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Automated เครื่องมือที่ใช้วัดความดัน of rotationally symmetrical components
Everything from a single supply – it‘s greater than just a advertising promise! Over 50 drawings of assorted elements served as the basis for the automation solution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s components did have one factor in widespread, they have been all rotationally symmetrical. This was the starting point for welding machine producer EWM of their mission to develop a customized 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 using centrifugal pumps. Their areas of utility embody refineries, power vegetation and nuclear vegetation, within the transport of liquefied pure fuel (LNG), in addition to in offshore rigs. They are additionally used all through the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The purpose is to weld all pump safety valve elements mechanically. These valves are connected on to the pumps and ensure steady operation of the pumps to forestall them operating dry or being broken by cavitation during minimal circulate circumstances. The pump safety valve is basically made up of the valve physique and the cone, which moves inside the valve physique. The sealing surfaces between the valve body and the cone have to be completely air and watertight. This is the one means to make sure correct functioning of the pump safety valve for decades to come. Normally, these elements are made using low-cost construction steel DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This process was beforehand performed manually, however, due to both the scarcity of fine welders and growing high quality assurance necessities, automation of this step was crucial. 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 also differed vastly in weight, ranging from a couple of hundred grams to 2 and a half tonnes. But all of the components had one thing in widespread: they were all rotationally symmetrical, making them excellent for an automated process. 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 match the bill when it came to automating this specific process. Having to deal with so many alternative half sizes was a cause for concern. Large components require a large welding positioner. These, nonetheless, cannot provide the dynamics required for the smaller elements. This quickly gave rise to the concept of three processing stations: one massive L-positioner with tilting operate for the large 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 another parts. The top of the building was additionally a selected problem. The parts had to have the power to be placed on the benches with the crane. The crane hook, however, was solely approximately three metres excessive – extremely small for an industrial software. To guarantee accessibility while making certain extraction, both the extraction hood or the system benches had been made to be cell. The robotic was fitted in a particularly small sales space within the centre between the three stations. This sales space additionally includes each the ability supply and a Titan XQ. These 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 a hundred iD in all three stations at all essential positions can be ensured due to the intense arm size of two metres and optimised area contained in the booths.
Special torch for excessive areas
Each valve physique is supplied with a cone information which is welded from above. With an inside diameter of just 32 mm, access is extremely difficult. 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 unusual. EWM was only capable of accept this job as a result of they manufacture the torches, emphasising the importance of the welding torch for this software. The welding torch for Schroeder Valves is a particular development with a particularly small torch head and unconventionally lengthy torch neck. Of course, the special application had to be tailored to accommodate this unusual design: as a result of dilution between the mother or father metal and the armouring must be as little as attainable, solely a little power is used. This ensures safe heat dissipation despite the intense welding torch dimensions.
Secure welding results via defined parameters
As the components had been rotationally symmetrical, it was straightforward to teach the elements; educating is all the time based on the identical applications. Even new parts may be welded routinely quickly. Users simply have to set the radius, variety of passes and the geometric dimensions of the surfaced elements and the robotic management will care for the remaining. The desired welding result is all the time assured because the welding process is outlined with all of its parameters. The quality can be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was originally designed and meant for one particular application, Schroeder is already considering of latest concepts and uses. Schroeder wish to try out a number of the varied welding procedures that are included within the Titan XQ welding machine as normal. This will enable to further optimise different kinds of surfaced elements. Schroeder are additionally trying to broaden and improve the range of welding duties.
There are tons of of Schroeder Valves installed in crops in southern Africa defending property at companies like Sasol, Eskom, Mondi and Sappi to name a number of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning services 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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