Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s more than just a advertising promise! Over 50 drawings of varied parts served as the idea for the automation solution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one thing in common, they were all rotationally symmetrical. This was the starting point for welding machine producer 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 round the world for transporting liquids utilizing centrifugal pumps. Their areas of software embrace refineries, power crops and nuclear plants, within the transport of liquefied pure gasoline (LNG), in addition to in offshore rigs. They are also used throughout the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one software.
The goal is to weld all pump protection valve elements mechanically. These valves are related on to the pumps and guarantee steady operation of the pumps to prevent them operating dry or being damaged by cavitation during minimal circulate conditions. The pump safety valve is largely made up of the valve body and the cone, which strikes inside the valve body. The sealing surfaces between the valve body and the cone must be absolutely air and watertight. This is the one means to make sure correct functioning of the pump protection valve for many years to come back. Normally, these elements are made using low-cost development steel DIN 1.0460. The sealing surfaces are reinforced with chrome steel DIN 1.4370. This course of was beforehand performed manually, however, due to both the shortage of excellent welders and rising high quality assurance necessities, automation of this step was crucial. The inside diameter of the valve bodies and the cone diameters have been between 32 mm and four hundred mm. The elements being moved additionally differed vastly in weight, ranging from a few hundred grams to two and a half tonnes. But the entire components had one thing in widespread: they had been all rotationally symmetrical, making them perfect for an automatic course of. 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 grew to become clear that only a robotic system would fit the invoice when it came to automating this explicit course of. Having to take care of so many different part sizes was a trigger for concern. Large elements require a large welding positioner. These, nevertheless, cannot provide the dynamics required for the smaller parts. This quickly gave rise to the concept of three processing stations: one large L-positioner with tilting perform for the large valve our bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a 3rd station with a system bench without positioners for any other parts. The top of the constructing was also a selected challenge. The elements had to find a way to be placed on the benches with the crane. The crane hook, nevertheless, was only roughly three metres excessive – extremely small for an industrial software. To guarantee accessibility whereas ensuring extraction, both the extraction hood or the system benches have been made to be cell. The robot was fitted in an especially small booth in the centre between the three stations. This sales space additionally contains both the facility source and a Titan XQ. These are positioned behind the L-positioner on the large processing station. The Rob 5 drive 4X wire feeder mounted on the robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations in any respect necessary positions is also ensured because of the intense arm length of two metres and optimised space inside the cubicles.
Special torch for extreme areas
Each valve body is equipped with a cone guide which is welded from above. With an inside diameter of just 32 mm, entry is extremely troublesome. For manual welding, the welder is unable to see the weld seam and as an alternative must rely on their experience. Even for automated welding, these areas are very unusual. EWM was only in a place to settle for this job because they manufacture the torches, emphasising the significance of the welding torch for this application. The welding torch for Schroeder Valves is a particular development with a particularly small torch head and unconventionally long torch neck. Of course, the particular software had to be adapted to accommodate this unusual design: because dilution between the father or mother steel and the armouring needs to be as low as possible, solely somewhat energy is used. This ensures secure warmth dissipation regardless of the intense welding torch dimensions.
Secure welding results via outlined parameters
As the components have been rotationally symmetrical, it was straightforward to teach the components; teaching is always based mostly on the same packages. Even new components could be welded mechanically shortly. Users simply need to set the radius, number of passes and the geometric dimensions of the surfaced parts and the robotic control will care for the rest. The desired welding result’s all the time assured as a result of the welding process is outlined with all of its parameters. The high quality can also be proven retrospectively as all welding parameters are constantly monitored and recorded. Even though the system was initially designed and meant for one specific application, Schroeder is already considering of latest ideas and makes use of. Schroeder want to try out some of the various welding procedures that are included within the Titan XQ welding machine as normal. เครื่องมือวัดความดันคือ will enable to additional optimise completely different kinds of surfaced elements. Schroeder are additionally looking to expand and improve the range of welding tasks.
There are hundreds of Schroeder Valves installed in plants in southern Africa defending belongings at corporations like Sasol, Eskom, Mondi and Sappi to call a couple of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning amenities 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 more.
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