Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s more than just a advertising promise! Over 50 drawings of various elements served as the idea for the automation answer developed by EWM for pump safety valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s components did have one factor in frequent, they had been all rotationally symmetrical. This was the starting point for welding machine manufacturer EWM of their mission to develop a custom automation solution tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all over the world for transporting liquids using centrifugal pumps. Their areas of application embody refineries, power plants and nuclear vegetation, within the transport of liquefied natural gasoline (LNG), as nicely as in offshore rigs. They are additionally used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The purpose is to weld all pump safety valve components routinely. These valves are linked on to the pumps and guarantee continuous operation of the pumps to prevent them operating dry or being broken by cavitation throughout minimum circulate conditions. The pump protection valve is essentially made up of the valve body and the cone, which moves contained in the valve physique. The sealing surfaces between the valve body and the cone have to be absolutely air and watertight. This is the one means to make sure proper functioning of the pump safety valve for decades to come. Normally, these parts are made utilizing low-cost building steel DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This course of was beforehand carried out manually, nonetheless, because of both the shortage of fine welders and growing quality assurance requirements, automation of this step was essential. The internal diameter of the valve our bodies and the cone diameters had been between 32 mm and 400 mm. The components being moved additionally differed vastly in weight, starting from a couple of hundred grams to 2 and a half tonnes. But all of the parts had one factor in widespread: they have been all rotationally symmetrical, making them excellent for an automatic process. With this as a place to begin, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon became clear that only a robot system would match the invoice when it got here to automating this specific course of. Having to deal with so many alternative half sizes was a cause for concern. Large parts require a big welding positioner. These, nonetheless, can’t present the dynamics required for the smaller elements. This quickly gave rise to the idea of three processing stations: one large L-positioner with tilting perform for the massive valve our bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a third station with a system bench without positioners for some other components. The peak of the constructing was also a specific challenge. The components had to have the flexibility to be placed on the benches with the crane. The crane hook, however, was only approximately three metres high – extraordinarily small for an industrial application. To assure accessibility while ensuring extraction, either the extraction hood or the system benches were made to be cellular. The robot was fitted in an extremely small booth within the centre between the three stations. This sales space also consists of both the facility supply and a Titan XQ. These are positioned behind the L-positioner at the large processing station. The Rob 5 drive 4X wire feeder mounted on the robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations at all needed positions is also ensured because of the extreme arm size of two metres and optimised space inside the cubicles.
Special torch for excessive areas
Each valve physique is supplied with a cone guide which is welded from above. With an inside diameter of just 32 mm, entry is extremely tough. For manual welding, the welder is unable to see the weld seam and as an alternative must rely on their expertise. Even for automated welding, these areas are very uncommon. EWM was only in a place to accept this job as a result of they manufacture the torches, emphasising the importance of the welding torch for this software. The welding torch for Schroeder Valves is a particular construction with a particularly small torch head and unconventionally lengthy torch neck. Of course, the special application needed to be adapted to accommodate this unusual design: as a outcome of dilution between the father or mother metallic and the armouring must be as little as possible, solely slightly power is used. This ensures safe warmth dissipation despite the intense welding torch dimensions.
Secure welding outcomes via outlined parameters
As the components had been rotationally symmetrical, it was easy to show the parts; educating is at all times primarily based on the identical packages. Even new parts could be welded routinely rapidly. Users merely have to set the radius, variety of passes and the geometric dimensions of the surfaced elements and the robotic control will care for the remaining. เกจวัดแรงดันน้ำมันเครื่อง desired welding result is at all times guaranteed as a outcome of the welding procedure is outlined with all of its parameters. The quality can be proven retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was initially designed and intended for one particular utility, Schroeder is already considering of new ideas and makes use of. Schroeder want to check out some of the various welding procedures which might be included within the Titan XQ welding machine as commonplace. This will permit to additional optimise totally different sorts of surfaced components. Schroeder are additionally seeking to expand and enhance the range of welding duties.
There are hundreds of Schroeder Valves installed in vegetation in southern Africa defending property at firms like Sasol, Eskom, Mondi and Sappi to name a quantity of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore 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 phone 011 397 2833 or 0861 103 103 to study extra.
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