Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s greater than only a marketing promise! Over 50 drawings of varied elements served as the idea for the automation resolution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one factor in common, they had been all rotationally symmetrical. digital pressure gauge was the start line for welding machine manufacturer EWM of their mission to develop a customized automation resolution tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of utility include refineries, energy plants and nuclear vegetation, in the transport of liquefied pure gasoline (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The goal is to weld all pump safety valve parts mechanically. These valves are connected on to the pumps and guarantee continuous operation of the pumps to forestall them working dry or being damaged by cavitation throughout minimal flow conditions. The pump protection valve is largely made up of the valve body and the cone, which strikes inside the valve body. The sealing surfaces between the valve body and the cone must be completely air and watertight. This is the only method to ensure proper functioning of the pump protection valve for many years to return. Normally, these elements are made utilizing low-cost building steel DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This course of was previously carried out manually, nonetheless, as a outcome of each the scarcity of good welders and growing high quality assurance necessities, automation of this step was crucial. The inside diameter of the valve our bodies and the cone diameters were between 32 mm and 400 mm. The components being moved also differed vastly in weight, starting from a few hundred grams to two and a half tonnes. But all the parts had one thing in frequent: they were all rotationally symmetrical, making them excellent for an automatic 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 quickly grew to become clear that solely a robotic system would fit the bill when it came to automating this specific course of. Having to deal with so many different part sizes was a cause for concern. Large components require a big welding positioner. These, however, can’t provide the dynamics required for the smaller components. This rapidly gave rise to the concept of three processing stations: one massive 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 with out positioners for any other elements. The peak of the constructing was additionally a particular problem. The components had to have the power to be positioned on the benches with the crane. The crane hook, nonetheless, was only roughly three metres high – extremely small for an industrial software. To guarantee accessibility while making certain 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 within the centre between the three stations. This sales space also consists of both the power source and a Titan XQ. These are positioned behind the L-positioner at the massive 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 at all needed positions can be ensured because of the acute arm length of two metres and optimised area contained in the booths.
Special torch for excessive 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 extremely troublesome. For handbook welding, the welder is unable to see the weld seam and as an alternative should rely on their experience. Even for automated welding, these areas are very uncommon. EWM was only in a position to settle for this job as a outcome of they manufacture the torches, emphasising the significance of the welding torch for this utility. 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 utility had to be tailored to accommodate this unusual design: as a end result of dilution between the mother or father metal and the armouring needs to be as little as possible, only somewhat power is used. This ensures protected heat dissipation despite the extreme welding torch dimensions.
Secure welding outcomes via outlined parameters
As the elements were rotationally symmetrical, it was easy to teach the components; teaching is all the time primarily based on the identical programs. Even new parts can be welded routinely shortly. Users merely have to set the radius, number of passes and the geometric dimensions of the surfaced components and the robotic control will take care of the rest. The desired welding result’s at all times guaranteed as a end result of the welding process is defined with all of its parameters. The quality may also be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was originally designed and supposed for one specific utility, Schroeder is already thinking of latest concepts and uses. Schroeder wish to check out a few of the varied welding procedures that are included within the Titan XQ welding machine as normal. This will enable to further optimise completely different kinds of surfaced elements. Schroeder are additionally seeking to broaden and enhance the vary of welding tasks.
There are hundreds of Schroeder Valves put in in plants in southern Africa defending assets at companies like Sasol, Eskom, Mondi and Sappi to name a quantity of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning facilities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact sales@valve.co.za, www.valve.co.za or phone 011 397 2833 or 0861 103 103 to learn more.
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