Automated surfacing of rotationally symmetrical components

Everything from a single supply – it‘s more than just a advertising promise! Over 50 drawings of assorted components served as the basis for the automation resolution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one factor in widespread, they have been all rotationally symmetrical. This was the place to begin for welding machine producer EWM of their mission to develop a customized automation answer tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all around the world for transporting liquids utilizing centrifugal pumps. Their areas of utility embody refineries, power vegetation and nuclear plants, within the transport of liquefied natural gasoline (LNG), as nicely as 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 application.
The purpose is to weld all pump safety valve components mechanically. These valves are related on to the pumps and guarantee continuous operation of the pumps to forestall them operating dry or being damaged by cavitation throughout minimal flow conditions. The pump protection valve is largely made up of the valve physique and the cone, which strikes inside the valve physique. The sealing surfaces between the valve body and the cone should be absolutely air and watertight. This is the only method to ensure correct functioning of the pump protection valve for decades to come back. Normally, these parts are made utilizing low-cost building metal DIN 1.0460. The sealing surfaces are bolstered with chrome steel DIN 1.4370. This course of was beforehand performed manually, however, as a result of each the scarcity of excellent welders and rising quality assurance requirements, automation of this step was essential. The inner diameter of the valve our bodies and the cone diameters were between 32 mm and 400 mm. The parts being moved also differed vastly in weight, starting from a quantity of hundred grams to two and a half tonnes. But all of the parts had one factor in common: they had been all rotationally symmetrical, making them perfect for an automated 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 soon grew to become clear that solely a robotic system would match the bill when it got here to automating this explicit process. Having to cope with so many various half sizes was a cause for concern. เกจวัดแรงดัน require a big welding positioner. These, nonetheless, can not provide the dynamics required for the smaller parts. This shortly gave rise to the idea of three processing stations: one massive L-positioner with tilting function for the big 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 without positioners for some other elements. The top of the constructing was additionally a selected challenge. The components had to have the power to be positioned on the benches with the crane. The crane hook, however, was solely roughly three metres high – extraordinarily small for an industrial utility. To guarantee accessibility while making certain extraction, both the extraction hood or the system benches were made to be mobile. The robot was fitted in a particularly small booth within the centre between the three stations. This sales space additionally consists of each the facility 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 robotic arm ensures safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations at all necessary positions can additionally be ensured due to the extreme arm size of two metres and optimised house inside the booths.
Special torch for excessive areas

Each valve body is provided with a cone guide which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily difficult. For handbook 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 able to settle for 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 particularly small torch head and unconventionally long torch neck. Of course, the particular software needed to be tailored to accommodate this uncommon design: as a end result of dilution between the mother or father metallic and the armouring must be as low as potential, only somewhat vitality is used. This ensures safe warmth dissipation regardless of the intense welding torch dimensions.
Secure welding results via defined parameters

As the elements were rotationally symmetrical, it was easy to teach the parts; instructing is at all times based on the same applications. Even new elements may be welded automatically shortly. Users merely have to set the radius, number of passes and the geometric dimensions of the surfaced parts and the robot management will care for the remaining. The desired welding result is always assured as a end result of the welding process is outlined with all of its parameters. The quality can additionally be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even though the system was initially designed and intended for one particular application, Schroeder is already considering of new ideas and makes use of. Schroeder want to try out some of the numerous welding procedures that are included in the Titan XQ welding machine as commonplace. This will permit to additional optimise totally different sorts of surfaced parts. Schroeder are also looking to broaden and improve the vary of welding tasks.
There are hundreds of Schroeder Valves installed in crops in southern Africa protecting assets at corporations 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 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 more.
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