Automated surfacing of rotationally symmetrical components
Everything from a single source – it‘s more than just a advertising promise! Over 50 drawings of various components served as the basis for the automation answer developed by EWM for pump safety 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 beginning point for welding machine manufacturer EWM of their mission to develop a customized 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 software embody refineries, energy plants and nuclear vegetation, within the transport of liquefied pure gas (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one application.
The goal is to weld all pump protection valve elements automatically. These valves are connected on to the pumps and ensure continuous operation of the pumps to prevent them working dry or being broken by cavitation throughout minimal move situations. The pump safety valve is essentially made up of the valve body and the cone, which strikes contained in the valve body. The sealing surfaces between the valve physique and the cone should be completely air and watertight. This is the only method to ensure proper functioning of the pump protection valve for decades to come back. Normally, these parts are made using low-cost construction metal DIN 1.0460. The sealing surfaces are bolstered with chrome steel DIN 1.4370. This course of was beforehand performed manually, however, because of each the shortage of good welders and rising high quality assurance requirements, automation of this step was essential. The inner diameter of the valve bodies and the cone diameters were between 32 mm and 400 mm. The components being moved also differed vastly in weight, starting from a number of hundred grams to 2 and a half tonnes. But the entire components had one factor in frequent: they had been all rotationally symmetrical, making them excellent for an automated process. With เกจวัดความดันpressuregauge as a place to begin, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly turned clear that only a robot system would fit the invoice when it got here to automating this specific course of. Having to deal with so many different part sizes was a trigger for concern. Large components require a large welding positioner. These, however, can not provide the dynamics required for the smaller parts. This shortly gave rise to the concept of three processing stations: one large L-positioner with tilting operate for the massive valve 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 parts. The top of the building was also a specific challenge. The elements had to be able to be placed on the benches with the crane. The crane hook, nonetheless, was solely approximately three metres high – extremely small for an industrial utility. To assure accessibility while ensuring extraction, both the extraction hood or the system benches had been made to be cell. The robotic was fitted in an especially small booth within the centre between the three stations. This sales space additionally consists of both the facility supply and a Titan XQ. These are positioned behind the L-positioner at the massive 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 additionally be ensured because of the extreme 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, access is extremely tough. For guide welding, the welder is unable to see the weld seam and as an alternative must depend on their experience. Even for automated welding, these spaces are very unusual. EWM was solely able to accept this job as a result of they manufacture the torches, emphasising the significance of the welding torch for this application. The welding torch for Schroeder Valves is a particular construction with a very small torch head and unconventionally lengthy torch neck. Of course, the special utility needed to be adapted to accommodate this uncommon design: as a end result of dilution between the mother or father metal and the armouring needs to be as little as potential, solely somewhat power is used. This ensures safe heat dissipation regardless of the extreme welding torch dimensions.
Secure welding results through outlined parameters
As the parts were rotationally symmetrical, it was straightforward to teach the components; educating is at all times based on the identical packages. Even new parts can be welded mechanically shortly. Users simply need to set the radius, variety of passes and the geometric dimensions of the surfaced components and the robotic control will take care of the remaining. The desired welding result’s at all times assured as a result of the welding process is outlined with all of its parameters. The high quality may also be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and supposed for one specific software, Schroeder is already pondering of latest ideas and makes use of. Schroeder wish to check out a few of the numerous welding procedures which may be included within the Titan XQ welding machine as standard. This will enable to additional optimise different sorts of surfaced parts. Schroeder are additionally seeking to increase and enhance the range of welding duties.
There are lots of of Schroeder Valves put in in vegetation in southern Africa defending property at companies like Sasol, Eskom, Mondi and Sappi to name a couple of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning services are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or phone 011 397 2833 or 0861 103 103 to study extra.
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