in. (1,067 Nm). An equal moment could
be created by placing a 100 lb (444.8 N) person 96 in. (2.4 m) from the
fulcrum.
Another example would be to apply a 100 lb (444.8 N) force to a 6 in. (150
mm) wrench handle. This produces 600 lb-in. (67.8 Nm) of torque around
the nut or fulcrum point. The same 100 lb (444.8 N) pull applied to a 12 in.
(0.305m) long wrench will produce 1,200 lb-in. (135.7 Nm) of torque.
CAUTION: LOAD CALCULATIONS AND SIZING OF POSITIONING EQUIP-
MENT SHOULD BE PERFORMED BY A QUALIFIED ENGI-
NEER. THE USER SHOULD ALWAYS FOLLOW ALL OF THE
EQUIPMENT AND SHOULD CONSULT THE MANUFACTURER
REGARDING THE SUITABILITY OF THEIR EQUIPMENT FOR
ANY PARTICULAR APPLICATION.
(2) Tilt Torque
Proper understanding of the torque requirements for the tilting axis is one
of the most critical aspects of selecting a tilting-rotating positioner. To gain
this understanding, look at Figure 13 that shows a 2,000 lb (8,896 N)
weldment (W) with a center-of-gravity 12 in. (0.305 m) from the tilt axis
(F) fulcrum point. The total moment on the positioner can be determined by
multiplying the weight by the distance “F”:
12 in. X 2,000 lb = 24,000 lb-in. (0.305 m X 8,896 N = 2,713 Nm)
23
To hold this workpiece, the positioner’s tilt drive must be capable of

producing at least 24,000 lb-in. (2,713 Nm) of torque. An additional
capacity safety factor should always be included to accommodate
uncertainty in the weight of the load, center of gravity, and additions to
fixtures or other components. Another factor to consider in selecting the
capacity of a positioner is future work that may be placed on the unit.
Figure 12—Typical Tilting-Rotating Positioner
Figure 13—Workpiece Mounted on Tilting-Rotating Positioner
24
Figure 14—Capacity Plate Data for a Tilting-Rotating Positioner

Once the torque requirements of the load are known, the size and model of
the positioner can be selected from specification sheets or nameplate data.
Figure 14 shows a typical capacity nameplate for a tilting-rotating
positioner. The nameplate states that this positioner is designed to handle
loads of up to 40,000 lb (177,929 N) that have a center of gravity 12 in.
(0.305 m) from the surface of the table. Twelve inches (0.305 m) is the
standard stand-off distance for the center of gravity when specifying most
positioner models. The capacity nameplate shows that the positioner’s
built-in inherent overhang is 8.75 in. (0.222 m). All the information
required for loading the positioner is either on the capacity nameplate or can
be calculated from the data on the nameplate. For example, the nameplate
in Figure 14 shows that this positioner can provide up to 830,000 lb-in.
(93,859 Nm) of tilt torque. Here is how this capacity plate data was
calculated:
Tilt Capacity = Maximum work load
Inherent Overhang + CG Distance to Table at 12 in. (0.305 m) CG
distance from the table
830,000 lb-in.
8.75 in. + 12 in. = 40,000 lb (177,929 N)
The positioner nameplate also shows the maximum loading capacities for
other workpiece CG distances from the table surface. The maximum load
capacity is 18,500 lb (82,292 N) at a 36 in. (0.910 m) CG distance and
12,000 lb (53,378 N) at a 60 in. (1.52 m) CG distance. The maximum
capacity rating of 50,000 lb (222,411 N) is given for a CG of 6 in. (0.15 m)
from the table. Although there is still more tilt torque capacity in this
machine for less than a 6 in. (0.15 m) distance from the face of the table, the
capacity rating will not be any higher. Few positioners indicate an increase
in capacity for closer CG distances because the dead load on the machine’s
structure must be considered. The load ratings on the capacity plate are
maximum allowable loads for the machine. A positioner should never be
overloaded by relying on the safety factor built into every machine. A safety
factor is built in to ensure longevity, not to stretch the machine’s capability
beyond its limits.
25
It is possible to calculate the load capacity or the maximum workpiece

center of gravity distance for any weight workpiece not listed on the
nameplate. Just divide the maximum tilt capacity by the workpiece weight
and then subtract the inherent overhang to give the maximum allowable
workpiece CG.
It also is possible to determine the maximum load the positioner can support
at a given CG distance. Divide the maximum allowable tilt torque stated on
the nameplate capacity chart by the CG distance plus the inherent overhang.
For example, the maximum load in pounds at a 57 in. (1.45 m) CG location
for this positioner would be:
830,000 lb-in. (from capacity chart) = Maximum permitted load

Required CG + Inherent Overhang in pounds
830,000 lb-in. = 12,624 lb (56 154 N)
57 in. + 8.75 in
Therefore, at 57 in. (1.45 m) CG distance, the maximum workpiece that can
be loaded is about 12,624 lb (56,154 N).
(3) Rotation Torque
Considerations similar to those that apply to defining tilt torque also apply
to load calculations for table rotation. As shown in Figure 15, the rotation
axis of the positioner is the (F) fulcrum point and the load on the rotation
drive can be compared to a lever arm of a simple balance. The positioner in
Figure 15 needs to rotate a 2,000 lb (8896 N) weldment (W) on its table.
The CG of the weldment is 12 in. (0.305 m) from the center of the table. The
rotational torque moment created as shown in the figure is:
2,000 lb x 12 in. = 24,000 lb-in. (0.305 m X 8,896 N = 2,713 Nm)
The nameplate in Figure 14 indicates this positioner has a maximum
rotational torque capacity of 480,000 lb-in. (54,280 Nm). This means the
positioner can rotate a workpiece weighing up to 40,000 lb (177,929 N)
when the CG of the workpiece is no more than 12 in. (0.305 m) off-center
from the rotation axis.
The load calculation is: 480,000 lb-in. = 40,000 lb. (177,929 N)
12 in.
Alternatively, the maximum CG distance for a 40,000 load would be 12 in.
(0.305 m) from the rotation axis. This is shown by the following
calculation:
480,000 lb-in. = 12 in. (0.305 m)
40,000 lb
26
(0.305m)
(8,896 N)
(8,896 N)
(0.305 m)
(8,896 N) (8,896 N)
(0.305 m)
(0.305 m)
(2,713 Nm)
Figure 15—Rotation Axis of the Positioner as the Fulcrum

(4) Swing Clearance
When selecting a positioner, do not forget to leave clearance to swing the
work without hitting the floor when the table is tilted downward as far as
possible. A riser or sub-base can be used to elevate fixed-based positioners
to the proper height.
(5) Constant and Variable Speed Positioners
Another decision to be made when selecting a positioner is between the
need for constant speed drives or variable-speed drives. Constant speed tilt
and rotation drives are sufficient if the positioner is only to be used to move
a workpiece into position for welding. A variable speed drive allows the
operator to control the surface speed of the workpiece to a desired welding
speed to match the deposition rate of the welding process for mechanized
welding of joints. For example, a variable speed rotation drive would be
used when welding the circumferential seams on a pipe or cylindrical
pressure vessel that is mounted on the positioner (Figure 7). A variable
speed tilt drive would be used to weld meridian weld joints on a
hemispherical head placed on the positioner table as described in the drop-
center positioners section of this document.
(6) Calculating Surface Speed
The speeds of tilt and rotation motions of welding positioners are normally
stated in revolutions-per minute (rpm). Since welding speeds are normally
stated in inches per minute or meters per minute, rotation speed must be
converted from revolutions per minute to welding travel speed. A very
simple formula, I = RC, is used for this calculation. The “I” in the formula
stands for welding speed in inches per minute (m/min). The “R” is rpm and
the “C” is workpiece circumference in inches (meters). When using the
formula, make sure that all units are the same for I and C.
27
Consider an example where it is required to determine the number of

revolutions per minute (of rotational speed) needed to weld a 60 in. (1.52
m) diameter workpiece at 12 in. per minute (0.305 m/min) surface speed.
First determine that the circumference of a 60 in. diameter part is 188.5 in.
(4.78 m). Next divide the desired welding speed of 12 in/min (0.305 m/min)
by the workpiece circumference. The result is 0.064 rpm. An easy way to
remember the formula is to find the unknown quantity when the other two
are known by using Figure 16. Cover up the quantity on the diagram (either
I, R, or C) with your finger and perform the remaining calculation. For
example, to find R (rpm), cover up the R. This shows that I (IPM) must be
divided by C (circumference). The speed range of the positioner should be
selected depending on the largest diameter (slowest rpm) and smallest
diameter (fastest rpm) parts that need to be welded. Optional speed ranges,
or higher and lower extremes can be provided if standard speed ranges are
not adequate.
R×C
Figure 16—Diagram for Determining Revolutions Per Minute

(7) Speed Regulation
The moment imposed on a rotation drive can vary when using a positioner
to turn an unbalanced (eccentric) load. Consider the problem of welding an
elbow to a straight piece of pipe held by the positioner. The welding must
be done at a constant surface speed, but the eccentricity of the elbow will
tend to make the positioner speed vary as the elbow rotates. For example,
the eccentric elbow will create a full load on the drive motor, slowing it,
when the elbow is moving from the bottom dead-center position up through
the top dead-center position. When the eccentric elbow reaches the top of
the arc and starts down, it tends to speed up the drive motor, or create an
overhauling load moment. Speed variations during rotation can cause weld
defects. Most positioners are equipped with controls that accurately
regulate speed and prevent the motor from slowing down excessively when
a full load is applied. However, these controls do not prevent the motor from
speeding up when an overhauling load is applied. The only thing that
prevents the motor from speeding up is the proper sizing of the positioner
for the loads to be applied.
28
C. Powered-Elevation Positioners
Powered-elevation positioners provide powered vertical motion as well as tilt and
rotation of the table. A typical powered-elevation positioner is shown in Figure
17. This type of positioner is available in capacities from 2,500 lb to 60 tons
(11,120 N to 54.5 M tons).
Figure 17—Powered-Elevation Positioner in the 135° Tilt-Down Position

While height needed for large workpieces can be achieved by placing fixed bases
or adjustable bases under the positioner, powered elevation has several
advantages. The major advantage is that a powered elevation positioner lets the
operator use a minimum table height to load or unload the workpiece. The table
can then be raised to a height needed to clear the floor during tilting or rotation.
Powered-elevation positioners also have advantages for low headroom
manufacturing facilities. An adjustable-base or fixed-based positioner might
initially be set at a height that affords floor clearance for a large workpiece, but
the table may be too high to load the work due to the low headroom. The ability
to raise and lower the positioner also can permit more welding to be
accomplished at floor level, which minimizes the need for scaffolding or pits.
Figure 18 shows how a powered elevation positioner can be used to access three
different welds on a spool-shaped workpiece. In the first step (Figure 18A) the
table rotates to allow the girth weld to be completed at a constant arc height of 46
in. (1.17 m). Then in Figure 18B, the operator tilts the table up 45° and completes
a fillet weld on the rotating table at a height of only 55 in. (1.4 m). In Figure 18C,
the positioner’s height is increased and the table is tilted down to the 135°
position and a final fillet weld is deposited at a height of 31 in. (0.79 m) while the
table rotates.
29
Figure 18—Positioning Three Different Welds on a Spool-Shaped Workpiece Using

an Elevating Positioner
D. Drop-Center Tilting Positioners
Drop-center tilting positioners are another configuration of weldment
positioners. The surface of the table of a drop-center tilting positioner coincides
with the tilt axis or may even be below the tilt axis. Since the table surface of the
drop-center tilting positioner is below the tilt axis, any workpiece placed on the
unit will be closer to the floor and provide additional overhead clearance. This
design permits speed-controlled tilt motion for welding joints such as those
between the tapered sections of large hemispheres. Tracking the meridian welds
is easy when the hemisphere is moving concentrically about the tilt axis as shown
in Figure 19.
Hemispheres can be welded on a conventional tilting-rotating positioner,
provided they are placed down over the table (like a hat) so the hemisphere’s
equator coincides with the tilt axis. The workpiece surface will now move
concentrically with the tilt axis. This makes tracking of meridian welds possible.
Clamping the hemisphere to the table is more complicated than with the drop-
center tilting positioner. Hemispheres smaller than the positioner table cannot be
mounted as described above due to the inherent overhang limitations of the tilt
axis.
30
Figure 19—Drop-Center Tilting Positioner

The maximum size of workpiece that can be handled by a drop-center tilting
positioner depends on the height of the positioner and the distance between the
vertical side members. Very large workpieces can be handled provided sufficient
space is available between these side members. The positioner can tilt a full 360°
if the positioner is high enough to provide sufficient swing and rotation clearance
for the workpiece. The machine width and the table’s distance from the tilt axis
determine the power and gear-train strength required for tilting.
E. Turntable Positioners
Turntable positioners (see Figure 20) provide rotation in only the horizontal
plane, with load capacities from 50 lb to more than 500 tons (89 N to 227 M tons).
Turntables are used for flame cutting circular shapes, assembly, inspection,
positioning work for machining, as well as for positioning weldments to permit
easy access to weld joints.
31
Turntables can be equipped with constant or variable speed drives or can be

designed for manual table rotation. Turntable positioners are available with a
variety of bases, including track-mounted travel carriages. A limited amount of
table tilt is advantageous for some applications. Tilting bases can be supplied for
almost any turntable model. To prevent overloading the turntable’s spindle and
bearings, the amount of tilt is typically limited to 15° from the horizontal since
the moment due to the load is increased as the table is tilted. There also are a
number of options for indexing mechanisms, remote controls, zero-backlash
drives, and robotics integration. Robotics applications typically involve the
loading of a workpiece on one side of the turntable while the robot performs a
function on the other side. For this scenario, it is of particular importance to refer
to Section F.1., LARGE WORKPIECE INERTIA.
(1) Turntable Capacity Ratings
Turntable capacity is rated in pounds of load at a point 12 in. (0.305 m) from
the table’s center of rotation (see Figure 21). A typical capacity rating might
be 40,000 lb (177,929 N) with the CG 12 in. (0.305 m) from the center of
the table. While these positioners do not tilt, the center of gravity of the
load not being on the centerline of the table does create a bending moment
on the table’s spindle. To determine off-center load capacity, multiply the
weight of the workpiece by the rated CG off-center distance. The example
in Figure 21 shows a 40,000 lb (177,929 N) workpiece mounted 12 in.
(0.305 m) from the center of the turntable. This load has a 480,000 lb-in.
(54,279 Nm) load moment. If a turntable with this capacity is selected, the
weight of the workpiece and associated fixtures located at the CG distance
should not exceed the 480,000 lb-in. (54,279 Nm) load moment. Extra
capacity may be needed to accommodate additional loads, rotation speeds,
inertia, start and stop cycle times, and shock that may occur during loading
and unloading of workpieces. Damage to operators or equipment may occur
if these load considerations are neglected. Refer to Section F.1. LARGE
WORKPIECE INERTIA.
Figure 20—Typical Turntable Positioner
32
(0.305 m)
(177,929 N)
(54,279 Nm)
(0.305 m)
Figure 21—Turntable Capacity Ratings
CAUTION: LOAD CALCULATIONS AND SIZING OF POSITIONING
EQUIPMENT SHOULD BE PERFORMED BY A QUALIFIED
ENGINEER. THE USER SHOULD ALWAYS FOLLOW ALL OF THE
F. Headstock and Tailstock Positioners
Headstock and tailstock positioners can be used to hold and rotate long
workpieces to make welds easily accessible to the welder. Figure 22 shows a
typical headstock and tailstock positioner unit capable of supporting a workpiece
about a horizontal centerline similar to a giant lathe. The headstock is always
powered, just like a lathe. The tailstock is not powered and is used to support one
end of a long workpiece or fixture. In some applications, the headstock unit is all
that is required. Since headstock and tailstock positioners do not tilt, they are
mechanically simpler and cost less than a tilting-rotating positioner of equal
capacity.
All of the weld joints on a workpiece may not be able to be placed in the flat
position, since there is only a single rotation axis. The capacities of headstock and
tailstock positioners range from 500 lb to 120 tons (2,224 N to 109 M tons). These
capacities indicate the maximum total load that can be supported between a
headstock and tailstock.
The principal advantage of a headstock and tailstock over a single tilting-rotating
positioner is that the tilting-rotating positioner would need to be larger to handle
an equivalent long workpiece and would require much more floor space. The
workpiece would have to be mounted crosswise on the table and turn like a
propeller blade. If not mounted crosswise, the workpiece would extend far from
the table. The extended workpiece center of gravity and huge moment would
require an enormous positioner base.
33
Load overhang and rotational requirements are two basic considerations when
selecting headstock and tailstock positioners. Figure 23 illustrates how a
headstock or tailstock is rated for overhanging loads. The load capacity in pounds
decreases with increasing center of gravity distances from the table. When using
a single headstock or tailstock, the user should determine how far the center of
gravity of a workpiece (and associated fixtures) will be located from the table and
then select the model with the capacity to do the job.
Selecting the load capacity for rotation is exactly like selecting rotational torque
for tilting-rotating positioners described in section II.B.2. The model selected
must possess overhang capacity and rotational torque large enough to turn the
workpiece as well as considerations for the effects of inertia. The model that will
handle the greatest of these requirements should always be selected. Constant-
speed rotation is usually adequate when headstock and tailstock units are used
only for moving the part to the desired welding position. When making
circumferential welds on cylindrical workpieces, a variable speed rotation is
required to adjust surface speed for uniform welding deposition rates. When
extreme eccentricity is encountered during rotation, a regenerative-type drive or
the addition of a counterweight should be considered.
(1) Large Workpiece Inertia
The effects of inertia must be considered when specifying any headstock
and tailstock positioner. These effects are easy to visualize. For example, a
helicopter cannot immediately start the lifting blades at a maximum speed.
If it did, it would tear the blades off the helicopter rotor. Instead, the blades
start slowly and gradually speed up to maximum rotation speed. This
situation is even more extreme with a massive workpiece. Extra rotational
torque must be built into a headstock unit if sudden stops and starts are
required. The effect of inertia is different from that of conventional rotation
moments. Inertia varies by the square of the workpiece radius, even when
the workpiece weight remains the same. In all three conditions shown in
Figure 24, the workpiece weighs the same and the center of gravity is on the
rotational axis. Rotational torque will be the same to rotate each workpiece,
but the inertia is different because each radius is different. The rotational
inertia of the second workpiece is four times greater than the first because
the radius is twice as large. The inertia of the third workpiece is 16 times
greater than the first because the radius is four times larger. This indicates
that it is four times harder to start, or stop, the second workpiece than the
first one, and 16 times harder to start, or stop, the third workpiece than the
first. Formulas exist for calculating inertia, and determining the added
capacity needed to handle large workpieces. The manufacturer of the
positioner also can be consulted for guidance on the inertia effects of large
workpieces.
34
Figure 22—Typical Headstock and Tailstock Positioners
(12,010 N) (6,895 N) (4,893 N)
(20,017 N) (8,896 N) (5,783 N)
(0.153 m)
(0.305 m)
(0.457 m)
(0.610 m)
(0.762 m)
(0.914 m)
Figure 23—Headstock and Tailstock Positioner Ratings for Overhanging Load

Capacity
(2) Mounting Workpieces on Headstock and Tailstock Positioners
The procedures described in Sections II.A.3. and II.A.4. for mounting
workpieces to tilting-rotating positioners also apply to headstock and
tailstock positioners. Beware, that an eccentric workpiece mounted on a
free-wheeling tailstock can swing freely if not restrained.
Headstocks and tailstocks must be installed so the centerlines of the two
tables coincide axially. Even with good layout, some misalignment
probably will occur during use because of fixture and workpiece
inaccuracies. A flexible connection or precision alignment between the
ends of the workpiece and the positioner tables is mandatory. A small
misalignment can create forces large enough to shear the work from the
table, ruin the positioner gears, or create unacceptable distortion in the
workpiece. Figure 25 shows a misaligned headstock and tailstock with a
long workpiece mounted rigidly between them. The stresses that will be
produced when the workpiece rotates can tear the work from the table. A
large amount of rotational drag will be created, even if everything holds.
High rotational drag combined with a large workpiece load moment could
stall the headstock drive or overload the gear train.
35
(0.305 m)
(8,896 N)
(8,896 N)
(0.305 m)
(8,896 N) (8,896 N)
(0.305 m)
(0.305 m)
(2,713 Nm)
(106,757 N)
(106,757 N)
(106,757 N)
Figure 24—Effect of Rotational Inertia of Large Workpieces

Flexible connections are easy to prepare and will overcome minor
misalignment between the workpiece and the centerline of the positioner
tables. Two methods are commonly used to provide a flexible connection.
Figure 26 shows how a stub-shaft can be attached to each end of the
workpiece to form a flexible joint. The stub-shaft can be engaged loosely
into the hollow table spindles to take the shear load of the workpiece. If the
tables do not have hollow spindles or suitable pilot holes, fixtures can be
36
fabricated to serve this purpose. This approach requires that either the
headstock or tailstock will be movable longitudinally to allow engagement
of the stub-shafts during workpiece loading and unloading. A steel-wheeled
sub-base and track under the tailstock can provide the necessary motion for
loading the work.
When a movable headstock or tailstock is used, they must be locked in place
when the load is rotated. Figure 27 shows a simpler mounting system called
a universal-pin mounting. A loose pin through the clevis connection affords
limited universal motion at the worktables. This system does not require
longitudinal movement for loading and unloading, and it also prevents the
headstock and tailstock from separating. In both examples, drive dogs are
needed to impart rotational motion to the workpiece and from the
workpiece into the tailstock table. The drive dogs also prevent overstressing
the small cross section on the universal-pin mounting. By mounting the
drive dogs at the greatest distance from the rotation axis, a greater lever
moment is imparted for the rotating work. The tang of the drive dog should
be attached rigidly to the workpiece while the fingers are rigidly attached to
the table on each side of the tang. There should be freedom for the tang to
move longitudinally between the fingers, but there should be no
unnecessary clearance between the fingers and sides of the tang. Any
excessive clearance will allow the tang and workpiece to jump ahead when
an eccentric load passes over the top dead-center position, and hesitate
when the eccentricity passes the bottom dead-center position.
The workpiece is supported at each end, and the center of gravity is located
somewhere in between so overhanging loads must be taken into
consideration. In Figure 27, half of the workpiece weight is bearing down
exactly on the removable pin on each end. The distance from the removable
pin centerline (or flexible point) to the table determines the overhanging
load on the headstock and tailstock. This loading must be compared to a
capacity chart for sizing the proper headstock and tailstock positioner.
When fabricating a work holding device, keep the flexible point as near to
the table as possible. The pilot mounting in Figure 26 is ideal because it
does not create an overhanging load condition. These same rules apply
when any type of positioner is used as the headstock with a tailstock unit,
or with outboard support rollers to hold a long workpiece. Rigid mountings
should be avoided unless precision alignment can be established and
maintained.
37
Figure 25—Misalignment of Headstock and Tailstock Due to Rigid Mounting of

Workpiece
Figure 26—Pilot Mounting Method Overcomes Minor Misalignment
Figure 27—Universal-Pin Mounting System

(3) Determining Swing Clearance
Determining the needed rotation axis swing clearance is required when
selecting headstock and tailstock positioners to avoid large workpieces
striking the floor. The rotation centerline height can be obtained by
calculating the point of the workpiece including all assemblies and
attachments that extend farthest from the rotational axis and adding margin
for clearing the floor. Risers or adjustable bases can be mounted under the
positioners to increase swing clearance for large workpieces.
38
(4) Powered-Elevation Headstock and Tailstock Positioners

Headstock and tailstock positioners are available with synchronized
powered elevation as shown in Figure 28 to lift the work from a loading or
working height to a suitable height for maximum rotational swing. This
lifting motion enhances the versatility and further reduces production time.
These units can be used to automate the welding of the varying radius arc
on large reducing elbows. While welding the bend radius, the turning speed
and elevation are varied to compensate for the steady change in bend radius.
Figure 28—HTS Positioners with Powered Elevation Feature

G. Balancing Positionsers
Balancing positioners are versatile general-purpose positioning devices (see
Figure 29 and Figure 30) that are available in capacities from 25 lb up to 4,000 lb
(111 N to 17,793 N). Balancing positioners are designed to permit the workpiece
to be moved manually. These positioners permit 360° rotation of the workpiece
around the center of gravity. The workpiece also can be rotated 360° around the
positioner’s column. Any workpiece position can be achieved with no more effort
than a light push. The positioner motions have been designed so the tilt and
rotation axes intersect, as shown in Figure 29. While most balancing positioners
are manually operated, some have powered-table rotation options.
(1) Determining Load Capacity
Load capacity ratings for balancing positioners are based on the weight of
the load and distance from the center of gravity to the surface of the table.
For example, a load rating of 1,000 lb at 12 in. (4,448 N at 0.305 m) means
that the workpiece can weigh as much as 1,000 lb (4,448 N) when its center
of gravity is up to 12 in. (0.305 m) from the table surface. The CG symbol
in Figure 30 is shown with a dimension of 13 in. (0.330 m) above the
centerline of the work arm. This indicates the maximum CG height that can
be intersected by the tilt axis within the 30° angle adjustment range. Since
the distance from the table to the centerline of the work arm is 3.25 in.
(0.082 m) the CG axis for balancing purposes can only be adjusted to 9.75
in. (0.248 m) above the table. Any greater distance indicates the need for
counterweights.
39
Do not confuse the two separate center of gravity considerations of

balancing positioners. One is the center of gravity of the workpiece used for
determining the load capacity rating of the positioner. The center of gravity
(CG) shown in Figure 30 is the maximum CG distance that can be
intersected by the tilt axis for a given model. Counterweight, work arm
adjustment angle, and workpiece orientations all need to be considered
when establishing work envelope conditions.
Figure 29—Intersection of Tilt and Rotation Axes on Balancing Positioner
Figure 30—Determining Load Capacity of a Balancing Positioner

CAUTION: LOAD CALCULATIONS AND SIZING OF POSITIONING EQUIP-
MENT SHOULD BE PERFORMED BY A QUALIFIED ENGI-
NEER. THE USER SHOULD ALWAYS FOLLOW ALL OF THE
40
(2) Mounting the Work on Balancing Positioners

Proper use of the balancing positioner requires the center of gravity of the
workpiece to be determined. This can be done as described in Sections
II.A.1. and II.A.2. The workpiece must be mounted on the positioner so that
the center of gravity is located directly over the center of the rotation axis
as shown in Figure 29. Pin locks are provided to positively lock the rotation
and tilt axes during loading, unloading, and when tool pressure is applied.
Mount the workpiece on a balancing positioner table so that the axis of the
center of gravity is exactly on the table’s rotation axis. Securely bolt or
clamp the work to the table and provide some type of shear stops to prevent
the workpiece from sliding on the table. Next, lower the workpiece and
work arm until the axis of the center of gravity of the workpiece is below
the tilt axis of the positioner. Orienting the workpiece so that the center of
gravity is below the tilt axis makes the workpiece bottom heavy and helps
prevent it from unexpectedly moving when pin locks or brakes are released.
The workpiece will settle right-side up or bottom-side up. Simply raising
the work arm will bring the center of gravity up to the tilt axis. Slight
rocking of the load as adjustments are being made will let the workpiece
settle into perfect balance when the center of gravity of the workpiece
intersects the tilt axis.
When properly mounted, the workpiece will not drift out of position since
it is perfectly balanced on the rotation axis. When properly balanced, only
a small force is required to move even heavy workpieces. When the
workpiece is mounted on the table, the work arm can be raised or lowered,
within its limits, to move the workpiece up and down.
(3) Making Minor Balance Adjustments
Counter-balancing weight may be placed temporarily on the workpiece to
bring it back into balance as weld metal and parts are added. Another option
is to tighten the brake slightly to add drag on the rotation and tilt axis.
Counterweights are available that fasten to the tilt arm to counterbalance the
load around the tilt axis. A counterweight attachment is required when a
workpiece center of gravity axis is beyond the table and the work arm
cannot be lowered enough to allow the tilt axis to intersect the center of
gravity axis of the workpiece. The counterweight creates a counteracting
moment that brings the center of gravity axis of the workpiece within the
angle-adjustment range of the work arm. Be sure to install the
counterweight as shown in Figure 31 so the center of gravity is located
directly opposite the center of gravity of the mounted workpiece, to assure
that a minimum amount of force is required for tilting the work. An
imbalance can occur on the tilt axis if either the workpiece center of gravity
axis or the counterweight center of gravity axis is not centered on the same
line. This can cause the table to tilt in whichever direction is off-center.
Make sure that if counter balances are used, they do not exceed the load
capacity of the positioner.
41
Figure 31—Installation of a Counterweight

(4) Motorized Tables
Powered table rotation is an advantage when making circumferential welds
on pipe or cylindrical workpieces. Never select motorized rotation to handle
unbalanced rotational loads. As previously discussed, the center of gravity
of the workpiece must remain on the rotation axis to avoid unbalanced loads
on the tilt axis.
III. TURNING ROLLS
Turning rolls are used to position workpieces for fit-up, welding, inspection, and
finishing operations. Turning rolls can hold and rotate cylindrical workpieces so that
circumferential joints can be welded automatically or semi-automatically. Once
oriented properly on the turning rolls, longitudinal joints can be welded with a welding
head mounted on a side beam and carriage, or welding head manipulator. The basic
turning roll setup includes two powered rolls and a companion set of non-powered idler
rolls. The powered rolls support one end of the workpiece and impart rotational motion.
The idler rolls merely support the other end of the workpiece as it rotates. Cylindrical
shapes weighing from 500 lb (2,224 N) to over 500 tons (454.5 M tons) are readily
positioned using a set of powered rolls and idler rolls. Turning capacity can be
increased to over 1,800 tons (1,636 M tons) with multiple idler rolls.
Cement kilns, municipal garbage digesters, chemical reactor vessels, boilers, pressure
vessels, rocket casings, large-diameter pipe, and penstocks are examples of welding
applications that use turning rolls. Turning rolls can be mounted on a tilting frame or
on rail cars to transport vessels through a fabrication shop. Roll drive speeds range
from 0 ipm (inches per minute) to 80 ipm (0.0 to 2.03 meters per minute). When turning
rolls are used only to rotate a workpiece for accessibility to the weld area, constant-
42
speed rotation is suitable. When the workpiece has to be rotated at a desired rate for
welding circumferential joints, variable-speed drives are mandatory. Power is
transferred to drive roll wheels by gears, chains, or friction drives.
A. Fixed Centerline Turning Rolls
Fixed centerline turning rolls are manufactured with constant wheel spacing (see
Figure 32). The separable drive and idler rolls can be spaced for various
workpiece lengths. Most small-capacity pipe rolls have a fixed centerline and a
friction drive.
Figure 32—Fixed Centerline Turning Rolls

B. Adjustable Centerline Turning Rolls
Adjustable centerline turning rolls are manufactured to permit them to adapt to
workpieces of different diameters. The separable powered rolls and idler rolls can
also be spaced for various workpiece lengths. Gears or chains drive most
adjustable centerline rolls. Adjustment of the centerline distance between the
rolls can be achieved with drive shaft extensions, synchronized drives, angular
orientation, etc. to fit almost any application (see Figure 33).
Figure 34 shows an adjustable turning roll designed for welding applications
when the vessel centerline must be maintained over the center of the turning roll
chassis. This requires both wheels to be adjusted equal distances from the chassis
centerline to accommodate different diameter workpieces. Maintaining vessel
centerline reduces the need for welding torch movement for different diameter
workpieces.
43
Figure 33—Adjustable Centerline Turning Rolls
Figure 34—Vessel Turning Rolls with Adjustable Centerline

C. Fit-Up Rolls
When joining two or more cylinders or sections of vessels to each other, the ends
of each section seldom perfectly match and the sections usually are out-of-round.
Fit-up idler rolls can be used to help line up the ends of these cylindrical sections.
Fit-up idler rolls can be positioned at different locations along the workpiece as
needed.
Figure 35 shows how fit-up rolls can be used to align separate vessel sections for
tack welding. The powered turning roll is placed under one end of one section and
an idler roll under the opposite end of the other section. Fit-up rolls are then
positioned under the two ends to be joined. The two fit-up rolls can be adjusted
to bring the ends of the sections into alignment. Moving both wheels horizontally
in the same direction shifts the section left or right, as shown in Figure 35.
Bringing the fit-up rolls together raises the vessel and moving them apart lowers
the section.
44
Another procedure would be to place a conventional drive roll and idler under one
vessel section. Two fit-up rolls can then be used to support the second section of
the vessel. These rolls can be adjusted to raise or lower and align the mating ends
of the two sections. When the fit-up is completed and the sections are tack welded
together, the fit-up rolls are moved out of contact and the turning rolls used for
finish welding.
Figure 35—Using Turning Rolls for Fit-Up Roll Adjustment

D. Unitized-Frame Turning Rolls
Some turning roll applications require rotating workpieces with limited
diameters, lengths, and weights. Unitized-frame turning rolls, such as those
shown in Figure 36 normally have only one powered axle with one or more
wheels, multiple support wheels, and built-in wheel alignment. The companion
wheel opposite the powered wheel is an idler that may have a fixed or adjustable
centerline to accommodate small or large diameter workpieces. Pre-drilled holes
in the chassis frame permit proper alignment of all of the wheels. The wheels on
each axle can be moved longitudinally for short or long workpieces. Since they
have only one powered axle, traction is not always sufficient for unbalanced
vessels. Rotational power considerations are the same for unitized-frame turning
rolls as for conventional turning rolls. Multiple axle drive options and long roller
bed applications are available.
Figure 36—Unitized-Frame Turning Rolls
45
E. Tilting Turning Rolls

A tilting base can be added to a unit-frame turning roll to provide a second motion
in addition to rotation. Tilting turning rolls can handle limited workpiece
diameters, weights and lengths. Tilting allows the heads or ends of the workpiece
to be welded in the most desirable position of 45° while the cylinder rotates. End
stops are incorporated into each unit to prevent gravity from causing end creep as
the tilted cylinder rotates.
F. Sling Style Rolls
Sling style turning rolls use a chain or sling to handle thin or weak-walled work,
such as missile casings, milk coolers and silos. The chain sling provides a much
greater support area than conventional wheels. Quite often these types of vessels
have settled into an elliptical shape just from their own weight. Sling style units
tend to round-up these vessels during fabrication without denting their sides. Care
must be taken to make sure workpieces are lowered vertically into the chain
slings. Sling style turning rolls can be placed on a common frame that is mounted
on casters for increased versatility. These mobile units can transport a workpiece
through several workstations without having to lift it from its support cradle.
G. Powered and Idler Rail Cars
Mounting powered rolls and idler rolls on cars traveling on rails provides for
longitudinal movement of the workpiece as shown in Figure 37. The powered roll
is usually installed on a powered rail-mounted car and the idler rolls on idler cars.
In most rail car applications the weight of the vessel produces sufficient traction
on the turning roll wheels so that the vessel itself serves as the drabber between
the powered and idler cars. A drabber should be installed to assure that the
powered and idler cars remain accurately spaced, when there is insufficient
traction for a weak-walled or lightweight workpiece.
Most turning roll rail cars are designed to operate on standard 56.5 in. (1.44 m)
gauge track. The car wheels often are adjustable to fit tracks that are not held
exactly to the standard gauge. The cars will travel properly for making
longitudinal welds if the track is accurately aligned, flat, straight, and level.
Crane lifts can be eliminated by use of travel cars to transport a workpiece from
one workstation to another. This can increase production and provide safe
material movement. Weld joints along the length of a workpiece can be welded
by traversing the seam under a welding head while the part is mounted on turning
rolls. Variable speed cars are required for welding longitudinal weld seams.
Constant speed travel is sufficient when only transporting work.
46
Figure 37—Rail Cars for Powered and Idler Turning Rolls

H. Non-Cylindrical Work
Turning rolls are not limited to handling only cylindrical vessels. It is sometimes
more economical to add fixture rings to non-cylindrical shapes so that they can
be placed on turning rolls, than to fixture the work for a headstock and tailstock
or another type of positioner. Figure 38 shows a welding fixture mounted on
turning rolls that allows work to be performed on the end of the workpiece as well
as on all sides.
Figure 38—Turning Roll Setup for Non-Cylindrical Work

I. Pipe Hold-Down Attachments
A pipe hold-down attachment applies pressure to the pipe to hold it in contact
with the turning roll wheels. This assures traction on the drive wheels, but may
not prevent an eccentric load from overturning the rolls or dislodging the hold-
down. In general, use of a restraining mechanism is a poor alternative to proper
setup, unless there is a thorough knowledge of the particular application.
47
J. Weight Capacity
The first factor in selecting any set of turning rolls is to determine the total
workpiece weight. Each powered roll unit has a load rating and the number of
turning roll units needed, or the size of unit-frame units can be determined once
the weight and size of the part to be handled is known. For symmetrical
workpieces, it is assumed that each set of rolls supports an equal portion of the
weight. Therefore, if a single powered roll and single idler roll set are used, each
will support half the total weight of the workpiece. Multiple sets are figured by
dividing the total weight by the number of roll units used to support it.
CAUTION: LOAD CALCULATIONS AND SIZING OF TURNING ROLL
EQUIPMENT SHOULD BE PERFORMED BY A QUALIFIED
K. Rotation Power Ratings
The drive power required to rotate a workpiece also must be taken into
consideration. A powered turning roll is rated in terms of the weight it will
support and turning capacity. For example, a powered roll rated to support a 30
ton (27.3 M tons) workpiece also has a rated turning capacity of 90 tons (81.8 M
tons). If the total load was 90 tons, two additional 30 ton capacity idler rolls are
needed. The ratings refer to the support and power that is provided by the
powered roll to rotate a smooth-walled, straight-sided, concentric cylinder.
L. Tractive-Pull Ratings
Turning capacity does not indicate the power available to rotate cylinders that
have a center of gravity that is not on the center of their rotation axis. Domes on
one side of a workpiece, manhole cutouts, or an off-center tube bundle can cause
unbalanced loads with respect to the centerline. If the center of gravity of the
weldment is off-center, a tractive-pull power rating must be used to select the
proper sized powered roll. Tractive-pull is stated in pounds (Newtons) of force
available at the surface of the powered wheels to rotate the vessel.
The powered roll tractive-pull rating is derived from the axle torque that is
available. When a powered roll has 60,000 lb-in. (6,779 Nm) of axle torque and
is equipped with 20 in. (0.508 m) diameter wheels, then the tractive-pull will be
6,000 lb (26,689 N). This is calculated by dividing the axle torque by the radius
of the wheel as follows:
60,000 lb axle torque = 6,000 lb tractive pull (26, 869 N)
10 in. wheel radius
To fully appreciate tractive-pull, consider the eccentric vessel shown in the
Figure 39. First determine the distance from the center of gravity of the eccentric
dome to the center of rotation. This distance multiplied by the weight of the dome
(offset load) will give the moment that must be rotated. The moment is divided
by the wheel radius to determine the tractive-pull needed at the surface of the
workpiece to rotate the vessel without including drag inherent in the system.
48
(1.9 m)
(1.52 m)
(11,120 N)
(222,400 N)
52,500 lb
(21,128 Nm) total weight
(233,532 N)
(27,800 N)
(0.508 m)
Figure 39—Tractive-Pull Ratings

The following example illustrates the complete tractive-pull calculation for the
eccentric vessel shown in Figure 39. The vessel consists of a cylinder weighing
50,000 lb (222 400 N) with an attached dome weighing 2,500 lb (11,120 N). The
center of gravity (CG) of the cylinder is on the center of the rotation axis and
therefore does not create a moment. However, since the dome’s center of gravity
is 75 in. (1.90 m) from the center of rotation axis it creates a moment of 187,500
lb-in. (21,128 Nm).
2,500 lb X 75 in. = 187,500 lb-in. (21,128 Nm)
The tractive-pull required to rotate the vessel will be applied at the surface of the
cylinder that has a 60-in. (1.52 m) radius from the rotation axis. Dividing the
moment by the radius results in a tractive-pull requirement of 3,125 lb (13,900 N)
as follows:
187,500 lb-in = 3,125 lb (13,900 N)
60 in.
49
Common practice is to double this calculated amount to provide adequate pull to

overcome drag from misalignment, vessel inaccuracies and extra idlers. In this
example the powered turning roll would have to be rated at a minimum of 26,250
lb (116,766 N) weight (one half of the weight of the total vessel) and 6,250 lb
(27,800 N) tractive-pull (3,125 lb x 2 = 6,250 lb total required).
Always request the tractive-pull rating from the manufacturer when selecting
turning rolls. Different designs of turning rolls may have the same weight
capacity and motor sizes, but different gear train efficiencies that affect the usable
power at the wheel surface. Always select a powered roll according to the greatest
task it must perform, whether that is weight capacity or tractive-pull.
M. Included Angle
The distance between the wheels of a turning roll unit also is important for
supporting the workpiece and for the amount of torque required or available to
turn the work. Figure 40 shows the angle between two lines extending from the
center of the workpiece to the center of each axle of a set of turning rolls. This
angle is called the “included angle” of the workpiece. The effect of the included
angle on the force applied to the turning roll wheels follows the same law that
applies to hoist slings. The greater the angle of the sling at the lifting hooks, the
greater the forces on the sling where it cradles the workpiece. Further information
on this subject may be found in most engineering handbooks.
The following sections show how to calculate the effect of included angle. The
greater the included angle, the greater the force on the turning roll wheels and the
larger the force needed to turn the work. Angles between 30° and 60° are common
for many applications. Larger included angles require greater amounts of torque
at the wheels. Referring to Figure 40, a 46° included angle requires the least
amount of tractive-pull needed to rotate the cylinder and an 80° angle requires
more tractive-pull. However, larger amounts of traction are provided as the
included angle increases. When compared with a 46° included angle, the 62° and
80° included angles, respectively, provide 8% more and 22% more traction.
Figure 40—Comparison of Included Angle of Workpieces

An eccentric load requires more traction to keep the wheels from slipping.
Therefore, greater wheel spacing can be used to provide greater traction. Keep in
mind, increased wheel spacing requires more torque and the greater torque
requirement could be enough to stall the powered roll. If this occurs,
counterweights may be added to the eccentric workpiece to reduce the amount of
total workpiece imbalance.
50
N. Traction Calculation
The example in Figure 39 can be used to illustrate how to calculate the required
tractive-pull and the actual traction available to rotate the load. First determine
the weight imposed on the drive wheels and then the friction, or traction in this
case. The effective weight on the wheels is influenced by the included angle
between the turning roll wheels.
The included angle from the center of the cylinder to the wheel centers can be
calculated as illustrated in Figure 41. This figure shows that half of the wheel
spacing is 30 in. (0.760 m) and this also is the distance from the center of the
cylinder to one axle. This dimension forms one side (c) of a triangle. The value
for side (a) of the triangle equals the 60 in. (1.52 m) radius of the vessel plus the
10 in. (0.254 m) radius of the wheel, or a total of 70 in. (1.77 m). The angle C can
be calculated using the Sine function from trigonometry and the formula:
C = Sine C For this example; 30 = 0.4287 which is the sine of 25o 23’
A 70
Since this calculation gives only one-half of the included total angle, the 25° 23’
angle must be multiplied by two (X2) and the result can be rounded off to
approximately 50°.
Returning to the example in Figure 39, the weight on each of the drive wheels is
one-half of the total 52 500 lb (233,532 N) vessel weight, or 26 250 lb (116,766
N). The actual force pressing against the wheels is this weight acting through the
angle C which was calculated above to be 25o 23’. Therefore, the effective weight
pressing on each wheel can be found, again using trigonometry as follows:
Effective weight = Weight = 26,250 lb = 26,250 lb = 28,963 lb (128,834 N)
cos angle cos 25° 0.90631
This means the force between the vessel and each wheel is 28,963 lb (128,834 N).
The traction force between the wheel and the vessel can be found by using the
formula for friction force which equals the force times the coefficient of friction
between contacting surfaces.
Friction force (traction force) = normal force X coefficient of friction
Different materials used for turning roll wheels have different coefficients of
friction. Clean and dry wheels and workpiece surfaces provide the greatest
friction. A coefficient of friction between 0.25 and 0.40 would be appropriate for
most of these situations. As a rule, most facilities do not have clean and dry
surfaces. Using the more conservative value of 0.25 permits the traction force to
be calculated as follows:
Traction = effective weight X coefficient-of-friction
For this example:
28,963 lb X 0.25 = 7,241 lb (32,210 N).
51
This means that 7,241 lb (32,210 N) of traction on the vessel’s surface is needed
to assure transmission of the required 6,250 lb (27,800 N) of tractive-pull
(calculated earlier) to rotate the vessel in this example.
Table 1 can be used to determine the effective weight for a number of values of
included angle between turning roll wheels. Simply select the correct included
angle and multiply the weight imposed on the powered wheels by the
corresponding factor. For example, the 26,250 lb (116,766 N) load on the wheels
with a 50° included angle would be:
26,250 lb X 1.103 = 28,954 lb (128,794 N) effective Weight
Figure 41—Calculating Included Angle for Turning Rolls (See Section III.N.)
52
Table 1. Determining Traction for Selected Included Angles

Included Included Weight
Weight Factor Included Angle Weight Factor
Angle Angle Factor
0° 1.000 48° 1.095 68° 1.206
30° 1.035 50° 1.103 70° 1.221
32° 1.040 52° 1.113 72° 1.236
34° 1.046 54° 1.122 74° 1.252
36° 1.052 56° 1.133 76° 1.269
38° 1.058 58° 1.143 78° 1.287
40° 1.064 60° 1.155 80° 1.305
42° 1.071 62° 1.167 82° 1.325
44° 1.079 64° 1.179 84° 1.346
46° 1.086 66° 1.192
O. Selection of Turning Roll Wheel Materials

Steel turning roll wheels provide a number of advantages. Steel wheels are far
less sensitive to heat from a preheated workpiece and can support greater weights
than other materials. A narrow wheel face requires a narrow path to rotate the
workpiece, and becomes important when the workpiece has objects protruding
from its surface. Steel wheels should be crowned to relieve the high pressure on
the edge of the wheel face. This reduces workpiece marring and lengthens wheel
life.
Rubber or polyurethane wheel tires need to be wider than steel since they do not
support weight as well. Their greater width tends to reduce the pressure on the
vessel which is an advantage for thinner-walled vessels. Rubber or polyurethane
wheels may be preferred to prevent a dent where the wheel contacts the vessel.
Softer, resilient wheels are also more forgiving when a weld seam must pass over
their surface. Overload discs may be added to rubber or polyurethane turning roll
wheels to support the sides of the wheel and prevent the tire from rupturing or
breaking its bond with the steel rim to which it is fixed.
There are times when both steel and rubber are undesirable. Heavy, small
diameter workpieces such as turbine rotors are an example. The narrow journals
will not accept a wide rubber tire and steel wheels may damage the part. Wheels
can be constructed of a phenolic-laminated material that will not mar the critical
surfaces of the work, and has load-carrying capacity to assure wheel longevity.
P. Alignment
Turning rolls are susceptible to instability from one or more misalignment modes.
The best turning roll setup uses only one powered roll and one idler to support the
workpiece. The best turning roll alignment uses only one set of powered rolls and
one idler set to support the workpiece. Figure 42 shows a proper setup. The
wheel-axle centerlines are parallel to the centerline of the workpiece. Each of the
turning roll units is on a flat, hard, level floor and preferably on a flat steel plate.
Do not anchor the turning roll units to the floor. Let them “float” into the best
53
alignment. If any of these conditions are neglected, the wheel surfaces of the rolls
will make a helix contact angle with the workpiece surface. Any helical contact
between the wheel and the workpiece will cause lateral movement or spiraling of
the workpiece as it rotates. This condition commonly is known as “end creep.”
Figure 42—Proper Setup for Turning Roll Alignment

End-creep can be caused by any of the conditions shown in Figure 43. End-creep
requires constant adjustments of the welding arc to track circumferential weld
joints as the part rotates. If only one revolution is needed to finish a weld joint, a
minor amount of end-creep might be tolerated. If several passes are required, the
workpiece could move enough longitudinally to require periodic relocation of the
workpiece on the turning rolls. Without proper attention the workpiece might
creep enough to fall off the rolls.
Assuming the rolls are located on a level floor so the roll bases are on the same
plane, the quickest way to check alignment is to measure the diagonal distance
between the four corners of the wheel axles to square them with each other. Each
diagonal measurement must be of equal length for the rolls to be square. If roll
alignment is accurate and end-creep is still experienced during rotation, then the
work, itself, might not be straight or might have a different diameter at each end.
One solution is to intentionally misalign one of the turning roll units to counteract
the end-creep tendency of such a workpiece. Beware that intentional
misalignment of the turning rolls (shown in Figure 44) can cause a number of
problems. The misaligned turning roll wheels scrub the workpiece surface and
create drag. Added drag increases the power required to rotate the load and might
be enough to stall the drive roll. The weight of the vessel could be imposed on the
edge of the wheel face, damaging the wheel or marring the vessel.
End stops or thrust rollers are sometimes used to bear against the ends of the
workpiece to prevent end-creep. End stops prevent the small wandering caused
by minor misalignment, but add extra drag to the rotation of the workpiece. The
use of end stops to compensate for end-creep due to improper turning roll
alignment is not recommended.
54
Figure 43—Conditions that Cause End-Creep
Figure 44—Intentional Misalignment of Turning Rolls to Counteract End-Creep

Q. Overturning Instability
In some instances, it is necessary to support a workpiece with the center of gravity
(CG) located off center either in a radial or longitudinal direction as shown in
Figures 45A through 45D. When this condition exists, overturning stability must
be verified. This verification needs to make sure the center of gravity of the
workpiece is within the length and the width of the wheel spacing envelope. If the
center of gravity during rotation can exceed this envelope, an unstable condition
occurs that may cause the workpiece to tip or roll out of the rolls. If the center of
gravity is close to the edge of this envelope, be aware that end-creep
longitudinally, or even someone leaning against the workpiece can move the
center of gravity enough to cause an unstable condition. If any of these conditions
exist, an offset counterweight may be used to orient the center of gravity safely
within the envelope. It also may be possible to widen the wheel spacing to
overcome a radial condition. Remember to review traction and included angle
calculations to not overload the drive roll.
55
Figure 45—Overturning Instability of Workpiece on Turning Rolls
Figure 45B
56
Figure 45C
Figure 45D
R. Setting Up Turning Rolls for Multiple Sections
A workpiece often has more than one section, as shown in Figure 46. One
powered turning roll (D) and two or more idler turning rolls (I) may be needed to
support the work. A powered roll and an idler roll might hold the first section
while two idler rolls hold the second section. When the first two sections of the
work are tacked and welded together, the idler rolls can be moved into a new
location to receive the third section. This procedure is repeated until the
workpiece is complete. The multiple turning roll units share the load as the length
of the workpiece increases. Alignment becomes increasingly important, as the
work grows longer. Each added idler roll is another source of possible
misalignment and drag.
Using a built-in alignment system can save time and effort when multiple turning
roll units must be relocated periodically to support several sections making up a
single workpiece. V-groove wheels under the units, guided on rails, make it
convenient to relocate the unit, without having to check its alignment (see Figure
47).
If the workpiece was straight and concentric, multiple roll units would equally
share the load and each turning roll unit could be selected to share its portion of
the load. However, a large workpiece being straight and fully concentric around
its centerline is often not the case. Figure 48 shows a workpiece that is bent in an
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exaggerated shape and is supported by three rolls, one at each end and one in the
middle. Once every revolution the belly of the workpiece is at the top and the total
load must be supported by the two outboard units.
When the work rotates 180° the belly is down, placing most of the load on the
center unit. When more than two units are required to support a load, always
select one powered roll and one idler roll of sufficient capacity to share the total
workpiece load. Each additional idler roll should be equal in capacity to the
powered roll. When the workpiece weight shifts from unit to unit each will have
enough capacity to support one-half the workpiece weight. Accommodations in
roll placement must also be made to make sure the powered roll is in sufficient
contact with the workpiece at all times during rotation. Failure to properly space
turning rolls could allow a workpiece of this type to rotate out of control.
Figure 46—Turning Roll Set Up for Workpiece with Multiple Sections
Figure 47—Welding Head Manipulator and Multiple Turning Roll Alignment System
Figure 48—Bent Workpiece Supported by Multiple Turning Roll Units
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S. Shock Loading
The most damaging moment in the life of a turning roll is when the workpiece
hits the wheels during loading. It is practically impossible for a crane operator to
lower a vessel or other load so that the workpiece simultaneously contacts all the
powered and idler wheels at once. Often the workpiece strikes one wheel first.
This wheel receives the full shock-load of the dropping vessel, before it settles
equally on all the wheels. When that wheel is on the powered unit, the impact
force produces a rotary force transmitted back through the entire drive train.
CAUTION: FAILURE IN ANY OF THESE COMPONENTS COULD ALLOW
THE DRIVE WHEEL TO ROTATE OUT OF CONTROL. OFTEN
WHEN AN EXCESSIVE SHOCK-LOAD OCCURS, NO VISIBLE
DAMAGE TO THE ROLLS IS APPARENT. IF THERE IS DAMAGE
AND AN ECCENTRIC LOAD, DURING MOTOR START-UP A
FAILURE COULD OCCUR CAUSING THE WORKPIECE TO
ROTATE UNCONTROLLED UNTIL ITS HEAVY SIDE RESTS AT
BOTTOM DEAD CENTER. THIS IS A MAJOR HAZARD TO
WORKERS AND EQUIPMENT IN THE AREA.
T. Weld Joints
Turning rolls can be damaged when a longitudinal weld seam or a lap joint passes
over the wheels of the powered roll. The extra thickness of the weld seam or lap
joint changes the vessel’s radius where it contacts the powered wheels. When the
lap joint passes over the wheels, the vessel must be lifted. This causes a
momentary “chocking” of the wheel rotation. Additional rotational torque is
needed to transmit full rotation power through only one wheel to keep the
workpiece rotating. Therefore, each wheel’s drive train must be capable of
transmitting the full-rated motor power of the entire roll set when the load shifts.
Load shifting also can be caused by an unbalanced (eccentric) workpiece.
IV. WELDING HEAD MANIPULATORS
While welding positioners can be used to move the work under the welding process
equipment, welding head manipulators move the welding process equipment over the
work. Figure 49 illustrates the basic components of a welding head manipulator that
includes a vertical column or “mast” that has a horizontal “boom” mounted to it. The
welding head is normally mounted on one end of the boom (see Figure 47 and Figure
50). Moving the boom up and down the mast provides vertical motion, or “lift”. Motion
perpendicular to the mast, called “reach”, is provided by the boom moving in and out.
The mast can rotate up to 360° to provide coverage of any radial location around the
manipulator. The entire manipulator can be mounted on a car that travels on tracks to
provide longitudinal motion that permits welding long joints or traversing the
manipulator to reach multiple weld joints on large workpieces.
The size of a welding head manipulator is only limited by the needs of the job and the
available space. Welding head manipulators can be very large, with high load capacity
booms that tilt, swing, and telescope. Load capacities of welding head manipulators
range from 150 lb to 3,000 lb (667N to 13,345N). Manipulators can have vertical lift
travel of up to 40 feet (12 m) from the floor and booms extending out to 40 ft (12 m)
horizontally (see Figure 50). Manipulators can be highly sophisticated with track-
mounted traveling cars, flux recovery units and operator seats or walkways
59
(see Figure 51). On the other hand, they can be a simple mast and boom combination
just for holding spooled electrode, controls and the welding head. Other applications
involve automated welding equipment, often using multiple electrodes. Manipulators
are best used for repetitive welding sequences, surfacing large areas, or for long welds
where high travel speed pays out in high productivity.
A. Manipulator Selection
Selection of a welding head manipulator involves determining the motions
required to orient the welding equipment so that the arc covers the required
positions and dimensions of the workpiece. The second factor is the maximum
weight that the manipulator must support. The following sections detail the
factors that need to be considered in selecting the lift, reach, travel, and load
capacity of a welding head manipulator. It is recommended that a generous
allowance be made for extra lift and reach. The extra capacity will avoid finding
out later that the equipment is too small for the job. When sizing a welding head
manipulator, the extreme arc positions for reach and lift may have to be
determined when the workpiece is supported on positioners, headstock and
tailstock units, or turntables. Make sure that sufficient clearance is available to tilt
the workpiece without interfering with the welding head. Figure 52 shows one
such example. Be sure the manipulator boom can retract far enough from the
work to afford clearance when loading and unloading the workpiece from the
positioning equipment on which it is mounted.
Figure 49—Basic Motions of a Welding Head Manipulator
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Figure 50—Large Model Welding Head Manipulator
Figure 51—Welding Head Manipulator with Welding Equipment Installed on Both

Ends of the Boom
Figure 52—Determining Extreme arc Positions for Reach and Lift
61
B. Lift
When selecting a welding head manipulator, one decision is how low and how
high the welding head must travel for the desired workpiece. Figure 53 and
Figure 54 show an example that will be used to illustrate the range of lift and
reach motions needed. The figure shows a cylindrical vessel and a manipulator
that will be used to weld a joint along the length of the vessel as well as the
circumferential joints between vessel .sections (not shown in the figure). The
welding head must be able to reach the top of the weld joint on the outside of the
vessel as well as the inside of the weld when it is on the bottom of the vessel.
“Lift” is the amount of boom elevation required to reach the work and “lift range”
of the manipulator is the distance from the floor to the centerline of the boom. If
the workpiece is supported on turning rolls, extra height must be included when
choosing a proper lift range.
Proceed as follows to find the overall height of a 10 feet (3 m) diameter vessel on
turning rolls, as shown in Figure 53. The radius of the vessel (60 in.) (1.52 m) plus the
turning roll wheel radius (10 in.) (0.254 m) form the 70 in. (1.778 m) long hypotenuse
of a right triangle (60 in. + 10 in. = 70 in.) (1.52 m + 0.254 m = 1.778 m). Half of the
center-to-center distance between the wheel axles on the turning rolls will give the
base of the triangle 70 in. divided by 2 equals 35 in. (0.889 m). With these figures the
altitude, “b” of the triangle can be found using the formula: where “a” is the
hypotenuse (70 in.) and “c” is the base (35 in.) of a right triangle.
a2 - c2 = b2
70 X 70 - 35 X 35 = 3675
√3675 = 60.6
Add this number (60.6 in.) (1.54 m) to the radius of the vessel (60 in.) (1.52 m)
and also add the height of the wheel centerline above the floor (17.75 in.) (0.450
m). The result is a total height of (138.35 in.) (3.51 m) above the floor (60 in. +
60.6 in. + 17.75 in. = 138.35 in.) (1.52 m + 1.54 m + 0.45 m = 3.51 m). The
welding arc needs to be positioned at the top of the workpiece that is 138.35 in.
(3.51 m) above the plant floor.
To find the height of the inside bottom seam of the vessel, add the vessel’s wall
thickness (1 in. in this example) to the inside diameter of the vessel (1 in. + 118
in. = 119 in.). Subtract this figure from the distance from the floor to the top of
the workpiece (138.35 in. – 119 in. = 19.35 in. (0.490 m). The distance to the
inside of the weld joint in this example is 19.35 in.
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Figure 53—Determining Overall Height of a Vessel on Turning Rolls
Figure 54—Lift Range of a Welding-Head Manipulator

Figure 54 shows that the welding equipment will be mounted on the manipulator
boom so the welding arc is located 18 in. (0.457 m) below the centerline of the
boom. This distance is a function of the welding equipment being used. The
required maximum travel height of the centerline of the manipulator boom will
need to be the distance from the floor to the top of the work plus the distance from
the top of the work to the boom centerline (138.35 in. + 18 in. = 156.35 in.
(4.0 m).
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To weld the inside bottom weld seam of the vessel, the boom centerline will have
to be 119 in. lower. This exercise shows that this manipulator will need a
minimum of 119 in. of lift range.
138.35 in. – 19.35 in. = 119 in. (3.022 m).
The added dimensions of a manipulator that is equipped for mast rotation or one
that is mounted on a car also must be considered when doing lift range
calculations.
C. Lift System Safety
A safe lift system is the single most important aspect of any manipulator. Unlike
the other three motions (reach, mast rotation, and car travel) a failure in a lift
system threatens the safety of the operator, other personnel, and equipment. If the
boom falls down the mast, damage to the welding equipment is certain. Serious
injury or death may occur if the operator is under, or riding on the boom during a
lift failure. Care should be taken to perform frequent inspections and to perform
proper maintenance of the lift components and safety devices.
D. Reach
The second consideration in selecting a welding head manipulator is to determine
horizontal boom travel required to move the welding head the longest horizontal
welding length. Figure 55 shows a vessel with a weld length of 120 in. (3 m). The
end of the boom is 18 in. (0.457 m) from the centerline of the mast. The total
reach travel needs to be long enough to allow the proper boom engagement at
maximum reach. The distance from the end of the boom to the welding head must
also be considered. The welding head manipulator must be located far enough
from the vessel to allow clearance for the vessel to be loaded and unloaded from
the turning rolls without interference.
(0.46 m)
(3.5 m)
(3.045 m)
(3.045 m)
Figure 55—Determining Horizontal Boom Travel

E. Mast Rotation
Adding mast rotation increases the versatility of manipulators. Mast rotation of
360° can be used to position a welding head at different workstations, or when
loading and unloading another positioning device.
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F. Car Travel
While boom travel motion can be used to produce long straight welds, boom
lengths have practical limits based on rated payloads and allowable deflections.
The addition of a wheeled car under the manipulator can move the welding head
parallel to the workpiece centerline while the boom holds the welding head on the
weld joint. A car also can position the welding head over girth joints anywhere
along the workpiece length.
Add the length of the weld joint to the length of the car’s deck to determine the
total length of track needed for an application. Extra track length should be
provided so that the manipulator can be moved out of the loading area, or used
for jobs that might have weld run-off tabs. The track should be leveled during
installation to provide the accuracy needed for smooth, predictable arc travel.
CAUTION: FULL EXTENSION AND RETRACTION OF CAR TRAVEL, LIFT,
REACH AND ROTATION OF THE MAST MUST BE CONSIDERED
WHEN CALCULATING THE WORK ENVELOPE AND REQUIRED
CLEARANCE FOR SAFE OPERATION.
CAUTION: LOAD CALCULATIONS AND SIZING OF WELDING HEAD
MANIPULATORS SHOULD BE PERFORMED BY A QUALIFIED
G. Powered Motions
All four manipulator motions (lift, reach, mast rotation and car travel) can be
supplied with manual or motorized operation. Manual operation is practical only
for small manipulators where the boom can be reached from the floor and pushed
or hand-cranked into the desired position. The type of motion for each axis is
specified separately when ordering a manipulator. For example, variable-speed
boom motion may be needed for welding using the boom’s travel, constant-speed
lift for arc height adjustment, manual mast rotation for infrequent swinging of the
boom to another location, and variable car-traverse speed for welding long seams
while traveling on tracks.
Manipulator motions can also be integrated with turning roll or positioner motion
to provide a more automated system.
H. Manipulator Load Capacity
Manipulators are available in a wide variety of reach ranges, lift ranges, and load
carrying capacities. When determining the required load weight, include the
weight of the welding head, controls, welding electrodes, and submerged arc
welding flux recovery units. Do not forget to add the weight for the operator to a
load capacity if the manipulator is designed for the welding operator to ride on
the boom. It is not unusual to have a 750 lb to 1,000 lb (3,336 N to 4,448 N) load
on the head end of a manipulator boom.
65
To minimize the load at the head-end of the boom, equipment such as power
vacuum units for flux recovery and electrode pay-off packs can be installed on
the back-end of the boom. Select the manipulator that will carry the maximum
boom load wherever it occurs, on the front or the back end of the boom. For
example, a welding head may be mounted at each end of the boom (see
Figure 51). Take the distribution of the load on the boom into account and size
the manipulator for the maximum loading with the boom extended to its
maximum length. There are practical limits to boom length based on rated
payloads and allowable deflections. A stronger model is required if the load
becomes excessive for the given amount of reach range especially if manipulator
motion will provide weld head motion during welding or if the welding process
is sensitive to variations in torch to workpiece distances.
I. Location and Mounting of Welding Head Manipulators
The maximum overturning moment is transmitted to the base of the welding head
manipulator when the boom travels to either end of the extreme reach position.
Proper foundation preparation should be taken into consideration when securing
the base mounting of a welding head manipulator. A qualified engineer should
review all foundation and loading designs. Foundations are typically not needed
for manipulators mounted on travel cars or those designed with freestanding
bases.
J. Manipulator Equipment and Accessories
Welding head manipulators can be equipped with many optional accessories to
support a variety of welding processes, equipment, and applications. Some
examples are listed below:
• The manipulator boom can be of a fixed length or can have a telescoping
boom. The boom also may tilt for angular adjustment.
• The boom may be mounted with a side beam and carriage.
• When the application uses the boom’s travel motion combined with a
traveling car for making long welds, a swivel is usually required to orient
the welding head at 90° so the arc is presented properly for longitudinal
and circumferential weld joints. In some cases, a 180° swivel mount is
required to turn the welding head back in the direction toward the starting
point when making a second pass on a longitudinal seam using car travel.
• Sometimes a ±45° tilting swivel is required to position the arc to weld
flanged heads on the ends of a vessel.
• Manual and powered slides are often mounted to the end of the boom for
fine positioning control of the welding head.
• The welding power sources and flux recovery units can be placed on
shelves attached to the mast. This saves space and prevents problems
with tangled cables when the mast rotates.
66
• Turntables and electrode guides can help feed electrode wires from pay-
off packs located on the boom.
• The manipulator can include an operator’s seat to place the operator near
the welding head.
• A walkway also is quite useful. The operator can quickly and safely reach
welding equipment on both ends of the boom. A boom with a walkway
will not have to be lowered to the floor when the welding equipment
needs attention.
• A ladder attached to the manipulator mast gives access to the walkway at
any height, and for servicing power sources.
• When the manipulator travels on a track, a cable carrying system may be
desired to prevent dragging the power cables, gas or water hoses, and
remote control cables. Also, the welding ground circuit must be
completed from the workpiece to the power sources on the mast.
• Computer controls can be added to control weld processes, weld
schedules, motion controls, weld monitoring and other functions.
V. SIDE BEAM AND CARRIAGE EQUIPMENT
A welding side beam is a horizontal beam with guide rails for a traveling carriage as
shown in Figure 56. A welding head is mounted onto the carriage and the combination
of side beam and carriage provides linear motion of the welding equipment for welding
long weld joints. The carriage also can be used to position the welding head over girth
weld joints anywhere along the workpiece length.
Side beam track can be supplied in almost any length. Add the length of the weld joint
to the length of the carriage for a total side beam length. Extra side beam length should
be provided so the carriage can be moved out of the loading area, or used for jobs that
might have weld run-off tabs. The side beam should be leveled during installation to
provide the accuracy needed for smooth, predictable arc travel. A curved side beam
may be used to match the contour of the weld joint.
The load capacity of a carriage is based on a maximum load located a specific distance
from the mounting face. The information given previously for positioners can be used
to calculate moment and torque requirements for proper carriage loading.
Most carriages are equipped with variable speed controls to permit selection of the
desired welding speed. The drive also can be disengaged to allow manual positioning
of the carriage. Manual operation is practical where the carriage can be reached from
the floor and pushed to the desired position.
A. Side Beam and Carriage Equipment and Accessories
Fixed, adjustable height or power elevating stanchions may be used to support the
side beam in the proper orientation to the workpiece. Many of the same
accessories available for manipulators can be adapted for use with a side beam
and carriage. See Section IV.J.
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Computer controls of varying complexity can be added to control weld processes,

weld schedules, motion controls, weld monitoring, and other features and
functions.
Figure 56—Basic Side Beam and Carriage Application

A side beam and carriage can be used along with other positioning equipment or
fixtures to make longitudinal welds or to locate a welding head for
circumferential welding. Figure 57 shows a welding lathe, one example of this
type of application. A welding lathe can have one or more carriages that can be
used to make both longitudinal and circumferential welds.
In many applications a side beam carriage is attached or configured over a fixture.
The welding seamer shown in Figure 58 is another example of a side beam and
carriage positioned over tooling to hold flat or cylindrical parts for welding joints
along their length.
Figure 57—Welding Lathe
68
Figure 58—Seamer Side Beam and Carriage Application

VI. SAFETY CONSIDERATIONS
The use of mechanical positioners rather than manual labor to position weldments
during welding reduces the likelihood of injury during welding operations.
Nonetheless, the operation of industrial machinery requires the observance of safety
codes and procedures. Refer to Section IX. SAFETY DOCUMENTS for a list of safety
related documents that are applicable to the safe operation of welding positioning
equipment. Safe welding practices begin with reading operations manuals; observing
installation, maintenance, and operating instructions; and adhering to caution or
warning statements for safe equipment operations. Safety considerations related to
fixturing and positioning are discussed in more detail below.
A. Environmental Interference
Safe practice dictates that the area surrounding the workstation must be clear to
avoid interference between the weldment or manipulator and other objects in the
area. Operators working in areas traversed by positioners or workpieces must pay
close attention to obstructions at all times. Sufficient height must be provided for
weldments to clear the floor. Manual or powered elevation in the base of the
positioner is recommended for this purpose.
Operators must ensure that the floor and positioning devices are of sufficient
capacity for the work being performed. The work area must be kept clean and dry,
and stray chains, tools, cables, and rigging must be kept clear of the workpiece
and attached obstructions at all times. Proper storage and access platforms for
personnel should be provided to ensure that the equipment is not used as a work
platform. Equipment guards must be in place, and no electrical circuitry or
rotating machinery must be left exposed during operations. Precaution should be
taken to observe positioning equipment that moves very slowly or very rapidly,
depending on the application and the situation.
69
B. Fastening Loads
For safety, a weldment must be firmly mounted on a positioner to prevent its
moving or falling off during welding and allied operations. The weldment or the
fixture can be bolted or welded to the positioner table. In either case, the fastening
mechanism must be strong enough to hold the work securely under any condition
of tilt or rotation. The reaction loads at the fastening locations must be calculated
or correctly estimated to ensure that the load is secured by properly designed
fasteners.
C. Avoiding Instability
Positioners are designed to be stable when loaded within their rated capacity but
may be unstable if overloaded. Tilting positioners may be unstable during tilting
because of the inertia of the load. Injury to personnel or damage to equipment can
be serious if an overloaded positioner suddenly tips during operation. For this
reason, positioners must be fastened to the floor or other suitable foundation for
safe operation. The instructions provided by the manufacturer concerning
foundation design and fastening methods must be carefully followed to ensure
safe installation.
The overloading of positioners cannot be condoned. When a positioner table is
overloaded and then tilted to the 90° position, it may be impossible to return the
table to the flat position because of insufficient power. Shop management must
make every effort to ensure that the equipment is operated within its rated
capacity to assure safe operation and long life. The accurate determination of the
load, center of gravity, and eccentricity is imperative in the avoidance of
overload. The safety features required in positioning equipment include thermal-
limiting or current-limiting overload protection of the drive motor, low-voltage
operator controls, a load-capacity chart, and emergency stop controls.
Turning rolls are particularly susceptible to instabilities such as overturning,
creep, drag, and overload. Therefore, the safe practices associated with their use
should include periodic stability checks. The workpiece and the rolls should be
inspected to ensure clear, unobstructed rotation, paying close attention to any
protrusion or interference. In addition, caution should be taken to avoid dropping
a workpiece onto the rolls, which may damage the equipment and create an
occupational hazard. Since turning rolls typically rotate at very slow speeds,
operators must be sure to stop a turning roll when it is not in use.
D. Other Safe Practices
When using powered weldment clamping fixtures, a safety electrical interlock
should prevent rotation (or elevation where applicable) until the clamping
mechanism is fully locked to the weldment components. The use of proximity
and limit switches is also advisable, especially in the positioning of oversized
loads to avoid overtravel or collision of the weldment with the floor or other
obstructions.
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E. Economic Considerations
With respect to cost, the use of a positioner can be either positive or negative,
depending primarily on welding and handling costs. On the positive side are the
high deposition rates, high operating factor, and high product quality that can be
achieved when using a positioner to orient the work for flat-position welding.
When used properly, positioners reduce the risk of accidents during the handling
of weldments. On the negative side, handling costs are incurred in loading and
unloading the positioner.
Economic considerations for turning rolls compare similarly to positioners. Weld
lathes and manipulators provide optimal economic benefits when long,
continuous welds are required or when unfavorable ergonomic factors can be
overcome or when computer controlled welding is desired.
F. Deposition Rates
In arc welding, the highest deposition rates and the fewest passes are obtained
when welding is performed in the flat position because gravity keeps the molten
metal in the joint. Welds made with a minimum of passes generally contain less
welding stress and associated distortion. It should be noted, however, that heat
input limitations must be observed with some alloy steels. As the positioning of
weldments increases the deposition rate and the arc time, this practice results in
a significant reduction of welding costs.
G. Operator Factor and Set-Up Costs
The operator factor is calculated from the ratio of the arc time to the total time
that a welder dedicates to a weldment. In the absence of a positioner, the welder
must manually reposition the weldment, wait for a crane operator to move it, and
often weld in positions other than flat. Consequently, the operator factor is low,
and welding costs are high. The operator factor is higher when a weldment is
rapidly positioned for welding using a positioner. Nonetheless, the labor costs for
both the safe loading and unloading of a heavy weldment on a positioner and for
the repositioning of a weldment with a crane or other lift must be considered.
Turning rolls, manipulators and weld lathes are typically utilized when the
handling, the size or weight of work pieces, or other unfavorable ergonomic
factors would otherwise adversely affect the operator factor.
H. Welding Skill
Arc welding in the flat position requires less skill than other welding positions
because this position makes it easier for the welder to control the molten weld
pool. Therefore, welding positioning can reduce labor costs as the assembly can
be easily manipulated for welding joints in the flat position.
For relatively short, small welds, it may be more economical to weld the joints in
fixed positions than to reposition the weldment for ease of welding. In this case,
welding costs are somewhat higher, but the overall labor costs are lower because
of cost savings with respect to handling. However, quality welds performed in
welding positions that are not optimal require additional operator training and
skills, and operator fatigue tends to reduce productivity and weld quality. The
71
cost of positioning equipment and material handling must be offset by cost

savings in labor and improvements in weld quality. In addition, computer controls
can control and monitor the welding process to ensure consistent quality and cost.
VII. CONCLUSION
The advantages of weldment fixturing and positioning are significant. Positioning the
weldment in the proper orientation minimizes operator fatigue during welding and
cleaning operations, resulting in a minimum of discontinuities and weld repair.
Welding in the flat position renders equal fillet legs, smoother weld beads, and
improved penetration. With downhand welding, the effects of gravity improve the
handling of molten metal to improve weld quality.
Weld positioners and turning rolls can provide workpiece orientation and weldment
fixturing required for integration with electronically or computer controlled welding
head manipulators and robots.
VIII. BIBLIOGRAPHY
American National Standards Institute (ANSI) Z49.1, Safety in Welding, Cutting and
Allied Processes, Miami, American Welding Society
Blodgett, O.W. 1976. Design of Weldments. Cleveland: The James F. Lincoln Arc
Welding Foundation.
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IX. SAFETY DOCUMENTS

ANSI/RIA R15.06-American National Standard for Industrial Robots and Robot
Systems - Safety Requirements
ANSI Z41, Personal Protection - Protective Footwear
ANSI/ASSE Z87., Occupational and Educational Personal Eye and Face Protection
Devices
ANSI/AIHA Z88.2, Practices for Respiratory Protection
ANSI Z49.1:, Safety in Welding, Cutting and Allied Processes
AWS F1.1, Method for Sampling Airborne Particulates Generated by Welding and
Allied Processes.
AWS F1.2, Laboratory Method for Measuring Fume Generation Rates and Total Fume
Emission of Welding and Allied Processes.
AWS F1.3, Evaluating Contaminants in the Welding Environment: A Strategic
Sampling Guide.
AWS F1.4, Methods for Analysis of Airborne Particulates Generated by Welding and
Allied Processes.
AWS F1.5, Methods for Sampling and Analyzing Gases from Welding and Allied
Processes.
AWS F3.2, Ventilation Guide for Welding Fume Control
AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping That Have Held Hazardous Substances.
AWS SHF, Safety and Health Facts Sheets.
CGA P-1, Safe Handling of Gas in Containers
NFPA 70, National Electric Code
NFPA 51B, Fire Prevention during Welding, Cutting and other Hot Work
NIOSH Publication No. 88-110, Criteria for a Recommended Standard: Welding,
Brazing and Thermal Cutting
OSHA, Handbook for Small Businesses
73
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74

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The Practical Reference

This publication is designed to provide information in regard to the subject matter

550 N.W. LeJeune Road, Miami, FL 33126

International Standard Book Number: 978-0-87171-086-4

Basic Safety Precautions

Intentionally Left Blank

Figure Page No.

Figure 1—Center of Gravity of a Solid Cube

Figure 2—Center of Gravity of a Cylindrical Object

Figure 3—Finding the Center of Gravity of Small Workpieces

Figure 4A—Finding the Center of Gravity of Large Workpieces by Balancing them

Figure 4B—Alternate View

Figure 5B—Alternate View

(3) Mounting Work onto a Weldment Positioner

Figure 6—Effects of Tilting and Weldment Geometry on Positioner Fastener

CAUTION: MOUNTING METHODS, FASTENERS, AND TACK WELDING

Figure 7—Use of a Three-Jaw Self-Centering Chuck

Figure 8—Calculation of Total Tilt-Load Moment Requirements

(6) Floor Anchors

Figure 9—Force of Inertia on the Base of a Positioner

Figure 11—Examples of 45°–90° and 135° Tilting-Rotating Positioners

With an understanding of how torque ratings for positioners work, the

To hold this workpiece, the positioner’s tilt drive must be capable of

Figure 12—Typical Tilting-Rotating Positioner

Figure 13—Workpiece Mounted on Tilting-Rotating Positioner

Figure 14—Capacity Plate Data for a Tilting-Rotating Positioner

It is possible to calculate the load capacity or the maximum workpiece

830,000 lb-in. (from capacity chart) = Maximum permitted load

Figure 15—Rotation Axis of the Positioner as the Fulcrum

Consider an example where it is required to determine the number of

Figure 16—Diagram for Determining Revolutions Per Minute

Figure 17—Powered-Elevation Positioner in the 135° Tilt-Down Position

Figure 18—Positioning Three Different Welds on a Spool-Shaped Workpiece Using

Figure 19—Drop-Center Tilting Positioner

Turntables can be equipped with constant or variable speed drives or can be

Figure 20—Typical Turntable Positioner

Figure 22—Typical Headstock and Tailstock Positioners

(12,010 N) (6,895 N) (4,893 N)

(20,017 N) (8,896 N) (5,783 N)

Figure 23—Headstock and Tailstock Positioner Ratings for Overhanging Load

Figure 24—Effect of Rotational Inertia of Large Workpieces

Figure 25—Misalignment of Headstock and Tailstock Due to Rigid Mounting of

Figure 26—Pilot Mounting Method Overcomes Minor Misalignment

Figure 27—Universal-Pin Mounting System

(4) Powered-Elevation Headstock and Tailstock Positioners

Figure 28—HTS Positioners with Powered Elevation Feature

Do not confuse the two separate center of gravity considerations of

Figure 29—Intersection of Tilt and Rotation Axes on Balancing Positioner

Figure 30—Determining Load Capacity of a Balancing Positioner

(2) Mounting the Work on Balancing Positioners

Figure 31—Installation of a Counterweight

Figure 32—Fixed Centerline Turning Rolls

Figure 33—Adjustable Centerline Turning Rolls

Figure 34—Vessel Turning Rolls with Adjustable Centerline

Figure 35—Using Turning Rolls for Fit-Up Roll Adjustment

Figure 36—Unitized-Frame Turning Rolls

E. Tilting Turning Rolls

Figure 37—Rail Cars for Powered and Idler Turning Rolls

Figure 38—Turning Roll Setup for Non-Cylindrical Work

Figure 39—Tractive-Pull Ratings

Common practice is to double this calculated amount to provide adequate pull to

Figure 40—Comparison of Included Angle of Workpieces

Table 1. Determining Traction for Selected Included Angles