Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s greater than only a advertising promise! Over 50 drawings of assorted parts served as the basis for the automation answer developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one factor in widespread, they had been all rotationally symmetrical. This was the start line for welding machine manufacturer EWM in their mission to develop a customized automation answer tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all over the world for transporting liquids using centrifugal pumps. Their areas of utility embrace refineries, energy vegetation and nuclear crops, within the transport of liquefied natural gasoline (LNG), in addition to in offshore rigs. They are also used throughout the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The goal is to weld all pump safety valve components mechanically. These valves are connected on to the pumps and ensure steady operation of the pumps to forestall them running 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 strikes inside the valve physique. The sealing surfaces between the valve body and the cone should be completely air and watertight. This is the one means to make sure proper functioning of the pump safety valve for many years to come. Normally, these parts are made using low-cost building steel DIN 1.0460. The sealing surfaces are reinforced with stainless-steel DIN 1.4370. This process was previously carried out manually, however, due to both the scarcity of fine welders and rising high quality assurance necessities, automation of this step was crucial. The internal diameter of the valve bodies and the cone diameters have been between 32 mm and four hundred mm. The elements being moved also differed vastly in weight, starting from a few hundred grams to two and a half tonnes. But all the elements had one thing in frequent: they have been all rotationally symmetrical, making them perfect for an automated process. With this as a place to begin, EWM was in a position to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon turned clear that solely a robotic system would fit the invoice when it got here to automating this particular course of. Having to cope with so many various half sizes was a trigger for concern. Large components require a large welding positioner. These, however, can not provide the dynamics required for the smaller parts. This rapidly gave rise to the idea of three processing stations: one large 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 without positioners for some other parts. ที่วัดแรงดันน้ำ of the building was additionally a selected problem. The components had to have the flexibility to be placed 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 ensuring extraction, either the extraction hood or the system benches have been made to be mobile. The robot was fitted in an especially small sales space in the centre between the three stations. This booth additionally includes both the facility supply and a Titan XQ. These are positioned behind the L-positioner on 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 in any respect essential positions can also be ensured because of the acute arm size of two metres and optimised area inside the cubicles.
Special torch for extreme spaces
Each valve body is supplied with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extremely difficult. For handbook welding, the welder is unable to see the weld seam and as a substitute must depend on their experience. Even for automated welding, these areas are very uncommon. EWM was solely capable of settle for this job because they manufacture the torches, emphasising the significance of the welding torch for this software. The welding torch for Schroeder Valves is a special development with a particularly small torch head and unconventionally lengthy torch neck. Of course, the particular application had to be tailored to accommodate this uncommon design: because dilution between the father or mother metal and the armouring needs to be as low as attainable, only somewhat vitality is used. This ensures secure heat dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes through outlined parameters
As the parts had been rotationally symmetrical, it was simple to show the elements; teaching is all the time based on the same programs. Even new components could be welded automatically quickly. Users simply should set the radius, number of passes and the geometric dimensions of the surfaced elements and the robotic control will care for the rest. The desired welding result is all the time assured because the welding process is defined with all of its parameters. The quality can be proven retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and intended for one specific application, Schroeder is already thinking of recent ideas and uses. Schroeder would like to try out a few of the various welding procedures that are included in the Titan XQ welding machine as commonplace. This will allow to further optimise totally different sorts of surfaced parts. Schroeder are additionally trying to expand and improve the range of welding duties.
There are lots of of Schroeder Valves put in in plants in southern Africa protecting assets at firms 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 amenities 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 be taught extra.
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