Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of varied elements served as the premise for the automation resolution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s components did have one thing in common, they have been all rotationally symmetrical. This was the start line for welding machine manufacturer EWM of their mission to develop a customized automation solution tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all over the world for transporting liquids utilizing centrifugal pumps. Their areas of utility include refineries, power vegetation and nuclear plants, within the transport of liquefied pure gasoline (LNG), as nicely as in offshore rigs. They are also used throughout the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one software.
The goal is to weld all pump safety valve parts automatically. These valves are connected on to the pumps and guarantee steady operation of the pumps to stop them working dry or being damaged by cavitation during minimum circulate conditions. The pump safety valve is largely made up of the valve physique and the cone, which strikes inside the valve physique. The sealing surfaces between the valve physique and the cone must be absolutely air and watertight. This is the one method to ensure correct 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 strengthened with stainless-steel DIN 1.4370. This process was previously carried out manually, nonetheless, as a outcome of each the scarcity of excellent welders and rising high quality assurance necessities, automation of this step was crucial. The inside diameter of the valve bodies and the cone diameters had been between 32 mm and 400 mm. The elements being moved also differed vastly in weight, starting from a quantity of hundred grams to two and a half tonnes. But all the parts had one thing in widespread: they were 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 only a robot system would fit the bill when it got here to automating this particular course of. Having to deal with so many alternative half sizes was a trigger for concern. Large components require a large welding positioner. These, nonetheless, can not provide the dynamics required for the smaller elements. This quickly gave rise to the thought of three processing stations: one large L-positioner with tilting function for the big 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 without positioners for any other elements. The height of the constructing was also a selected challenge. The parts had to be able to be placed on the benches with the crane. The crane hook, nevertheless, was only roughly three metres excessive – extremely small for an industrial utility. To guarantee accessibility whereas making certain extraction, either the extraction hood or the system benches had been made to be cell. The robot was fitted in a particularly small booth in the centre between the three stations. This sales space also contains both the ability supply 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 robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations in any respect needed positions can be ensured due to the acute arm length of two metres and optimised space inside the booths.
Special torch for extreme areas
Each valve physique is equipped with a cone information which is welded from above. With an inside diameter of just 32 mm, access is extraordinarily tough. For guide 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 unusual. EWM was only capable of settle for this job because they manufacture the torches, emphasising the importance of the welding torch for this utility. The welding torch for Schroeder Valves is a special construction with a very small torch head and unconventionally long torch neck. Of course, the special software needed to be tailored to accommodate this uncommon design: as a result of dilution between the mother or father metallic and the armouring needs to be as low as possible, solely slightly energy is used. This ensures secure heat dissipation regardless of the intense welding torch dimensions.
Secure welding outcomes by way of defined parameters
As the components had been rotationally symmetrical, it was simple to show the components; teaching is always based mostly on the identical applications. Even เกจวัดแก๊สหุงต้ม can be welded mechanically shortly. Users simply have to set the radius, variety of passes and the geometric dimensions of the surfaced components and the robotic management will care for the rest. The desired welding result’s all the time guaranteed as a result of the welding process is outlined with all of its parameters. The quality can be confirmed retrospectively as all welding parameters are continuously monitored and recorded. Even although the system was originally designed and intended for one particular software, Schroeder is already thinking of new ideas and uses. Schroeder wish to check out some of the varied welding procedures which are included within the Titan XQ welding machine as normal. This will allow to further optimise totally different kinds of surfaced parts. Schroeder are also seeking to expand and improve the vary of welding tasks.
There are tons of of Schroeder Valves installed in vegetation in southern Africa protecting property at corporations like Sasol, Eskom, Mondi and Sappi to call a quantity of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore and reconditioning facilities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or cellphone 011 397 2833 or 0861 103 103 to study extra.
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