Rio Tinto case study

Upgrading Smelter Operations with Robotic Welding.

Background

Rio Tinto is a global mining company supplying materials essential to the energy transition, with operations across 35 countries. At its Tiwai Point site in New Zealand, Rio Tinto produces high-purity aluminium with a commitment to low-carbon production powered by hydroelectric energy.

Anode yoke repair is a critical part of maintaining the smelter’s production process. While robotic welding was already in place for this task, Rio Tinto engaged Autoa to upgrade the system — supporting long-term reliability, improving safety, and enhancing overall performance.

Project Overview

Customer: Rio Tinto
Product: Anode Yoke Repair Cell
Country: Tiwai Point, New Zealand
Installed: 2024
Industry: Aluminium Smelting
Solution: Custom Robotic Welding Cell
Featured Equipment: OTC B6 Through-Arm Welding Robots, OTC V100 Handling Robot, OTC Daihen P502L Power Source + 500A Water Cooled Torch and Water Cooler, FD19 Controller and Teach Pendant, Autoa Servo Controlled Slider, Laser Cleaning, Custom Jigging Solution for Yoke Handling & Support.

The Solution

Autoa worked with Rio Tinto to upgrade the existing anode yoke repair system with a custom robotic welding cell, designed to meet the operational needs of the Tiwai Point smelter.

The new setup features dual OTC B6 through-arm welding robots for consistent, high-quality welds, alongside an OTC V100 handling robot that automates the loading and positioning of each yoke. A custom jigging system supports multiple yoke sizes and ensures accurate placement during repair. To streamline preparation, the system includes integrated laser cleaning to remove rust and oxidation before welding, while also improving air quality in the work area.

A servo-controlled slider extends the robot’s working range, enabling efficient access across the full weld zone. Automatic height sensing and seam detection allow the system to adjust for variations in yoke size, maintaining precision and repeatability. Together, these upgrades have delivered a safer, more reliable, and more efficient approach to an essential process within the smelter.

The Results

Since the upgrade, the new anode yoke repair system has delivered significant gains in efficiency, consistency, and safety at the Tiwai Point smelter. The system remains in continuous operation 24/7, supporting high throughput and reliable performance within the smelter’s workflow.

Automated loading and weld control have improved consistency and reduced variation between welds. The system maintains a steady processing rate, with the capacity to repair up to 550 yokes in a 24-hour period. Manual handling has been significantly reduced. With robots managing the positioning and welding process, more than 30,000 kg of daily lifting has been removed from the task — helping to lower fatigue and reduce the risk of strain injuries.

Integrated laser cleaning has enhanced weld preparation while improving air quality in the work area. Gas and wire sensors provide additional support by alerting operators when consumables are low, helping to avoid unplanned downtime.

Overall, the upgrade has strengthened the repair process, delivering a more efficient, consistent, and operator-friendly system.

The IMPACT ON Rio Tinto

The upgraded anode yoke repair system has become a critical part of Rio Tinto’s maintenance operations at Tiwai Point, contributing to improved performance, reduced risk, and long-term reliability.

By reducing manual handling and automating repetitive tasks, the system has supported a safer, more ergonomic working environment. Operators are no longer exposed to pinch points or hot zones, and hazardous processes such as manual cleaning have been fully removed from the workflow.

The upgrade has also reduced downtime and maintenance overhead. Standardised components, improved consumable life, and enhanced system monitoring have helped streamline day-to-day operation and support.

Importantly, the cell was designed with scalability in mind. Its modular layout and flexible configuration allow it to adapt to future changes in production requirements, making it a long-term investment in the smelter’s ongoing success.

“It’s about keeping people away from the load. People and safety first.” – Paul Cavanagh, long-serving staff member at Rio Tinto’s Tiwai Point smelter.

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