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How to Weld Long Straight Seams Automatically

Long straight seams are the easiest welds to mechanise and usually the first place a shop sees a return: one setup, metres of travel, and a bead that looks the same at the end of the plate as at the start.

The Basics

Straight track for flat plates, flexible track for anything else

A rigid straight track holds the carriage on a fixed line, which is exactly what a long seam on a flat plate needs. A flexible stainless belt does the same job on a curved shell, an inside corner or a plate you cannot lay flat. Both run at a set travel speed with adjustable oscillation, so the weld no longer depends on how steady the operator's hand is at metre nine.

  • Travel speed set once and held for the whole seam (0–990 mm/min on our carriages)
  • Oscillation width, angle, frequency and dwell time adjustable per pass
  • Suction / magnetic fixing — minutes to set up, no jigs and no fixture design
  • Remote control so the operator sets parameters from a safe distance
What we recommend: ZG series straight-track carriage for flat plate and long tank seams; RG series flexible-track carriage where the geometry curves or the plate cannot be turned.
See the ZG Straight-Track Carriage
Straight track welding carriage welding a long horizontal seam Automatic welding carriage running on a straight track on steel plate
Selection Table

Which Carriage for Which Straight Seam

Seam / workpieceRecommended machineNote
Long flat butt seam on plate or deck panelZG straight-track carriageRigid track, single pass or multi-pass
Long seam on a curved or formed shellRG flexible-track carriageBelt follows the curvature
Vertical seam on a tank wall or ship panelRG flexible-track carriageMagnetic adsorption, no scaffold
Stiffener / rib welds on large panelsZG with narrow track, or CX crawlerShort seams in long runs — position fast
Inside welds in confined vessel sectionsRG flexible or CX crawlerCompact machines fit where a fixture cannot
Parameters & Method

Four Things That Decide Weld Quality

SET 01

Track Alignment

Set the track parallel to the seam — a carriage follows the track, so any misalignment shows up as weave drift. Two pointers or a chalk line are enough.

SET 02

Oscillation

Weave width, frequency and dwell time are set per joint; wider weave with dwell at the sidewalls gives penetration without a hot, convex cap.

SET 03

Start and Stop

Run-on and run-off tabs outside the workpiece, or set the carriage to start away from the plate edge, so the crater lands somewhere you can cut off.

SET 04

Multi-Pass

For thick plate, stack passes with the same travel speed; the oscillation settings come from your WPS and are simply dialled in again for the next run.

FAQ

Questions We Get Asked Before the First Quote

Can a carriage weld a seam longer than the track?
Yes, within limits. The carriage travels along the track, so a longer seam needs either a longer track, a track extension, or a magnetic crawler that grips the plate itself and walks the seam without a track. Tell us the maximum seam length when quoting.
How close to the plate edge can it start?
The carriage body needs to sit on the plate or track, so plan for roughly the machine length at each end. Run-on and run-off tabs outside the joint solve the problem on short plates.
Does it handle both sides of a butt seam?
Yes. Position the track on the working side, weld the first side, then flip the plate or move the track to the other side for the back pass. Nothing about the machine changes.
Will it work with the welding machines we already have?
In almost every case, yes. The carriage carries a standard torch and connects to your existing power source and wire feeder — you are buying the motion, not a new welding system.
Keep Reading

Related Pages for Straight Seam Welding

How Long Are Your Longest Seams?

Send us the seam length, plate thickness and position — we will tell you whether a track carriage or a crawler is the better fit, and quote it.

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