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Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s more than just a marketing promise! Over 50 drawings of varied elements served as the premise for the automation resolution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading 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 resolution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used all around the world for transporting liquids utilizing centrifugal pumps. Their areas of software embrace refineries, power crops and nuclear crops, in the transport of liquefied natural gasoline (LNG), in addition to in offshore rigs. They are also used throughout the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one application.
The aim is to weld all pump safety valve parts mechanically. These valves are related on to the pumps and guarantee continuous operation of the pumps to forestall them working dry or being broken by cavitation during minimal move situations. The pump safety valve is basically made up of the valve body and the cone, which strikes inside the valve physique. The sealing surfaces between the valve physique and the cone must be completely air and watertight. This is the only way to ensure correct functioning of the pump protection valve for decades to come. Normally, these components are made using low-cost building metal DIN 1.0460. The sealing surfaces are bolstered with stainless-steel DIN 1.4370. This process was beforehand carried out manually, nonetheless, due to both the scarcity of fine welders and growing quality assurance requirements, automation of this step was essential. The internal diameter of the valve bodies and the cone diameters have been between 32 mm and 400 mm. The elements being moved also differed vastly in weight, ranging from a couple of hundred grams to two and a half tonnes. But all of the parts had one factor in widespread: they have been all rotationally symmetrical, making them excellent for an automated process. With this as a beginning point, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly turned clear that solely a robotic system would fit the invoice when it got here to automating this particular process. Having to deal with so many different half sizes was a cause for concern. Large components require a big welding positioner. These, nonetheless, cannot provide the dynamics required for the smaller elements. This rapidly gave rise to the thought of three processing stations: one large L-positioner with tilting operate for the large 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 height of the constructing was additionally a selected challenge. The components had to be able to be positioned on the benches with the crane. The crane hook, nevertheless, was solely approximately three metres high – extraordinarily small for an industrial application. To guarantee accessibility while making certain extraction, both the extraction hood or the system benches have been made to be cellular. The robot was fitted in a particularly small booth within the centre between the three stations. This sales space additionally contains each the power supply and a Titan XQ. These are positioned behind the L-positioner at 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 100 iD in all three stations in any respect needed positions can be ensured thanks to the acute arm length of two metres and optimised house inside the cubicles.
Special torch for excessive spaces
Each valve physique is provided with a cone guide which is welded from above. With an inside diameter of simply 32 mm, entry is extremely difficult. For เกจวัดแรงอัดกระบอกสูบ , the welder is unable to see the weld seam and as an alternative should depend on their experience. Even for automated welding, these spaces are very unusual. EWM was solely able to settle for this job as a result of they manufacture the torches, emphasising the significance of the welding torch for this software. The welding torch for Schroeder Valves is a particular construction with a particularly small torch head and unconventionally lengthy torch neck. Of course, the particular software had to be adapted to accommodate this unusual design: as a end result of dilution between the parent steel and the armouring needs to be as little as potential, solely slightly power is used. This ensures protected warmth dissipation regardless of the acute welding torch dimensions.
Secure welding results by way of outlined parameters
As the elements had been rotationally symmetrical, it was easy to teach the components; educating is all the time based mostly on the identical packages. Even new parts could be welded routinely shortly. Users simply need to set the radius, number of passes and the geometric dimensions of the surfaced parts and the robotic management will care for the remainder. The desired welding result is all the time assured as a end result of the welding process is outlined with all of its parameters. The high quality can be proven retrospectively as all welding parameters are continuously monitored and recorded. Even although the system was originally designed and supposed for one particular utility, Schroeder is already considering of recent ideas and makes use of. Schroeder want to try out a few of the varied welding procedures that are included within the Titan XQ welding machine as standard. This will allow to additional optimise totally different sorts of surfaced parts. Schroeder are additionally seeking to increase and improve the vary of welding tasks.
There are tons of of Schroeder Valves installed in vegetation in southern Africa protecting belongings at firms like Sasol, Eskom, Mondi and Sappi to call a number of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore and reconditioning amenities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact sales@valve.co.za, www.valve.co.za or cellphone 011 397 2833 or 0861 103 103 to study extra.
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