Automated surfacing of rotationally symmetrical components
Everything from a single supply – 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 protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s elements did have one thing in widespread, they were all rotationally symmetrical. This was the place to begin for welding machine producer EWM in their mission to develop a custom automation solution tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of application embrace refineries, power crops and nuclear crops, in the transport of liquefied pure gasoline (LNG), in addition to in offshore rigs. They are additionally used throughout the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one software.
The aim is to weld all pump safety valve parts automatically. These valves are connected on to the pumps and guarantee steady operation of the pumps to stop them working dry or being broken by cavitation during minimum flow conditions. 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 method to ensure proper functioning of the pump protection valve for many years to come. Normally, these components are made using low-cost development steel DIN 1.0460. The sealing surfaces are strengthened with stainless steel DIN 1.4370. This course of was beforehand performed manually, however, because of both the scarcity of excellent welders and growing quality assurance requirements, automation of this step was essential. The inner diameter of the valve our bodies and the cone diameters were between 32 mm and four hundred mm. The elements being moved also differed vastly in weight, starting from a few hundred grams to 2 and a half tonnes. But all the elements had one factor in common: they were all rotationally symmetrical, making them good for an automatic course of. With this as a starting point, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly turned clear that solely a robot system would fit the invoice when it got here to automating this specific course of. Having to cope with so many various part sizes was a trigger for concern. Large parts require a big welding positioner. These, nonetheless, can’t present the dynamics required for the smaller parts. This quickly gave rise to the concept of three processing stations: one giant L-positioner with tilting function for the big valve bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a third station with a system bench with out positioners for any other components. The top of the building was additionally a particular challenge. The components had to have the ability 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 making certain extraction, either the extraction hood or the system benches have been made to be cell. The robotic was fitted in an especially small sales space within the centre between the three stations. This booth additionally includes both the power supply 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 robotic arm ensures safe wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations in any respect essential positions is also ensured because of the intense arm size of two metres and optimised house contained in the booths.
Special torch for extreme spaces
Each valve physique is equipped with a cone guide which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily troublesome. For handbook welding, the welder is unable to see the weld seam and as an alternative must rely on their expertise. Even for automated welding, these areas are very unusual. EWM was solely capable of settle for 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 very small torch head and unconventionally lengthy torch neck. Of course, the particular application needed to be tailored to accommodate this uncommon design: as a outcome of dilution between the father or mother metal and the armouring must be as low as possible, solely somewhat energy is used. This ensures protected warmth dissipation despite the intense welding torch dimensions.
ร้านซ่อมเครื่องวัดความดัน welding outcomes via outlined parameters
As the elements were rotationally symmetrical, it was straightforward to teach the elements; teaching is all the time based mostly on the identical programs. Even new parts may be welded routinely shortly. Users simply need to set the radius, number of passes and the geometric dimensions of the surfaced parts and the robot control will take care of the remainder. The desired welding result is all the time guaranteed because the welding process is outlined with all of its parameters. The quality can also be proven retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was initially designed and meant for one specific utility, Schroeder is already pondering of latest concepts and uses. Schroeder want to check out a few of the various welding procedures which may be included in the Titan XQ welding machine as standard. This will permit to additional optimise totally different kinds of surfaced components. Schroeder are additionally seeking to broaden and improve the range of welding duties.
There are hundreds of Schroeder Valves put in in plants in southern Africa defending belongings at firms like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning amenities can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or telephone 011 397 2833 or 0861 103 103 to study extra.
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