Flexi Hose Welder - First choice for connector tube welding

One of the most difficult process in the hydraulic industry is to weld the flexible metallic hoses that not only requires high precision but also controlled skill to orchestrate the pattern of weld to fuse the initial layers. Once the fusion of all the three elements are done, i.e; the bellow, the mesh & the sleeve, then the connectors & the flange joints has to be welded along with wire feeding. And all these process has to go through high pressure leak test before forming the right joint post welding.
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Flexi hose welder the has a vast range of welding area varying from 10mm to 300mm with absolutely no limitation on the length of the hose. The pattern weave by the tig torch is the most unique configuration of this system as this creates an interwoven beads as done by highly qualified weld professionals, thus creating a layer of exemplary weld bead. The system has been tested and certified by more than 5000 hours of actual production cycles.

Keeping the component stationary and rotating the torch along with the wire feeder gives a better control for the system to weld different patterns of weld bead at various angles around the periphery of the component both in fusion and wire feed modes.

Flexi Hose Welder Features & Benefits

  • Faster Rotary Movement : Runs up to 15rpm in Open loop system.
  • Pattern Weave Welding : Variable from 0.5mm to 25mm.
  • Complex profiles in circular periphery can be held aligned & welded.
  • 7” Wide screen Human Machine Interface.
  • Load capacity on fixture bed is up to 50kgs on height adjusting v block.
  • Robotic Closed cage cable management systems.
  • Gearbox with high precision and low backlash of 6 Arcmin.
  • Milled Bottom base frame mounting bed.
  • Dual Motion Control Systems with 8 axes drive having dual three axes interpolation.
  • Analog communication-based Stepper Systems which optimizes complete open loop motion control with safety limit interlocks.
  • Additional Input & Output Module for safety systems & provision for expansion of axes as option.
  • New & Improvised NIKIT – Teach User Interface with 10 programs & expandable up to 250 programs.
  • Optional Accessory IIOT module integration for online data & alert monitoring (requires internet connectivity). All the data logging & machine process alert files with program upgradation can be done online.
  • Play / Pause feature for step-by-step analysis of weld program.
  • Component presence monitoring system for weld safety.
  • Aluminum Al6164 for component fixture for high heat dissipation and low holding torque.
  • Inbuilt purging system as optional for better penetration.
  • Auto component fixture positioning system for ease of vertical positioning for variety of job lengths up to 250mm height.
  • Swift mode torch retraction system for ease of weld job unloading.
  • Rotary wire feeding system ensures highest efficiency in wire feeding for complicated weld profiles.






Multiple Pass

Flexi Hose Welder Applications


Flexible hoses


Flexible hoses with fange


Connector welding of hoses


Hydraulics Industry


Flexible hose fusion welding




Food Processing Industry


Automobile Industry

Data Logging and Cloud Monitoring

The machine Data Logger represents leading edge technology in welding and machine data collection and logging. The micro-controller based weld data acquisition system provides a means of measuring and documenting all basic machine parameters when used with external PC.
Cloud-based monitor that requires either an Ethernet connection or can be used on a cellular network. Once the physical connections have been set and powered, the rest of the setup is

Basic Feature

  • Input & Output Monitoring
  • Maintenance Monitoring
  • LAN Module
  • Sequence Reports
  • Purging Enable / Disable
  • Remote Monitoring
  • Machine Data Logging
  • Weld Cycle Limits

Advanced Feature

  • Error Report Sheets
  • Gas Pressure Monitoring
  • Wire Feed Monitoring
  • Air Pressure Monitoring
  • Camera Monitoring System
  • Operator Data Logging
  • + Basic Features

Monitoring Benefits

Operator Data Logging

  • Can get the reports of operator work timings in the machine.

Air Pressure Monitoring

  • Complete machine pneumatic line air pressure can be monitored.

Error Report

  • Machine errors, input/output errors, sequence errors etc. Can be monitored through the report generated by the system.

Sequence Report

  • Machine sequence. Flow chart can be monitored.

Machine Data Logging

  • Machine used time, production rate, power consumption etc can be monitored.

Weld Cycle Limits

  • Can monitor and set the weld cycle limits per shift or based on the production requirements.

Wire Feed Monitoring

  • MIG / TIG wire feeding can be monitored. (Helps in planning for the pre ordering of wire spools without interrupting the production)

Maintenance Monitoring

  • Machine maintenance report, online service, programming modification/ change, copy etc can be done.

Purging Enable/Disable

  • Fine art of getting a URUNAMI weld bead by creating a gas chamber inside the component. (feature is available only for the orbital welder)

Camera Monitoring System

  • Can monitor & access the camera setting and features. (If camera is used in the machine)

Remote Monitoring

  • All features of the machine can be monitored over the internet through this Machine facility.

LAN Module

  • LAN cable connecting port is provided to connect & transfer the data from control system to cloud storage facility over internet.

Gas Pressure Monitoring

  • Welding gas pressure can be monitor.

Input & Output Monitoring

  • Machine IP/ OP can be monitored.

Model Specifications

  • Main rotary r1 axis:
    Stroke: 400mm.
    Stroke: +/-360 deg.
    Interpolaton speed: 30mm/sec.
  • Main x1 axis:
    Stroke: 400mm.
    Speed(peak): 50mm/sec
    Interpolaton speed: 20mm/sec.
  • Main z1 axis:
    Stroke: 400mm.
    Speed(peak): 20mm/sec
    Interpolaton speed: 20mm/sec.
  • Torch rotary r2 axis:
    Stroke: +/- 90 deg.
    Speed(peak): 10rpm.
  • Sub x2 axis
    Stroke: 200mm
    Speed(peak): 20mm/sec.
  • Component height adjuster z2 axis:
    Stroke: 450mm
    Speed(peak): 15mm/sec
  • Component self center sc axis:
    Self centre stroke: 90mm per side
    Self centre range: 10mm – 200mm

Available Accessories

  • Welding power source TIG
  • Welding power source MIG
  • Fume extraction system
  • Cloud Monitoring
  • Remote access
  • Auto darkening Welding helmet
  • Gloves & welding apron
  • UPS –3KVA
  • Auto torch cleaning system
  • Camera monitoring system
  • Weld Parameter integration
  • AVC
  • MIG connector kit
  • Special customised fixture – Manual / Auto

Flexible Hose Welding by Nikit Engineers