Automated surfacing of rotationally symmetrical components

Everything from a single supply – it‘s greater than only a marketing promise! Over 50 drawings of assorted parts served as the basis for the automation resolution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one factor in common, they have been all rotationally symmetrical. This was the start line for welding machine manufacturer EWM in their mission to develop a custom automation answer tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used everywhere in the world for transporting liquids utilizing centrifugal pumps. Their areas of utility include refineries, power crops and nuclear plants, in the transport of liquefied natural gas (LNG), in addition to in offshore rigs. pressure gauge octa are also used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one application.
The goal is to weld all pump protection valve elements automatically. These valves are linked on to the pumps and ensure continuous operation of the pumps to stop them working dry or being broken by cavitation during minimal move situations. The pump protection valve is basically made up of the valve physique and the cone, which moves inside the valve physique. The sealing surfaces between the valve physique and the cone have to be absolutely air and watertight. This is the only way to ensure proper functioning of the pump protection valve for decades to return. Normally, these components are made utilizing low-cost construction steel DIN 1.0460. The sealing surfaces are reinforced with stainless-steel DIN 1.4370. This process was beforehand performed manually, however, as a result of each the scarcity of excellent welders and growing quality assurance requirements, automation of this step was essential. The internal diameter of the valve our bodies and the cone diameters have been between 32 mm and four hundred mm. The parts being moved additionally differed vastly in weight, starting from a number of hundred grams to two and a half tonnes. But the entire parts had one factor in frequent: they were all rotationally symmetrical, making them perfect for an automatic process. With this as a starting point, EWM was in a position to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations

It quickly turned clear that only a robotic system would fit the invoice when it got here to automating this particular course of. Having to take care of so many different part sizes was a trigger for concern. Large components require a large welding positioner. These, nevertheless, can’t provide the dynamics required for the smaller elements. This rapidly gave rise to the thought of three processing stations: one massive L-positioner with tilting function for the massive valve our bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a 3rd station with a system bench with out positioners for another components. The height of the constructing was additionally a selected problem. The parts had to have the flexibility to be placed on the benches with the crane. The crane hook, nonetheless, was only approximately three metres high – extremely small for an industrial utility. To guarantee accessibility while ensuring extraction, both the extraction hood or the system benches had been made to be cell. The robotic was fitted in an extremely small sales space in the centre between the three stations. This booth also consists of both the power source and a Titan XQ. digital pressure gauge are positioned behind the L-positioner at the giant 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 at all needed positions is also ensured due to the acute arm length of two metres and optimised house inside the cubicles.
Special torch for excessive areas

Each valve physique is supplied with a cone guide which is welded from above. With an inside diameter of simply 32 mm, access is extraordinarily troublesome. For manual welding, the welder is unable to see the weld seam and instead must rely on their expertise. Even for automated welding, these areas are very uncommon. EWM was only able to settle for this job as a result 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 very small torch head and unconventionally long torch neck. Of course, the special software had to be adapted to accommodate this unusual design: because dilution between the father or mother metallic and the armouring needs to be as low as possible, solely somewhat energy is used. This ensures secure warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding results through outlined parameters

As the elements had been rotationally symmetrical, it was easy to teach the parts; instructing is always primarily based on the identical programs. Even new elements can be welded mechanically rapidly. Users merely have to set the radius, variety of passes and the geometric dimensions of the surfaced components and the robotic control will deal with the remaining. The desired welding result’s all the time assured as a result of the welding procedure is outlined with all of its parameters. The quality can additionally be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was initially designed and intended for one particular utility, Schroeder is already considering of recent ideas and makes use of. Schroeder would like to try out some of the various welding procedures that are included in the Titan XQ welding machine as commonplace. This will allow to additional optimise different kinds of surfaced components. Schroeder are additionally looking to expand and improve the range of welding duties.
There are hundreds of Schroeder Valves installed in crops in southern Africa protecting belongings at companies like Sasol, Eskom, Mondi and Sappi to call a couple of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore and reconditioning facilities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or telephone 011 397 2833 or 0861 103 103 to be taught extra.
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