Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s more than just a advertising promise! Over 50 drawings of assorted elements served as the premise for the automation answer developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s components did have one factor 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 answer tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all around the world for transporting liquids utilizing centrifugal pumps. Their areas of utility embody refineries, power plants and nuclear crops, within 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 parts routinely. These valves are linked directly to the pumps and ensure steady operation of the pumps to forestall them operating dry or being damaged by cavitation throughout minimum circulate situations. The pump safety valve is largely made up of the valve physique and the cone, which moves inside the valve physique. The sealing surfaces between the valve body and the cone have to be completely air and watertight. This is the one way to ensure correct functioning of the pump safety valve for many years to come. Normally, these elements are made using low-cost construction metal DIN 1.0460. The sealing surfaces are reinforced with chrome steel DIN 1.4370. This course of was beforehand performed manually, however, due to both the shortage of good welders and growing quality assurance necessities, automation of this step was crucial. 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 few hundred grams to two and a half tonnes. But the entire elements had one factor in frequent: they have been all rotationally symmetrical, making them good for an automatic process. With this as a starting point, EWM was in a position to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly turned clear that solely a robot system would fit the invoice when it got here to automating this specific course of. Having to take care of so many various half sizes was a trigger for concern. Large components require a big welding positioner. These, however, cannot provide the dynamics required for the smaller parts. This rapidly gave rise to the idea of three processing stations: one large L-positioner with tilting function for the big 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 with out positioners for any other parts. The top 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 roughly three metres high – extraordinarily small for an industrial application. To assure accessibility while ensuring extraction, either the extraction hood or the system benches were made to be cellular. The robotic was fitted in an extremely small sales space within the centre between the three stations. This booth additionally consists of each the ability 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 robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations in any respect needed positions is also ensured thanks to the acute arm size of two metres and optimised space contained in the booths.
Special torch for excessive areas
Each valve physique is equipped with a cone information which is welded from above. With an inside diameter of simply 32 mm, entry is extremely troublesome. For handbook welding, the welder is unable to see the weld seam and as an alternative should rely on their experience. Even for automated welding, these spaces are very unusual. EWM was only capable of settle for this job because they manufacture the torches, emphasising the significance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular construction with a very small torch head and unconventionally lengthy torch neck. Of course, the particular software needed to be tailored to accommodate this unusual design: as a end result of dilution between the parent metallic and the armouring needs to be as low as possible, only slightly power is used. This ensures safe heat dissipation regardless of the acute welding torch dimensions.
Secure welding outcomes through defined parameters
As the parts have been rotationally symmetrical, it was simple to teach the elements; teaching is always primarily based on the identical applications. Even new parts could be welded mechanically shortly. Users merely need to set the radius, variety of passes and the geometric dimensions of the surfaced components and the robotic management will care for the remainder. The desired welding result is at all times assured as a end result of the welding procedure is defined with all of its parameters. The high quality may also be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even though the system was originally designed and intended for one particular software, Schroeder is already considering of recent concepts and makes use of. เครื่องวัดแรงดันเกจที่นิยมใช้ wish to try out a number of the varied welding procedures that are included within the Titan XQ welding machine as normal. This will permit to further optimise different sorts of surfaced parts. Schroeder are also looking to increase and improve the range of welding tasks.
There are hundreds of Schroeder Valves put in in vegetation in southern Africa protecting belongings at firms 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 amenities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or telephone 011 397 2833 or 0861 103 103 to be taught more.
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