Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of varied parts 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 components did have one thing in widespread, they have been all rotationally symmetrical. This was the begin line for welding machine producer EWM of their mission to develop a customized automation solution tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used everywhere in the world for transporting liquids utilizing centrifugal pumps. Their areas of application embrace refineries, power plants and nuclear vegetation, within the transport of liquefied pure gas (LNG), in addition to 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 utility.
digital pressure gauge is to weld all pump protection valve elements automatically. These valves are related directly to the pumps and guarantee continuous operation of the pumps to forestall them running dry or being broken by cavitation during minimum circulate circumstances. The pump protection valve is essentially 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 must be completely air and watertight. This is the only means to ensure proper functioning of the pump protection valve for decades to come. Normally, these parts are made using low-cost development steel DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This process was previously carried out manually, however, due to each the scarcity of excellent welders and growing high quality assurance requirements, automation of this step was essential. The inside diameter of the valve bodies and the cone diameters had been between 32 mm and 400 mm. The elements being moved additionally differed vastly in weight, starting from a couple of hundred grams to 2 and a half tonnes. But the entire parts had one factor in widespread: they were all rotationally symmetrical, making them good for an automatic course of. With this as a starting point, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon became clear that only a robot system would fit the invoice when it got here to automating this specific process. Having to cope with so many alternative part sizes was a cause for concern. Large components require a large welding positioner. เกจวัดแรงดัน , however, can not provide the dynamics required for the smaller components. This rapidly gave rise to the idea of three processing stations: one massive L-positioner with tilting function for the large 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 any other elements. The peak of the constructing was also a particular problem. The parts had to be able to be placed on the benches with the crane. The crane hook, nevertheless, was solely approximately three metres excessive – extraordinarily small for an industrial utility. To assure accessibility while guaranteeing extraction, both the extraction hood or the system benches were made to be cellular. The robotic was fitted in a particularly small booth in the centre between the three stations. This booth additionally includes 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 secure wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations at all needed positions can additionally be ensured thanks to the intense arm length of two metres and optimised house inside the cubicles.
Special torch for excessive areas
Each valve physique is provided with a cone guide which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily difficult. For manual welding, the welder is unable to see the weld seam and instead should depend on their experience. Even for automated welding, these spaces are very uncommon. EWM was only able to accept this job as a outcome of they manufacture the torches, emphasising the significance of the welding torch for this software. The welding torch for Schroeder Valves is a special building with a very small torch head and unconventionally lengthy torch neck. Of course, the special software needed to be tailored to accommodate this unusual design: because dilution between the father or mother steel and the armouring must be as little as possible, only somewhat energy is used. This ensures safe heat dissipation despite the acute welding torch dimensions.
Secure welding results through defined parameters
As the parts had been rotationally symmetrical, it was straightforward to show the elements; educating is all the time based on the identical packages. Even new elements could be welded routinely rapidly. Users simply should set the radius, variety of passes and the geometric dimensions of the surfaced elements and the robotic management will take care of the rest. The desired welding result is all the time assured as a outcome of the welding procedure is defined with all of its parameters. The high quality can be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was originally designed and supposed for one specific application, Schroeder is already considering of new concepts and uses. Schroeder wish to check out some of the various welding procedures which are included within the Titan XQ welding machine as commonplace. This will permit to additional optimise completely different kinds of surfaced elements. Schroeder are additionally seeking to expand and improve the range of welding tasks.
There are lots of of Schroeder Valves installed in plants in southern Africa protecting property at companies like Sasol, Eskom, Mondi and Sappi to name a number of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning facilities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact email@example.com, www.valve.co.za or phone 011 397 2833 or 0861 103 103 to study extra.