Automated surfacing of rotationally symmetrical elements
Everything from a single source – it‘s more than only a advertising promise! Over 50 drawings of varied components served as the premise for the automation solution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s elements did have one thing in frequent, they had been all rotationally symmetrical. This was the place to begin for welding machine producer EWM of their mission to develop a custom automation resolution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all over the world for transporting liquids utilizing centrifugal pumps. Their areas of application embrace refineries, power crops and nuclear vegetation, within the transport of liquefied pure gasoline (LNG), in addition to in offshore rigs. They are also used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one application.
The aim is to weld all pump safety valve components automatically. These valves are related directly to the pumps and ensure continuous operation of the pumps to prevent them working dry or being damaged by cavitation during minimum move conditions. The pump safety valve is basically made up of the valve physique and the cone, which strikes inside the valve physique. The sealing surfaces between the valve body and the cone should be completely air and watertight. This is the only method to make sure correct functioning of the pump safety valve for decades to come. Normally, these components are made using low-cost development steel DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This process was previously performed manually, nonetheless, due to each the scarcity of fine welders and rising high quality assurance requirements, automation of this step was crucial. The internal diameter of the valve our bodies and the cone diameters had been between 32 mm and 400 mm. The parts being moved additionally differed vastly in weight, starting from a couple of hundred grams to 2 and a half tonnes. But all the parts had one thing in common: they had been all rotationally symmetrical, making them excellent for an automatic process. With this as a starting point, EWM was capable of get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon turned clear that only a robot system would fit the bill when it came to automating this explicit process. Having to cope with so many various part sizes was a cause for concern. Large elements require a large welding positioner. These, however, can not present the dynamics required for the smaller elements. This shortly gave rise to the thought of three processing stations: one large L-positioner with tilting perform 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 any other parts. pressure gauge octa of the building was also a specific problem. The elements had to have the power to be placed on the benches with the crane. The crane hook, nonetheless, was only approximately three metres excessive – extremely small for an industrial software. To guarantee accessibility whereas ensuring extraction, either the extraction hood or the system benches were made to be mobile. The robot was fitted in an extremely small sales space within the centre between the three stations. This sales space also consists of both the power source and a Titan XQ. These are positioned behind the L-positioner at the giant processing station. The Rob 5 drive 4X wire feeder mounted on the robotic arm ensures secure wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations in any respect needed positions can be ensured due to the acute arm length of two metres and optimised house contained in the booths.
Special torch for excessive spaces
Each valve physique is equipped with a cone guide which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily tough. For manual welding, the welder is unable to see the weld seam and as an alternative should depend on their experience. Even for automated welding, these areas are very uncommon. EWM was only in a place to settle for this job as a end result of they manufacture the torches, emphasising the importance of the welding torch for this software. The welding torch for Schroeder Valves is a particular construction with a particularly small torch head and unconventionally lengthy torch neck. Of course, the particular software had to be adapted to accommodate this unusual design: as a outcome of dilution between the mother or father steel and the armouring must be as low as possible, only slightly power is used. This ensures safe heat dissipation despite the intense welding torch dimensions.
Secure welding outcomes by way of outlined parameters
As the components have been rotationally symmetrical, it was simple to show the parts; teaching is at all times based on the identical programs. Even new elements may be welded mechanically shortly. Users simply have to set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot management will care for the remainder. The desired welding result’s at all times assured as a result of the welding process is defined with all of its parameters. The quality can be confirmed retrospectively as all welding parameters are continuously monitored and recorded. Even although the system was initially designed and supposed for one particular utility, Schroeder is already considering of recent ideas and uses. Schroeder would like to try out some of the numerous welding procedures that are included in the Titan XQ welding machine as commonplace. This will permit to additional optimise different sorts of surfaced elements. Schroeder are additionally looking to broaden and enhance the range of welding tasks.
There are lots of of Schroeder Valves installed in vegetation in southern Africa defending belongings at firms like Sasol, Eskom, Mondi and Sappi to call a couple of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore and reconditioning facilities can be found 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 more.
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