Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s more than only a advertising promise! Over 50 drawings of various parts served as the idea 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 thing in frequent, they had been all rotationally symmetrical. This was the begin line for welding machine manufacturer EWM of their mission to develop a customized automation answer tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of utility embrace refineries, power vegetation and nuclear vegetation, within the transport of liquefied natural gas (LNG), in addition to in offshore rigs. They are additionally used all through the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The aim is to weld all pump safety valve components mechanically. These valves are linked directly to the pumps and ensure steady operation of the pumps to prevent them operating dry or being broken by cavitation throughout minimal move conditions. The pump protection valve is largely made up of the valve body and the cone, which moves inside the valve physique. The sealing surfaces between the valve body and the cone have to be completely air and watertight. This is the only means to ensure correct functioning of the pump protection valve for decades to come back. Normally, these components are made utilizing low-cost building metal DIN 1.0460. The sealing surfaces are strengthened with stainless-steel DIN 1.4370. This process was beforehand performed manually, nonetheless, because of both the scarcity of fine welders and rising quality assurance necessities, automation of this step was crucial. The inner diameter of the valve our bodies and the cone diameters have been between 32 mm and four hundred mm. The components 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 widespread: they were all rotationally symmetrical, making them perfect for an automated course of. With this as a place to begin, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon turned clear that only a robotic system would fit the bill when it came to automating this particular course of. Having to deal with xp2i was a trigger for concern. Large parts require a big welding positioner. These, nevertheless, can’t present the dynamics required for the smaller components. This rapidly gave rise to the idea 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 bodies, and a 3rd station with a system bench without positioners for some other parts. The peak of the constructing was also a specific problem. The elements had to have the flexibility to be placed on the benches with the crane. The crane hook, nonetheless, was solely roughly three metres high – extremely small for an industrial utility. To guarantee accessibility while making certain extraction, either the extraction hood or the system benches have been made to be cellular. The robot was fitted in an especially small booth within the centre between the three stations. This sales space also consists of each the facility source and a Titan XQ. These are positioned behind the L-positioner on the massive processing station. The Rob 5 drive 4X wire feeder mounted on the robotic arm ensures secure wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations in any respect necessary positions can be ensured thanks to the extreme arm length of two metres and optimised area contained in 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 just 32 mm, entry is extremely troublesome. For manual welding, the welder is unable to see the weld seam and as an alternative must depend on their expertise. Even for automated welding, these areas are very unusual. EWM was solely able to accept this job as a end result of they manufacture the torches, emphasising the significance of the welding torch for this utility. The welding torch for Schroeder Valves is a special construction with a particularly small torch head and unconventionally lengthy torch neck. Of course, the special utility needed to be adapted to accommodate this uncommon design: as a result of dilution between the parent steel and the armouring must be as low as possible, only somewhat power is used. This ensures safe heat dissipation regardless of the extreme welding torch dimensions.
Secure welding results via defined parameters
As the parts have been rotationally symmetrical, it was easy to teach the components; educating is at all times primarily based on the identical programs. Even new components can be welded automatically shortly. Users merely have to set the radius, variety of passes and the geometric dimensions of the surfaced elements and the robotic management will take care of the remainder. The desired welding result’s all the time guaranteed as a outcome of the welding procedure is outlined with all of its parameters. The high quality can be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was originally designed and intended for one particular 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 might be included within the Titan XQ welding machine as commonplace. This will allow to additional optimise different kinds of surfaced components. Schroeder are additionally seeking to expand and improve the vary of welding tasks.
There are tons of of Schroeder Valves installed in vegetation in southern Africa protecting assets at companies like Sasol, Eskom, Mondi and Sappi to name a couple of. เกจวัดแรงดันเบนซิน & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning amenities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or phone 011 397 2833 or 0861 103 103 to be taught more.
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