Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s more than just a advertising promise! Over 50 drawings of assorted parts served as the premise for the automation solution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s components did have one factor in frequent, they have been all rotationally symmetrical. This was the beginning point for welding machine manufacturer EWM of their mission to develop a custom automation answer tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all over the world for transporting liquids using centrifugal pumps. Their areas of utility include refineries, power plants and nuclear vegetation, within the transport of liquefied natural gas (LNG), as nicely as in offshore rigs. They 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 goal is to weld all pump protection valve parts automatically. These valves are connected directly to the pumps and guarantee steady operation of the pumps to stop them running dry or being damaged by cavitation during minimum flow conditions. The pump safety valve is largely made up of the valve physique and the cone, which strikes inside the valve body. The sealing surfaces between the valve body and the cone must be completely air and watertight. This is the only means to make sure correct functioning of the pump protection valve for decades to come. Normally, these elements are made utilizing low-cost construction steel DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This process was previously carried out manually, nevertheless, as a end result of each the scarcity of good welders and growing quality assurance requirements, automation of this step was essential. The internal diameter of the valve our 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 quantity of hundred grams to two and a half tonnes. But all of the elements had one factor in common: they had been all rotationally symmetrical, making them good for an automatic course of. With this as a place to begin, EWM was in a place 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 invoice when it came to automating this particular process. Having to deal with so many alternative half sizes was a trigger for concern. Large elements require a large welding positioner. These, however, can not provide the dynamics required for the smaller elements. This quickly gave rise to the idea of three processing stations: one large L-positioner with tilting operate for the massive valve bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a third station with a system bench with out positioners for some other elements. เพรสเชอร์เกจ of the building was also a specific challenge. The parts had to be able to be placed on the benches with the crane. The crane hook, however, was only roughly three metres high – extraordinarily small for an industrial application. To guarantee accessibility while ensuring extraction, both the extraction hood or the system benches were made to be mobile. The robotic was fitted in a particularly small sales space within the centre between the three stations. This sales space also contains both the facility source and a Titan XQ. These are positioned behind the L-positioner on the giant 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 needed positions is also ensured due to the intense arm size of two metres and optimised house inside 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 simply 32 mm, entry is extremely troublesome. For manual welding, the welder is unable to see the weld seam and as a substitute should rely on their expertise. Even for automated welding, these areas are very uncommon. EWM was solely able to settle for 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 building with a very small torch head and unconventionally long torch neck. Of course, the particular application had to be adapted to accommodate this uncommon design: because dilution between the parent metallic and the armouring needs to be as little as potential, solely a little power is used. This ensures secure heat dissipation despite the intense welding torch dimensions.
Secure welding outcomes via outlined parameters
As the parts had been rotationally symmetrical, it was simple to show the parts; instructing is at all times based on the same programs. Even new elements could be welded routinely rapidly. Users merely need to set the radius, number of passes and the geometric dimensions of the surfaced parts and the robot management will deal with the remaining. The desired welding result is at all times assured as a outcome of the welding process is outlined with all of its parameters. The high quality may additionally be proven retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was initially designed and supposed for one specific application, Schroeder is already considering of latest ideas and makes use of. Schroeder wish to check out some of the various welding procedures which are included in the Titan XQ welding machine as normal. This will permit to additional optimise different sorts of surfaced elements. Schroeder are also looking to broaden and enhance the range of welding tasks.
There are tons of of Schroeder Valves installed in plants in southern Africa defending property at firms like Sasol, Eskom, Mondi and Sappi to name a quantity of. 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 sales@valve.co.za, www.valve.co.za or cellphone 011 397 2833 or 0861 103 103 to learn extra.
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