Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s greater than only a advertising promise! Over 50 drawings of various parts served as the basis for the automation answer developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one thing in frequent, they had been all rotationally symmetrical. This was the starting point for welding machine producer EWM of their mission to develop a custom automation resolution tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of application embody refineries, power vegetation and nuclear vegetation, in the transport of liquefied natural gas (LNG), as well as in offshore rigs. They are additionally used all through the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one software.
The aim is to weld all pump protection valve parts mechanically. These valves are related directly to the pumps and guarantee continuous operation of the pumps to prevent them operating dry or being damaged by cavitation throughout minimal circulate conditions. The pump protection valve is largely made up of the valve body and the cone, which moves inside the valve physique. The sealing surfaces between the valve body and the cone have to be absolutely air and watertight. This is the one way to make sure proper functioning of the pump safety valve for decades to come. Normally, these elements are made utilizing low-cost construction metal DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This process was previously performed manually, nevertheless, as a outcome of each the shortage of fine welders and growing quality assurance requirements, automation of this step was crucial. The inside diameter of the valve our bodies and the cone diameters were between 32 mm and four hundred 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 elements had one thing in frequent: they had been all rotationally symmetrical, making them good for an automated course of. With this as a place to begin, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon became clear that only a robotic system would match the bill when it came to automating this specific course of. Having to cope with so many different half sizes was a trigger for concern. Large components require a large welding positioner. These, nonetheless, cannot provide the dynamics required for the smaller components. This rapidly gave rise to the concept 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 bodies, and a 3rd station with a system bench with out positioners for some other elements. The peak of the constructing was also a particular challenge. The components had to have the ability to be placed on the benches with the crane. The crane hook, nonetheless, was only approximately three metres high – extraordinarily small for an industrial utility. To assure accessibility while ensuring extraction, both the extraction hood or the system benches were made to be cell. The robot was fitted in an extremely small sales space within the centre between the three stations. This sales space also includes each the power supply and a Titan XQ. These are positioned behind the L-positioner at the large processing station. The Rob 5 drive 4X wire feeder mounted on the robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations in any respect needed positions is also ensured because of the extreme arm length of two metres and optimised house contained in the cubicles.
Special torch for excessive spaces
Each valve body is equipped with a cone guide which is welded from above. With an inside diameter of simply 32 mm, entry is extremely tough. For guide welding, the welder is unable to see the weld seam and instead should rely on their expertise. Even for automated welding, these spaces are very uncommon. EWM was only capable of settle for this job as a result of they manufacture the torches, emphasising the significance of the welding torch for this application. The welding torch for Schroeder Valves is a special construction with a particularly small torch head and unconventionally long torch neck. Of course, the special software had to be adapted to accommodate this uncommon design: because dilution between the father or mother metallic and the armouring needs to be as little as potential, only slightly vitality is used. This ensures safe warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes through defined parameters
As the elements were rotationally symmetrical, it was straightforward to show the elements; educating is all the time based mostly on the same programs. Even new parts can be welded automatically quickly. Users simply should set the radius, variety of passes and the geometric dimensions of the surfaced parts and the robot management will deal with the remainder. The desired welding result is at all times guaranteed because the welding procedure is outlined with all of its parameters. The quality may also be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even though the system was originally designed and intended for one specific software, Schroeder is already thinking of latest ideas and makes use of. เกจวัดแก๊ส would like to check out some of the various welding procedures which might be included within the Titan XQ welding machine as standard. This will allow to further optimise completely different kinds of surfaced elements. Schroeder are also looking to increase and improve the range of welding tasks.
There are tons of of Schroeder Valves installed in vegetation in southern Africa protecting belongings at corporations like Sasol, Eskom, Mondi and Sappi to call a number 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 contact, or phone 011 397 2833 or 0861 103 103 to learn extra.
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