Automated surfacing of rotationally symmetrical components
Everything from a single supply – it‘s more than just a advertising promise! Over 50 drawings of various elements served as the basis 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 widespread, they have been all rotationally symmetrical. This was the starting 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 everywhere in the world for transporting liquids using centrifugal pumps. Their areas of utility include refineries, energy vegetation and nuclear crops, in the transport of liquefied pure gas (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one software.
The goal is to weld all pump safety valve elements mechanically. These valves are linked on to the pumps and guarantee continuous operation of the pumps to stop them operating dry or being broken by cavitation throughout minimal move conditions. The pump safety valve is basically made up of the valve body and the cone, which moves contained in the valve physique. The sealing surfaces between the valve physique and the cone must be absolutely air and watertight. This is the one way to make sure correct functioning of the pump safety valve for decades to come. Normally, these parts are made using low-cost construction steel DIN 1.0460. The sealing surfaces are reinforced with stainless steel DIN 1.4370. This course of was previously performed manually, however, as a result of both the scarcity of good welders and growing high quality assurance requirements, automation of this step was crucial. The inner diameter of the valve our bodies and the cone diameters have been between 32 mm and 400 mm. The components being moved additionally differed vastly in weight, ranging from a few hundred grams to two and a half tonnes. But the entire components had one thing in common: they were 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 robotic system would match the invoice when it came to automating this specific process. Having to deal with so many different part sizes was a cause for concern. Large parts require a large welding positioner. These, nonetheless, cannot provide the dynamics required for the smaller elements. This quickly gave rise to the thought of three processing stations: one giant L-positioner with tilting perform 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 another elements. The height of the building was also a particular challenge. The elements had to have the power to be positioned on the benches with the crane. The crane hook, nevertheless, was only approximately three metres high – extremely small for an industrial application. To guarantee accessibility whereas ensuring extraction, either the extraction hood or the system benches had been made to be cell. The robot was fitted in a particularly small booth in the centre between the three stations. This booth also contains both the power source 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 a 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 area inside the cubicles.
Special torch for extreme spaces
Each valve physique is supplied with a cone information which is welded from above. With an inside diameter of just 32 mm, access is extremely tough. For handbook welding, the welder is unable to see the weld seam and instead must rely on their expertise. Even for automated welding, these spaces are very uncommon. EWM was only able to accept this job because they manufacture the torches, emphasising the importance of the welding torch for this software. The welding torch for Schroeder Valves is a special construction with a very small torch head and unconventionally long torch neck. Of course, the special application had to be tailored to accommodate this uncommon design: as a result of dilution between the mother or father steel and the armouring needs to be as little as potential, solely slightly vitality is used. This ensures secure heat dissipation despite the intense welding torch dimensions.
Secure welding results via outlined parameters
As the parts had been rotationally symmetrical, it was easy to show the parts; teaching is at all times based mostly on the identical programs. Even new components can be welded mechanically shortly. Users simply should set the radius, number of passes and the geometric dimensions of the surfaced parts and the robot management will care for the rest. The desired welding result’s at all times assured as a end result of the welding procedure is outlined with all of its parameters. The quality may also be proven retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and supposed for one specific application, Schroeder is already thinking of latest concepts and uses. Schroeder wish to try out some of the varied welding procedures that are included within the Titan XQ welding machine as standard. This will permit to additional optimise totally different sorts of surfaced elements. Schroeder are also looking to expand and enhance the range of welding duties.
There are tons of of Schroeder Valves put in in crops in southern Africa defending belongings at companies like Sasol, Eskom, Mondi and Sappi to call a couple of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning services are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please เกจแรงดัน @valve.co.za, www.valve.co.za or cellphone 011 397 2833 or 0861 103 103 to learn extra.
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