Automated surfacing of rotationally symmetrical components

Everything from a single supply – it‘s more than just a marketing promise! Over 50 drawings of assorted components served as the basis for the automation resolution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s components did have one factor in frequent, they were all rotationally symmetrical. This was the begin line for welding machine manufacturer EWM of their mission to develop a customized automation resolution tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all round the world for transporting liquids utilizing centrifugal pumps. Their areas of software embrace refineries, energy crops and nuclear crops, in the transport of liquefied pure gas (LNG), as properly as in offshore rigs. They are also used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The aim is to weld all pump safety valve components automatically. These valves are linked on to the pumps and ensure continuous operation of the pumps to forestall them running dry or being damaged by cavitation throughout minimal circulate circumstances. The pump safety valve is largely 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 only way to ensure correct functioning of the pump safety valve for many years to return. Normally, these components are made using low-cost construction metal DIN 1.0460. The sealing surfaces are strengthened with stainless-steel DIN 1.4370. This course of was beforehand carried out manually, nonetheless, as a end result of each the scarcity of good welders and growing quality assurance necessities, automation of this step was essential. The inside diameter of the valve our bodies and the cone diameters have been between 32 mm and four hundred mm. The components being moved additionally differed vastly in weight, ranging from a number of hundred grams to 2 and a half tonnes. But all the elements had one thing in widespread: they were all rotationally symmetrical, making them excellent for an automated 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 quickly turned clear that only a robotic system would match the invoice when it got here to automating this particular 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, cannot provide the dynamics required for the smaller elements. This shortly gave rise to the concept of three processing stations: one massive L-positioner with tilting operate for the large valve 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 some other elements. The peak of the building was additionally a selected challenge. The components had to have the ability to be placed on the benches with the crane. The crane hook, nevertheless, was only roughly three metres excessive – extraordinarily small for an industrial software. To guarantee accessibility while guaranteeing extraction, either the extraction hood or the system benches had been made to be mobile. The robotic was fitted in an especially small booth within the centre between the three stations. This sales space additionally consists of each the ability source and a Titan XQ. These are positioned behind the L-positioner on the giant 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 is also ensured thanks to the acute arm size of two metres and optimised area inside the cubicles.
Special torch for extreme spaces

Each valve physique is equipped with a cone information which is welded from above. With an inside diameter of simply 32 mm, access is extremely difficult. For handbook welding, the welder is unable to see the weld seam and as an alternative should rely on their expertise. Even for automated welding, these spaces are very uncommon. EWM was solely capable of settle for this job as a outcome of they manufacture the torches, emphasising the significance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular development with a very small torch head and unconventionally lengthy torch neck. Of course, the special application needed to be adapted to accommodate this uncommon design: because dilution between the father or mother metal and the armouring must be as little as potential, solely slightly vitality is used. This ensures safe heat dissipation regardless of the acute welding torch dimensions.
Secure welding results through outlined parameters

As the elements were rotationally symmetrical, it was simple to show the parts; teaching is at all times based on the identical packages. Even new parts can be welded automatically shortly. Users simply should set the radius, variety of passes and the geometric dimensions of the surfaced elements and the robot control will take care of the remainder. The desired welding result is at all times assured because the welding procedure is defined with all of its parameters. The quality can additionally be proven retrospectively as all welding parameters are continuously monitored and recorded. Even although the system was initially designed and intended for one particular utility, Schroeder is already considering of latest concepts and uses. Schroeder wish to try out a few of the numerous welding procedures which might be included in the Titan XQ welding machine as commonplace. This will enable to further optimise completely different kinds of surfaced components. Schroeder are additionally seeking to increase and enhance the range of welding duties.
There are ไดอะแฟรม of of Schroeder Valves put in in plants in southern Africa protecting property at firms 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 can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or telephone 011 397 2833 or 0861 103 103 to be taught more.
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