Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s more than only a advertising promise! Over 50 drawings of varied elements served as the basis for the automation answer developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one thing in widespread, they had been all rotationally symmetrical. This was the begin line for welding machine manufacturer EWM in their mission to develop a customized automation answer tailored 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 embody refineries, power plants and nuclear plants, in the transport of liquefied pure gasoline (LNG), in addition to in offshore rigs. เพรสเชอร์เกจnuovafima are additionally used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The aim is to weld all pump protection valve elements mechanically. These valves are related directly to the pumps and ensure steady operation of the pumps to stop them operating dry or being broken by cavitation during minimal flow circumstances. The pump protection valve is essentially made up of the valve physique and the cone, which moves inside the valve body. The sealing surfaces between the valve physique and the cone must be completely air and watertight. This is the only way to ensure correct functioning of the pump safety valve for decades to return. Normally, these components are made utilizing low-cost building metal DIN 1.0460. The sealing surfaces are reinforced with stainless steel DIN 1.4370. This course of was previously carried out manually, nonetheless, because of each the shortage of fine welders and growing quality assurance necessities, automation of this step was crucial. The inside diameter of the valve our bodies and the cone diameters had been between 32 mm and 400 mm. The parts being moved additionally differed vastly in weight, starting from a quantity of hundred grams to two and a half tonnes. But all the parts had one thing in widespread: they were all rotationally symmetrical, making them excellent for an automatic process. 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 soon grew to become clear that only a robotic system would fit the bill when it got here to automating this particular course of. Having to take care of so many alternative half sizes was a trigger for concern. Large components require a big welding positioner. These, however, cannot provide the dynamics required for the smaller elements. This rapidly gave rise to the concept 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 third station with a system bench with out positioners for any other parts. The height of the building was also a selected problem. The components had to have the ability to be placed on the benches with the crane. The crane hook, nonetheless, was solely approximately three metres excessive – extraordinarily small for an industrial application. To assure accessibility while making certain extraction, either the extraction hood or the system benches have been made to be cell. The robot was fitted in a particularly small booth within the centre between the three stations. This sales space additionally contains both the facility 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 100 iD in all three stations in any respect essential positions can also be ensured thanks to the extreme arm length of two metres and optimised area contained in the cubicles.
Special torch for excessive areas
Each valve physique is equipped with a cone guide which is welded from above. With an inside diameter of simply 32 mm, access is extraordinarily tough. For manual welding, the welder is unable to see the weld seam and as an alternative should depend on their expertise. Even for automated welding, these spaces are very unusual. EWM was solely capable of 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 particular building with a particularly small torch head and unconventionally long torch neck. Of course, the particular application had to be adapted to accommodate this uncommon design: as a outcome of dilution between the parent metal and the armouring must be as low as possible, solely somewhat vitality is used. This ensures secure heat dissipation despite the intense welding torch dimensions.
Secure welding outcomes by way of defined parameters
As the elements had been rotationally symmetrical, it was straightforward to show the parts; teaching is at all times based on the same applications. Even new elements could be welded routinely quickly. Users merely should set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot management will take care of the remainder. The desired welding result is always assured because the welding process is defined with all of its parameters. The quality may additionally be proven retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and intended for one specific software, Schroeder is already considering of latest ideas and makes use of. Schroeder wish to check out some of the various welding procedures that are included within the Titan XQ welding machine as standard. This will allow to additional optimise different kinds of surfaced parts. Schroeder are additionally looking to expand and improve the vary of welding duties.
There are lots of of Schroeder Valves installed in vegetation in southern Africa protecting assets at companies like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning services are available 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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