Automated surfacing of rotationally symmetrical elements
Everything from a single source – it‘s more than just a marketing promise! Over 50 drawings of assorted components served as the idea for the automation answer developed by EWM for pump safety valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one factor in frequent, they have been all rotationally symmetrical. This was the begin line for welding machine producer EWM of their mission to develop a customized automation resolution tailor-made 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 embody refineries, energy plants and nuclear plants, within the transport of liquefied natural fuel (LNG), in addition to in offshore rigs. They are additionally used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one software.
The purpose is to weld all pump safety valve elements mechanically. These valves are related on to the pumps and ensure steady operation of the pumps to stop them running dry or being damaged by cavitation during minimum move circumstances. The pump protection 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 must be completely air and watertight. This is the one way to ensure correct functioning of the pump safety valve for decades to come. Normally, these parts are made utilizing 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 both the scarcity of fine welders and rising high quality assurance requirements, automation of this step was crucial. The inner diameter of the valve bodies and the cone diameters have been between 32 mm and 400 mm. The elements being moved also differed vastly in weight, ranging from a few hundred grams to 2 and a half tonnes. But all of the elements had one factor in frequent: they have been all rotationally symmetrical, making them perfect for an automated process. 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 became clear that only a robotic system would match the invoice when it came to automating this particular course of. Having to deal with so many different half sizes was a trigger for concern. Large elements require a large welding positioner. เกจวัดแรงดันน้ําไทวัสดุ , however, can’t present the dynamics required for the smaller components. This quickly gave rise to the thought of three processing stations: one large L-positioner with tilting perform for the massive valve our bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a third station with a system bench with out positioners for another parts. The top of the constructing was also a particular challenge. The parts had to have the flexibility to be positioned on the benches with the crane. The crane hook, nevertheless, was solely roughly three metres high – extremely small for an industrial software. To assure accessibility whereas making certain extraction, either the extraction hood or the system benches have been made to be cell. The robot was fitted in an especially small sales space within the centre between the three stations. This sales space additionally consists of both the ability source and a Titan XQ. These are positioned behind the L-positioner at the giant 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 at all needed positions is also ensured thanks to the acute arm size of two metres and optimised space contained in the cubicles.
Special torch for extreme areas
Each valve body is equipped with a cone information which is welded from above. With an inside diameter of just 32 mm, access is extremely troublesome. 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 spaces are very uncommon. EWM was only able to accept this job as a outcome of they manufacture the torches, emphasising the importance of the welding torch for this utility. The welding torch for Schroeder Valves is a special building with a particularly small torch head and unconventionally long torch neck. Of course, the particular application had to be tailored to accommodate this uncommon design: as a outcome of dilution between the mother or father metal and the armouring needs to be as little as potential, only somewhat power is used. This ensures secure heat dissipation regardless of the intense welding torch dimensions.
Secure welding outcomes via outlined parameters
As the elements have been rotationally symmetrical, it was easy to show the components; teaching is always primarily based on the same programs. Even new elements can be welded mechanically rapidly. 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 remaining. The desired welding result is all the time assured as a outcome of the welding procedure is defined with all of its parameters. The high quality may additionally be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even though the system was initially designed and supposed for one particular software, Schroeder is already considering of latest ideas and makes use of. Schroeder wish to try out a variety of the numerous welding procedures that are included within the Titan XQ welding machine as normal. This will allow to further optimise completely different kinds of surfaced components. Schroeder are additionally looking to expand and enhance the vary of welding tasks.
There are hundreds of Schroeder Valves installed in plants in southern Africa defending assets at corporations like Sasol, Eskom, Mondi and Sappi to call a couple of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning services can be found 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 study extra.
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