Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s more than only a advertising promise! Over 50 drawings of assorted elements served as the basis for the automation solution developed by EWM for pump safety valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one factor in common, they had been all rotationally symmetrical. This was the beginning point for welding machine producer EWM in their mission to develop a customized automation solution tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all around the world for transporting liquids using centrifugal pumps. Their areas of software embody refineries, energy crops and nuclear plants, within the transport of liquefied natural gas (LNG), in addition to in offshore rigs. They are additionally used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The purpose is to weld all pump protection valve parts mechanically. These valves are linked directly to the pumps and ensure continuous operation of the pumps to forestall them operating dry or being damaged by cavitation throughout minimal circulate situations. The pump protection valve is largely made up of the valve physique and the cone, which moves inside the valve body. The sealing surfaces between the valve physique and the cone must be absolutely air and watertight. This is the only way to ensure correct functioning of the pump safety valve for decades to come. Normally, these elements are made using low-cost construction steel DIN 1.0460. ราคาเพรสเชอร์เกจ sealing surfaces are bolstered with chrome steel DIN 1.4370. This course of was previously carried out manually, however, as a outcome of each the shortage of excellent welders and growing quality assurance requirements, automation of this step was essential. The internal diameter of the valve bodies and the cone diameters had been between 32 mm and four hundred mm. The elements being moved also 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 perfect for an automatic process. With this as a beginning point, EWM was capable of 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 bill when it came to automating this particular process. Having to take care of so many various half sizes was a cause for concern. Large components require a big welding positioner. These, nevertheless, can’t provide the dynamics required for the smaller parts. This quickly gave rise to the idea of three processing stations: one massive L-positioner with tilting perform for the big valve bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a third station with a system bench with out positioners for some other parts. The peak of the building was additionally a specific challenge. The components had to be able to be placed on the benches with the crane. The crane hook, however, was solely approximately three metres excessive – extremely small for an industrial utility. To guarantee accessibility whereas ensuring extraction, either the extraction hood or the system benches had been made to be mobile. The robot was fitted in an extremely small booth within the centre between the three stations. This booth additionally includes both the facility 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 in any respect necessary positions can additionally be ensured because of the intense arm size of two metres and optimised house contained in the booths.
Special torch for excessive areas
Each valve body is provided with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily tough. For guide welding, the welder is unable to see the weld seam and as an alternative must rely on their experience. Even for automated welding, these areas are very uncommon. EWM was solely in a position to accept this job because they manufacture the torches, emphasising the importance of the welding torch for this utility. จำหน่ายเกจวัดแรงดัน for Schroeder Valves is a particular construction with a very small torch head and unconventionally lengthy torch neck. Of course, the special software needed to be adapted to accommodate this uncommon design: as a outcome of dilution between the father or mother metal and the armouring needs to be as little as potential, only slightly energy is used. This ensures secure warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes by way of outlined parameters
As the components were rotationally symmetrical, it was simple to teach the components; educating is all the time based mostly on the identical programs. Even new components could be welded mechanically quickly. Users simply should set the radius, number of passes and the geometric dimensions of the surfaced parts and the robot management will deal with the rest. The desired welding result is at all times assured as a outcome of the welding process is defined with all of its parameters. The quality may additionally be proven retrospectively as all welding parameters are constantly monitored and recorded. Even though the system was initially designed and supposed for one particular utility, Schroeder is already pondering of recent ideas and uses. Schroeder wish to check out a variety of the varied welding procedures which may be included within the Titan XQ welding machine as normal. This will enable to additional optimise completely different sorts of surfaced elements. Schroeder are also trying to expand and improve the range of welding tasks.
There are hundreds of Schroeder Valves put in in plants in southern Africa defending assets at corporations like Sasol, Eskom, Mondi and Sappi to call a few. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning facilities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or cellphone 011 397 2833 or 0861 103 103 to study more.
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