Automated surfacing of rotationally symmetrical elements
Everything from a single source – it‘s more than just a marketing promise! Over 50 drawings of various parts served as the idea for the automation solution developed by EWM for pump safety valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one thing in common, they have been all rotationally symmetrical. This was the place to begin for welding machine manufacturer 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 all over the world for transporting liquids using centrifugal pumps. Their areas of software embrace refineries, power vegetation and nuclear crops, in the transport of liquefied natural fuel (LNG), in addition to in offshore rigs. They are additionally used throughout the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The aim is to weld all pump protection valve elements automatically. These valves are related on to the pumps and ensure steady operation of the pumps to stop them working dry or being broken by cavitation throughout minimal move circumstances. The pump safety valve is largely made up of the valve physique and the cone, which strikes contained in the valve body. The sealing surfaces between the valve physique and the cone have to be completely air and watertight. This is the only way to ensure correct functioning of the pump protection valve for many years to come back. Normally, these components are made using low-cost building steel DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This course of was beforehand carried out manually, nonetheless, due to both the shortage of excellent welders and rising quality assurance requirements, automation of this step was essential. The internal diameter of the valve our bodies and the cone diameters were between 32 mm and 400 mm. The parts being moved additionally differed vastly in weight, starting from a few hundred grams to 2 and a half tonnes. But all the parts had one factor in common: they were all rotationally symmetrical, making them excellent for an automated course of. With this as a place to begin, EWM was capable of get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly grew to become clear that only a robotic system would match the invoice when it got here to automating this specific course of. Having to take care of so many different part sizes was a cause for concern. Large parts require a large welding positioner. These, however, cannot provide the dynamics required for the smaller components. This shortly gave rise to the concept of three processing stations: one large L-positioner with tilting perform for the large valve bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a third station with a system bench with out positioners for another elements. The top of the constructing was also a selected problem. The parts had to find a way to be placed on the benches with the crane. The crane hook, nevertheless, was only approximately three metres high – extremely small for an industrial software. To assure accessibility whereas making certain extraction, either the extraction hood or the system benches were made to be cell. The robotic was fitted in an extremely small sales space in the centre between the three stations. This sales space also includes each the power source 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 100 iD in all three stations in any respect necessary positions can be ensured because of the intense arm size of two metres and optimised area contained in the cubicles.
Special torch for excessive areas
Each valve physique is supplied with a cone guide which is welded from above. With an inside diameter of simply 32 mm, entry is extraordinarily difficult. For handbook welding, the welder is unable to see the weld seam and as an alternative must rely on their expertise. Even for automated welding, these areas are very unusual. EWM was solely in a position to accept this job as a end result of they manufacture the torches, emphasising the significance of the welding torch for this software. The welding torch for Schroeder Valves is a particular building with a very small torch head and unconventionally lengthy torch neck. Of course, the particular utility needed to be tailored to accommodate this unusual design: as a outcome of dilution between the father or mother metallic and the armouring must be as low as potential, solely a little energy is used. This ensures secure warmth dissipation regardless of the intense welding torch dimensions.
Secure welding results via outlined parameters
As the elements had been rotationally symmetrical, it was straightforward to show the components; instructing is all the time based mostly on the same applications. Even new parts may be welded routinely shortly. Users simply have to set the radius, number of passes and the geometric dimensions of the surfaced parts and the robot control will take care of the remaining. เกจแรงดันสูง desired welding result’s all the time guaranteed as a result of the welding process is defined with all of its parameters. The high quality can be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even though the system was originally designed and intended for one particular application, Schroeder is already considering of new ideas and makes use of. Schroeder want to check out a few of the various welding procedures which are included in the Titan XQ welding machine as standard. This will permit to additional optimise totally different sorts of surfaced parts. Schroeder are also seeking to expand and enhance the vary of welding tasks.
There are hundreds of Schroeder Valves put in in vegetation in southern Africa protecting property at companies like Sasol, Eskom, Mondi and Sappi to call a few. 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 extra.
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