Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of varied components served as the basis for the automation solution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s components did have one factor in widespread, they were all rotationally symmetrical. This was the begin line for welding machine producer EWM in their mission to develop a custom automation solution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all around the world for transporting liquids using centrifugal pumps. Their areas of application embrace refineries, energy plants and nuclear crops, in the transport of liquefied pure fuel (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one application.
The purpose is to weld all pump safety valve components routinely. These valves are related directly to the pumps and guarantee continuous operation of the pumps to prevent them running dry or being broken by cavitation throughout minimum move conditions. The pump protection valve is essentially made up of the valve body and the cone, which strikes contained in the valve physique. The sealing surfaces between the valve physique and the cone have to be completely air and watertight. This is the one method to ensure proper functioning of the pump protection valve for many years to come back. Normally, these parts are made using low-cost building metal DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This course of was previously carried out manually, however, because of each the scarcity of excellent welders and growing high quality assurance necessities, automation of this step was essential. The inner diameter of the valve our bodies and the cone diameters have been between 32 mm and 400 mm. The components being moved also differed vastly in weight, ranging from a couple of hundred grams to two and a half tonnes. But the entire components had one factor in frequent: they had been all rotationally symmetrical, making them good for an automatic course of. 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 solely a robot system would fit the invoice when it came to automating this explicit process. Having to take care of so many different part sizes was a trigger for concern. Large parts 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 massive L-positioner with tilting perform for the massive valve our 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 elements. The top of the building was also a selected problem. The elements had to find a way to be placed on the benches with the crane. The crane hook, nonetheless, was solely roughly three metres excessive – extremely small for an industrial application. To guarantee accessibility whereas guaranteeing extraction, either the extraction hood or the system benches had been made to be cell. The robotic was fitted in an especially small booth within the centre between the three stations. This sales space additionally contains each the power 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 secure wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations in any respect necessary positions can be ensured due to the intense arm length of two metres and optimised space inside the booths.
Special torch for extreme areas
Each valve physique is equipped with a cone guide which is welded from above. With an inside diameter of simply 32 mm, access is extremely troublesome. For เครื่องมือที่ใช้วัดความดันโลหิต , the welder is unable to see the weld seam and as an alternative must rely on their expertise. Even for automated welding, these areas are very uncommon. EWM was only capable of accept this job as a end result of they manufacture the torches, emphasising the significance of the welding torch for this application. The welding torch for Schroeder Valves is a particular development with a very small torch head and unconventionally long torch neck. Of course, the special software needed to be adapted to accommodate this unusual design: as a end result of dilution between the parent metal and the armouring must be as low as potential, only slightly energy is used. This ensures protected heat dissipation despite the extreme welding torch dimensions.
Secure welding results by way of defined parameters
As the parts had been rotationally symmetrical, it was simple to teach the components; instructing is always based on the identical programs. Even new elements can be welded routinely rapidly. Users merely have to set the radius, number of passes and the geometric dimensions of the surfaced components and the robot management will deal with the remainder. The desired welding result is always assured as a end result of the welding procedure is defined with all of its parameters. The quality can also be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even though the system was initially designed and supposed for one specific utility, Schroeder is already pondering of latest ideas and makes use of. Schroeder would like to try out some of the varied welding procedures which are included within the Titan XQ welding machine as commonplace. This will enable to further optimise different sorts of surfaced components. Schroeder are additionally trying to broaden and improve the range of welding duties.
There are hundreds of Schroeder Valves installed in crops in southern Africa protecting belongings at corporations like Sasol, Eskom, Mondi and Sappi to call a few. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore and reconditioning services can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or telephone 011 397 2833 or 0861 103 103 to learn extra.
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