Automated surfacing of rotationally symmetrical elements
Everything from a single source – it‘s greater than only a advertising promise! Over 50 drawings of varied components served as the premise for the automation resolution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one factor in frequent, they have been all rotationally symmetrical. This was the starting point for welding machine producer EWM in their mission to develop a custom automation answer tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used everywhere in the world for transporting liquids utilizing centrifugal pumps. Their areas of application include refineries, energy crops and nuclear vegetation, in the transport of liquefied natural gas (LNG), in addition to in offshore rigs. They are additionally used throughout the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one application.
The purpose is to weld all pump safety valve elements automatically. These valves are linked directly to the pumps and guarantee steady operation of the pumps to prevent them operating dry or being damaged by cavitation during minimum move situations. The pump protection valve is essentially made up of the valve physique and the cone, which strikes contained in the valve physique. The sealing surfaces between the valve body and the cone must be absolutely air and watertight. This is the one means to ensure proper functioning of the pump protection valve for decades to return. Normally, these elements are made using low-cost development steel DIN 1.0460. The sealing surfaces are bolstered with stainless-steel DIN 1.4370. This process was beforehand carried out manually, nonetheless, as a end result of each the shortage of fine welders and rising quality assurance necessities, automation of this step was crucial. The inside diameter of the valve our bodies and the cone diameters had been between 32 mm and four hundred mm. The parts being moved also differed vastly in weight, starting from a couple of hundred grams to two and a half tonnes. But all of the parts had one thing in common: they were all rotationally symmetrical, making them perfect for an automatic process. 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 became clear that solely a robotic system would fit the invoice when it came to automating this explicit process. Having to take care of so many alternative part sizes was a cause for concern. Large parts require a large welding positioner. These, nevertheless, cannot provide the dynamics required for the smaller components. This quickly gave rise to the thought of three processing stations: one large L-positioner with tilting operate for the large valve our bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a 3rd station with a system bench without positioners for another components. The top of the building was additionally a particular problem. The components had to find a way to be positioned on the benches with the crane. The crane hook, nevertheless, was only approximately three metres excessive – extremely small for an industrial software. To guarantee accessibility while guaranteeing extraction, either the extraction hood or the system benches were made to be mobile. The robotic was fitted in an extremely small booth within the centre between the three stations. This booth also consists of each the power 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 robotic arm ensures secure wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations at all essential positions can be ensured thanks to the acute arm size of two metres and optimised area inside the cubicles.
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, access is extremely tough. For manual welding, the welder is unable to see the weld seam and as a substitute should depend on their expertise. Even for automated welding, these areas are very uncommon. EWM was solely able 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 special development with a very small torch head and unconventionally lengthy torch neck. Of course, the special software needed to be tailored to accommodate this unusual design: as a result of dilution between the parent steel and the armouring must be as low as attainable, solely slightly power is used. This ensures safe heat dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes by way of defined parameters
As the components had been rotationally symmetrical, it was simple to show the components; teaching is always based on the same packages. Even new parts can be welded automatically quickly. Users merely need to set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot management will take care of the remaining. The desired welding result’s all the time guaranteed as a end result of the welding process is outlined with all of its parameters. The quality may also be proven retrospectively as all welding parameters are continuously monitored and recorded. Even though เกจวัดแรงดันน้ำไทวัสดุ was originally designed and supposed for one specific utility, Schroeder is already pondering of new ideas and makes use of. Schroeder wish to check out some of the numerous welding procedures which may be included in the Titan XQ welding machine as normal. This will enable to further optimise totally different sorts of surfaced parts. Schroeder are also looking to broaden and improve the range of welding duties.
There are hundreds of Schroeder Valves put in in plants in southern Africa defending property at companies like Sasol, Eskom, Mondi and Sappi to name a number of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning amenities can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or cellphone 011 397 2833 or 0861 103 103 to learn extra.
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