Robots are reshaping pipe machining

Robots deliver consistently precise results. And unlike their human counterparts, they do not even bat an eyelid. Because robots “work” efficiently, reducing costs and improving sustainability, they are being used increasingly across the pipe and metal industries. Companies in these sectors see further automating their processes as a worthwhile investment. Pipe manufacturers and processors are supported by partners supplying the innovative production equipment they need.

Pipes and robots are simply a perfect match. Both areas are growing and complement each other: Data Bridge Market Research expects the European pipe market to grow by around 5% annually between 2023 and 2030. By 2030, the market could reach a value of almost 34 billion US dollars. This growth is driven in particular by developments in the European energy landscape and the increasing importance of pipelines. According to Data Bridge Market Research, the German pipe market is the fastest-growing in Europe.

Robot adoption has doubled  
Optimised processes are essential for growth in the areas of production and processing of pipes and metals – and robots have a role to play here. As the “World Robotics 2025” report from the International Federation of Robotics (IFR) highlights, global demand continues to surge. According to this report, 542,000 robots were installed in 2024, more than twice as many as a decade earlier. Annual installations have also now exceeded 500,000 units for the fourth year running. The OECD and IMF forecast growth of between 2.9% and 3.1% for the global robotics market in 2026.

Asia dominated the market in 2024, with 74% of new installations, compared with 16% in Europe and 9% in the Americas.

Worldwide, 4.664 million industrial robots were in operation in 2024, a year-on-year increase of 9% according to the IFR. China remains by far the largest market, accounting for 54% of all installations. Germany is Europe's largest and the world's fifth-largest market for robotics. Although installations fell by 5% in 2024 to 26,982 units, this still marks the second-best result, second only to the record year of 2023.

Improving efficiency, enhancing sustainability 
The metal and plastics machining industry, including the pipe sector, is increasingly turning to robots to boost efficiency, enhance sustainability and mitigate a growing shortage of skilled workers. A good example is KUKA. After securing a major order in 2024 for 23 Friction Stir Welding (FSW) cells with integrated robots for the electric vehicle production of a major US car manufacturer, the company has now received an additional order for twelve more cells to support a production expansion. These FSW cells, equipped with KUKA robots and clamping systems tailored to the welding process, are integrated into electric vehicle production lines and used across multiple stages of the production process.

Digitalisation plays a key role in the use of robots: for example, a central KUKA software platform covers the entire automation process and enables seamless data exchange across all planning and production steps. “Using robots has become easier and faster than ever before thanks to digital twins,” the company notes. Offline programming and virtual commissioning further support automation solutions within Industry 4.0 environments.

Fully integrated industrial robots 
The industry is focusing on closer collaboration to offer users the best possible solutions. As quality and packaging requirements continue to rise, so too do the demands placed on handling finished components such as springs, wires and bent-pipe components. Responding to this trend, WAFIOS has fully integrated robots from KUKA’s Agilus and Cybertech line into its WPS 3.2 EasyWay programming system. “This means the robot can be controlled just like a WAFIOS machine, eliminating the need for expensive specialist robot training,” the company explains. 

“Thanks to this complete integration of the industrial robot into the production process, the EasyRobot significantly reduces the programming time for bending programmes involving handling tasks, and reduces costs associated with specialist operator training.” In many WAFIOS CNC machines for producing springs, wire and bent-pipe components, the robot can now be directly controlled by the machine interface, allowing the component and robot programmes for the spring or the bent part to merge seamlessly. As WAFIOS notes, the time-consuming set-up of the robot in a separate step, along with the need for specialised programming skills and training, is no longer required.

Leveraging AI in industrial manufacturing 
Companies are preparing for the challenges of the future. For example, TRUMPF is working with partners in the “Cognitive Automation for Production” project to develop ways of automatically setting up large machine tools using robotics and artificial intelligence (AI). The aim of the research project is to automate manual and complex production steps, with a particular focus on the construction of special-purpose systems and the manufacture of small batches, explains TRUMPF. To this end, the partners are developing a modular software toolkit for cognitive automation functions in robotics, with AI forming an integral part of the approach.

AI-driven manufacturing is also at the heart of the collaboration between Maincor Rohrsysteme, Maxsyma, and the Fraunhofer Institute for Production Technology and Automation (IPA). This project is focused on optimising production processes and improving maintenance and quality assurance. As Maincor explains, “Precise monitoring and predictive maintenance are key to increasing efficiency and quality.” The central pillar of the project is an intelligent algorithm designed specifically to monitor ultrasonic welding, capable of detecting faulty welds immediately and significantly reducing scrap and machine downtime.

A strong outlook for the industry 
Companies are striving for the highest standards in manufacturing, helping to make pipe and materials processing fit for the future. The outlook for the industry is strong.

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