Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s greater than only a marketing promise! Over 50 drawings of various parts served as the basis for the automation resolution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one thing in common, they were all rotationally symmetrical. This was the beginning point for welding machine producer EWM in their mission to develop a customized automation answer tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used all round the world for transporting liquids utilizing centrifugal pumps. Their areas of application include refineries, energy crops and nuclear crops, in the transport of liquefied pure gas (LNG), as nicely as in offshore rigs. They are additionally used throughout the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one software.
The goal is to weld all pump safety valve parts mechanically. These valves are connected directly to the pumps and guarantee continuous operation of the pumps to forestall them running dry or being broken by cavitation during minimal move circumstances. The pump safety valve is largely made up of the valve body and the cone, which strikes contained in the valve physique. The sealing surfaces between the valve physique and the cone have to be absolutely air and watertight. This is the only method to make sure correct functioning of the pump safety valve for decades to return. Normally, these components are made using low-cost development steel DIN 1.0460. The sealing surfaces are reinforced with stainless steel DIN 1.4370. This process was previously carried out manually, nevertheless, because of each the scarcity of good welders and growing 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 four hundred mm. The components being moved also differed vastly in weight, starting from a couple of hundred grams to 2 and a half tonnes. But the entire components had one factor in common: they have been all rotationally symmetrical, making them excellent for an automated course of. With this as a beginning point, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon turned clear that only a robot system would match the invoice when it came to automating this specific process. Having to cope with so many different half sizes was a cause for concern. Large parts require a big welding positioner. These, however, can’t present the dynamics required for the smaller components. This rapidly gave rise to the thought of three processing stations: one giant L-positioner with tilting perform for the massive 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 additionally a selected challenge. The elements had to be able to be placed on the benches with the crane. The crane hook, nevertheless, was solely roughly three metres excessive – extremely small for an industrial application. To assure accessibility while ensuring extraction, both the extraction hood or the system benches had been made to be cell. The robotic was fitted in a particularly small sales space in the centre between the three stations. This sales space additionally consists of both the ability supply and a Titan XQ. These are positioned behind the L-positioner on the large processing station. The Rob 5 drive 4X wire feeder mounted on the robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations in any respect essential positions can be ensured because of the acute arm size of two metres and optimised house inside the booths.
Special torch for excessive spaces
Each valve body is provided with a cone guide which is welded from above. With an inside diameter of simply 32 mm, entry is extremely troublesome. For เกจวัดแรงดันnuovafima , the welder is unable to see the weld seam and as an alternative should depend on their expertise. Even for automated welding, these areas are very unusual. EWM was only able to accept this job because they manufacture the torches, emphasising the significance of the welding torch for this application. The welding torch for Schroeder Valves is a particular building with a very small torch head and unconventionally long torch neck. Of course, the special software needed to be adapted to accommodate this uncommon design: because dilution between the parent steel and the armouring needs to be as little as possible, only a little power is used. This ensures secure heat dissipation despite the extreme welding torch dimensions.
Secure welding results through defined parameters
As the components have been rotationally symmetrical, it was straightforward to show the elements; teaching is all the time primarily based on the identical programs. Even new parts can be welded mechanically shortly. Users simply should set the radius, number of passes and the geometric dimensions of the surfaced components and the robotic management will take care of the rest. The desired welding result is at all times assured as a result of the welding procedure is defined with all of its parameters. The quality can be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was initially designed and intended for one specific software, Schroeder is already considering of latest ideas and makes use of. Schroeder would like to check out a number of the varied welding procedures which may be included within the Titan XQ welding machine as commonplace. This will permit to additional optimise completely different kinds of surfaced parts. Schroeder are also looking to expand and improve the vary of welding tasks.
There are hundreds of Schroeder Valves put in in vegetation in southern Africa protecting assets at corporations like Sasol, Eskom, Mondi and Sappi to name a quantity of. Sulzer & 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 sales@valve.co.za, www.valve.co.za or cellphone 011 397 2833 or 0861 103 103 to study more.
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