Yaskawa and Tank Clinic transform aluminium tanker manufacturing with advanced robotic welding
A highly specialised robotic welding solution developed by Yaskawa Southern Africa is helping
Tank Clinic transform the way it manufactures aluminium road tankers, demonstrating how
advanced automation can address some of the most demanding challenges in South African
manufacturing.
The system, developed specifically around Tank Clinic’s requirements, combines a Yaskawa
AR1440 welding robot with an OTG-XYZ on-track gantry, rotating headstocks, positioners,
vision-based seam finding and aluminium welding technology.
The result is a large-scale robotic welding system capable of moving around the tanker while the
tanker itself rotates, providing the reach, accessibility and welding positioning required for the
final welding process.
The solution was showcased at Tank Clinic’s recent Open Day, held to mark the company’s 50th
anniversary, giving customers, industry stakeholders and visitors an opportunity to see the
technology operating in a live manufacturing environment.
The project originated from Tank Clinic’s need to improve the capacity, consistency and
repeatability of a welding process that had previously been carried out exclusively by skilled
welders. Rather than applying an off-the-shelf robotic cell, Yaskawa worked with Tank Clinic to
develop a system around the size, geometry and production requirements of its tankers.
“Large aluminium tankers present a very different challenge from the smaller, repetitive
applications where robotics are traditionally associated. The robot needs to reach across a large
workpiece, maintain the correct welding orientation and coordinate its movement with the
movement of the tanker itself,” says Devon Prinsloo, National Project Manager at Yaskawa
Southern Africa.
“The solution therefore required considerably more than putting a robot on a track. It involved
integrating the robot, gantry, positioners, welding equipment and vision system so that they
operate as one coordinated system.”
A conventional fixed robot would have significant limitations when working across a tanker of this
scale. The OTG-XYZ gantry provides approximately eight metres of track travel, with additional
multi-axis movement, while two headstocks rotate and position the tanker for welding.
The system also incorporates Fronius Cold Metal Transfer (CMT) technology for aluminium
welding and a Servo Robot i-Cube camera system for seam finding, alongside automatic torch
cleaning and safety systems.
Significant engineering, programming and R&D went into integrating the various technologies to
suit Tank Clinic’s specific manufacturing process. The Yaskawa robot controller also serves as
the central control system for the entire cell, eliminating the need for a separate PLC
(programmable logic controller), which would typically coordinate the different machines and
processes within an automated system.
The impact on production is equally significant. Tank Clinic previously averaged approximately
one week to fully weld a tanker. The automated system can now complete the welding process
within an eight-hour working day, depending on the specific tanker configuration.
Beyond production speed, automation provides consistent welding parameters and programmed
movement, reducing dependence on repetitive manual operations while enabling skilled
personnel to focus on areas where their expertise adds greater value.
For Tank Clinic, the investment represents an opportunity to combine its 50 years of
manufacturing experience with advanced technology designed for its future requirements.
“The significance for us is not simply having a unique piece of equipment. It demonstrates that
South African manufacturing can adopt and implement world-class technology for highly
specialised applications,” says Steven Holm, Technical Director at Tank Clinic. “The system
gives us greater consistency and repeatability, while allowing us to make more efficient use of
our skilled workforce.”
The installation is also significant for Yaskawa globally. It is the first OTG gantry system of this
type installed in South Africa and one of four worldwide, highlighting the engineering capability
required to apply advanced robotic technology to a complex, large-scale manufacturing
environment.
“As manufacturers look to improve productivity, quality and competitiveness, the opportunity is to
use automation to solve specific production challenges rather than simply automate for the sake
of automation,” Prinsloo says. “The Tank Clinic project is a good example of how robotics,
engineering and local manufacturing expertise can be brought together to create a solution
around a real industrial requirement.”
The project offers a tangible example of the role advanced robotics can play in the future of
South African manufacturing, combining global automation technology with local engineering
expertise to create highly specialised solutions for industry.
About Yaskawa Southern Africa
Yaskawa is a global leader in robotic automation and motion control technology, providing solutions that drive
efficiency, precision and innovation. With a strong presence in Southern Africa, Yaskawa supports industries across
automotive, packaging, welding, and beyond.
For more information on Yaskawa’s robotic solutions, visit www.yaskawa.za.com