Automated surfacing of rotationally symmetrical components
Everything from a single source – it‘s more than only a advertising promise! Over 50 drawings of varied elements served as the premise for the automation solution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one thing in common, they had been all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM of their mission to develop a customized automation resolution tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all round the world for transporting liquids utilizing centrifugal pumps. Their areas of software include refineries, power vegetation and nuclear plants, within the transport of liquefied pure gas (LNG), as properly as 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.
The purpose is to weld all pump protection valve elements automatically. These valves are connected on to the pumps and guarantee steady operation of the pumps to forestall them running dry or being damaged by cavitation during minimal move conditions. The pump safety valve is basically made up of the valve body and the cone, which strikes inside the valve physique. The sealing surfaces between the valve physique and the cone must be completely air and watertight. This is the only means to make sure proper functioning of the pump protection valve for many years to come back. Normally, these parts are made using low-cost construction steel DIN 1.0460. The sealing surfaces are reinforced with stainless-steel DIN 1.4370. This course of was beforehand carried out manually, however, as a end result of both the shortage of good welders and growing high quality assurance requirements, automation of this step was crucial. The internal diameter of the valve bodies and the cone diameters had been between 32 mm and 400 mm. The parts being moved also differed vastly in weight, ranging from a couple of hundred grams to two and a half tonnes. But all the components had one factor in common: they had been all rotationally symmetrical, making them excellent for an automated course of. With เกจวัดแรงลม as a place to begin, EWM was capable of get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly became clear that solely a robot system would fit the invoice when it got here to automating this explicit process. Having to take care of so many alternative part sizes was a trigger for concern. Large elements require a big welding positioner. These, nevertheless, can’t provide the dynamics required for the smaller components. This rapidly gave rise to the thought of three processing stations: one giant L-positioner with tilting function for the big valve our 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 some other components. The peak of the constructing was additionally a specific problem. The components had to find a way to be placed on the benches with the crane. The crane hook, nevertheless, was only roughly three metres excessive – extraordinarily small for an industrial software. To assure accessibility whereas ensuring extraction, either the extraction hood or the system benches have been made to be cellular. The robot was fitted in an extremely small sales space within the centre between the three stations. This sales space also includes each the facility source 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 robotic arm ensures safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations at all needed positions can also be ensured thanks 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 simply 32 mm, entry is extremely troublesome. For handbook welding, the welder is unable to see the weld seam and as a substitute should rely on their experience. Even for automated welding, these areas are very unusual. EWM was only capable of settle for this job as a result of they manufacture the torches, emphasising the importance 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 long torch neck. Of course, the particular utility needed to be tailored to accommodate this uncommon design: as a outcome of dilution between the father or mother metallic and the armouring must be as low as possible, only slightly energy is used. This ensures protected warmth dissipation regardless of the intense welding torch dimensions.
Secure welding outcomes by way of defined parameters
As the parts had been rotationally symmetrical, it was straightforward to teach the components; educating is always based on the same programs. Even new components can be welded automatically quickly. Users merely should set the radius, variety of passes and the geometric dimensions of the surfaced components and the robot management will deal with the rest. The desired welding result is at all times assured as a end result of the welding procedure is defined with all of its parameters. The quality may also be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was originally designed and meant for one specific application, Schroeder is already pondering of recent concepts and makes use of. Schroeder want to try out a number of the varied welding procedures which might be included in the Titan XQ welding machine as normal. This will enable to further optimise totally different kinds of surfaced parts. Schroeder are additionally trying to broaden and enhance the range of welding tasks.
There are hundreds of Schroeder Valves installed in crops in southern Africa protecting belongings at firms like Sasol, Eskom, Mondi and Sappi to call a quantity of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning amenities can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or cellphone 011 397 2833 or 0861 103 103 to be taught extra.
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