SCHROEDER – NEW WELDING ROBOT FOR PUMP PROTECTION VALVES

Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s more than just a advertising promise! Over 50 drawings of varied components served as the premise for the automation resolution developed by EWM for pump safety valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s elements did have one thing in widespread, they had been all rotationally symmetrical. This was the starting point for welding machine manufacturer EWM in their mission to develop a customized automation answer tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all around the world for transporting liquids utilizing centrifugal pumps. Their areas of software embrace refineries, energy crops and nuclear crops, in the transport of liquefied natural gasoline (LNG), as well as 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 goal is to weld all pump protection valve parts automatically. These valves are related directly to the pumps and guarantee continuous operation of the pumps to forestall them operating dry or being damaged by cavitation throughout minimal circulate situations. The pump protection valve is basically made up of the valve physique and the cone, which strikes inside the valve physique. The sealing surfaces between the valve physique and the cone should be absolutely air and watertight. This is the only means to ensure correct functioning of the pump protection valve for many years to come back. Normally, these parts are made using low-cost development steel DIN 1.0460. The sealing surfaces are strengthened with stainless steel DIN 1.4370. This course of was previously carried out manually, however, as a outcome of both the shortage of good welders and rising high quality assurance necessities, automation of this step was essential. The inside diameter of the valve our bodies and the cone diameters had been between 32 mm and four hundred mm. The components being moved also differed vastly in weight, starting from a few hundred grams to 2 and a half tonnes. But the entire components had one factor in common: they were all rotationally symmetrical, making them good 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 quickly became clear that only a robotic system would fit the bill when it came to automating this particular process. Having to take care of so many alternative half sizes was a cause for concern. เพรสเชอร์เกจวัดแรงดันน้ำ require a large welding positioner. These, nonetheless, can’t present the dynamics required for the smaller parts. This rapidly gave rise to the idea of three processing stations: one massive L-positioner with tilting function for the big 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 additionally a selected challenge. The parts had to find a way to be positioned on the benches with the crane. The crane hook, nonetheless, was solely approximately three metres excessive – extremely small for an industrial software. To assure accessibility while ensuring extraction, either the extraction hood or the system benches had been made to be cellular. The robotic was fitted in an extremely small sales space within the centre between the three stations. This booth additionally consists of both the facility supply and a Titan XQ. These are positioned behind the L-positioner on the massive processing station. The Rob 5 drive 4X wire feeder mounted on the robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations at all needed positions can be ensured because of the extreme arm length of two metres and optimised space contained in the booths.
Special torch for extreme spaces
Each valve body is supplied with a cone guide which is welded from above. With an inside diameter of simply 32 mm, entry is extraordinarily tough. For manual welding, the welder is unable to see the weld seam and instead must depend on their experience. Even for automated welding, these areas are very unusual. EWM was solely in a place to settle for this job as a outcome of they manufacture the torches, emphasising the importance of the welding torch for this software. The welding torch for Schroeder Valves is a special building with a particularly small torch head and unconventionally lengthy torch neck. Of course, the special application had to be adapted to accommodate this unusual design: as a result of dilution between the father or mother metal and the armouring needs to be as little as possible, solely slightly power is used. This ensures safe warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding results through defined parameters
As the elements have been rotationally symmetrical, it was straightforward to show the components; instructing is at all times based mostly on the identical packages. Even new components could be welded routinely shortly. Users simply need to set the radius, number of passes and the geometric dimensions of the surfaced parts and the robot management will care for the remaining. The desired welding result’s at all times guaranteed as a outcome of the welding procedure is outlined with all of its parameters. The quality may also be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even though the system was initially designed and supposed for one specific software, Schroeder is already thinking of latest concepts and makes use of. Schroeder wish to check out a few of the varied welding procedures which would possibly be included within the Titan XQ welding machine as commonplace. This will allow to further optimise different sorts of surfaced components. Schroeder are additionally trying to broaden and enhance the vary of welding duties.
There are tons of of Schroeder Valves installed in plants in southern Africa defending belongings at companies like Sasol, Eskom, Mondi and Sappi to name a couple of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore 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 learn extra.
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