Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s greater than just a advertising promise! Over 50 drawings of assorted elements served as the idea for the automation solution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s components did have one thing in common, they were all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM of their mission to develop a customized automation solution tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all over the world for transporting liquids using centrifugal pumps. Their areas of software embrace refineries, power crops and nuclear vegetation, in the transport of liquefied natural gasoline (LNG), in addition to in offshore rigs. They are additionally used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one software.
The goal is to weld all pump safety valve parts mechanically. These valves are linked on to the pumps and ensure continuous operation of the pumps to stop them operating dry or being broken by cavitation during minimal move circumstances. The pump protection valve is essentially made up of the valve body and the cone, which moves contained in the valve body. The sealing surfaces between the valve physique and the cone must be absolutely air and watertight. This is the one way to make sure proper functioning of the pump protection valve for many years to come back. Normally, these parts are made utilizing low-cost building steel DIN 1.0460. The sealing surfaces are reinforced with stainless-steel DIN 1.4370. This process was beforehand performed manually, nonetheless, as a result of each the scarcity of excellent welders and rising high quality assurance requirements, automation of this step was crucial. The inside 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 couple of hundred grams to 2 and a half tonnes. But the entire elements had one factor in common: they were all rotationally symmetrical, making them perfect for an automated course of. With this 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 only a robot system would match the invoice when it got here to automating this specific course of. Having to take care of so many various part sizes was a trigger for concern. Large parts require a large welding positioner. These, nevertheless, can not present the dynamics required for the smaller components. This shortly gave rise to the idea of three processing stations: one massive L-positioner with tilting perform for the big 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 without positioners for any other elements. The height of the constructing was additionally a particular problem. The parts had to be able to be positioned on the benches with the crane. The crane hook, nonetheless, was only approximately three metres high – extremely small for an industrial utility. To assure accessibility while making certain extraction, either the extraction hood or the system benches had been made to be mobile. The robotic was fitted in an extremely small booth within the centre between the three stations. This booth also consists of each the facility source 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 robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations in any respect needed positions is also ensured thanks to the acute arm length of two metres and optimised area contained in the booths.
Special torch for excessive areas
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 tough. For guide welding, the welder is unable to see the weld seam and as an alternative should depend on their experience. Even for automated welding, these spaces are very uncommon. EWM was solely in a place to accept this job as a outcome of they manufacture the torches, emphasising the importance of the welding torch for this software. The welding torch for Schroeder Valves is a special construction with a very small torch head and unconventionally lengthy torch neck. Of course, the particular software had to be tailored to accommodate this unusual design: as a result of dilution between the mother or father metallic and the armouring must be as low as attainable, solely somewhat power is used. This ensures protected warmth dissipation regardless of the intense welding torch dimensions.
Secure welding outcomes via defined parameters
As the parts were rotationally symmetrical, it was straightforward to teach the parts; educating is all the time based mostly on the identical programs. Even new parts may be welded routinely shortly. เครื่องมือวัดpressure have to set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot control will deal with the rest. The desired welding result is all the time assured as a outcome of the welding procedure is outlined with all of its parameters. The high quality can be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and intended for one specific utility, Schroeder is already pondering of new ideas and makes use of. Schroeder want to try out a few of the varied welding procedures which would possibly be included in the Titan XQ welding machine as commonplace. This will allow to further optimise completely different kinds of surfaced parts. Schroeder are also seeking to expand and improve the vary of welding duties.
There are lots of of Schroeder Valves put in in crops in southern Africa defending assets at corporations like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning facilities 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 more.
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