Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s more than just a advertising promise! Over 50 drawings of assorted components served as the basis for the automation resolution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one thing in common, they had been all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM in their mission to develop a customized automation solution tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all over the world for transporting liquids using centrifugal pumps. Their areas of software embrace refineries, power plants and nuclear vegetation, within the transport of liquefied pure gas (LNG), in addition to in offshore rigs. They are additionally used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one application.
The aim is to weld all pump safety valve components routinely. These valves are related on to the pumps and guarantee steady operation of the pumps to prevent them running dry or being broken by cavitation during minimal flow circumstances. The pump protection valve is largely made up of the valve physique and the cone, which strikes contained in the valve body. The sealing surfaces between the valve physique and the cone should be absolutely air and watertight. This is the only way to make sure proper functioning of the pump protection valve for many years to come. Normally, these components are made utilizing low-cost building metal DIN 1.0460. The sealing surfaces are reinforced with stainless steel DIN 1.4370. This course of was previously carried out manually, nevertheless, due to each the scarcity of excellent welders and growing quality assurance necessities, automation of this step was crucial. The internal diameter of the valve our bodies and the cone diameters have been between 32 mm and 400 mm. The parts being moved additionally differed vastly in weight, ranging from a couple of hundred grams to two and a half tonnes. But all of the elements had one thing in frequent: they were all rotationally symmetrical, making them excellent for an automated course of. With this as a place to begin, EWM was in a position to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon grew to become clear that only a robot system would fit the bill when it got here to automating this specific process. Having to deal with so many different part sizes was a trigger for concern. Large components require a large welding positioner. These, however, can’t provide the dynamics required for the smaller elements. This rapidly gave rise to the concept of three processing stations: one massive L-positioner with tilting function for the massive valve bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a third station with a system bench with out positioners for some other parts. The top of the constructing was additionally a specific challenge. The parts had to have the ability to be positioned on the benches with the crane. The crane hook, nevertheless, was only roughly three metres high – extraordinarily small for an industrial utility. To assure accessibility whereas making certain extraction, both the extraction hood or the system benches had been made to be cellular. The robotic was fitted in an extremely small sales space in the centre between the three stations. This sales space also includes each the facility source and a Titan XQ. These are positioned behind the L-positioner at the massive processing station. The Rob 5 drive 4X wire feeder mounted on the robotic arm ensures safe wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations at all essential positions can additionally be ensured thanks to the intense arm size of two metres and optimised area contained in the booths.
Special torch for extreme areas
Each valve body is equipped with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extremely troublesome. For guide welding, the welder is unable to see the weld seam and as a substitute must depend on their expertise. Even for automated welding, these spaces are very unusual. EWM was only capable of accept this job as a end result of they manufacture the torches, emphasising the importance of the welding torch for this software. The welding torch for Schroeder Valves is a special construction with a very small torch head and unconventionally lengthy torch neck. Of course, the particular utility needed to be adapted to accommodate this unusual design: as a result of dilution between the father or mother metal and the armouring must be as low as possible, solely somewhat power is used. This ensures safe heat dissipation regardless of the extreme welding torch dimensions.
Secure welding results by way of outlined parameters
As the parts were rotationally symmetrical, it was straightforward to show the elements; educating is all the time based mostly on the same packages. Even new elements can be welded automatically rapidly. Users merely need to set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot management will deal with the remainder. The desired welding result’s at all times assured because the welding procedure is defined with all of its parameters. The quality can be proven retrospectively as all welding parameters are continuously monitored and recorded. Even although the system was originally designed and intended for one particular application, Schroeder is already thinking of latest concepts and uses. Schroeder want to check out a variety of the numerous welding procedures which are included in the Titan XQ welding machine as commonplace. This will enable to further optimise completely different sorts of surfaced parts. Schroeder are additionally trying to increase and improve the vary of welding duties.
There are pressure gauge แบบ น้ำมัน of of Schroeder Valves put in in vegetation in southern Africa defending belongings at corporations like Sasol, Eskom, Mondi and Sappi to call a number of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning services are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact sales@valve.co.za, www.valve.co.za or cellphone 011 397 2833 or 0861 103 103 to be taught extra.
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