Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s greater than just a advertising promise! Over 50 drawings of assorted elements served as the premise for the automation answer developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s components did have one thing in widespread, they were all rotationally symmetrical. This was the start line for welding machine producer EWM of their mission to develop a customized automation answer tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used all around the world for transporting liquids utilizing centrifugal pumps. Their areas of software embrace refineries, power crops and nuclear crops, within the transport of liquefied pure gasoline (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one application.
The aim is to weld all pump safety valve elements routinely. These valves are connected on to the pumps and guarantee steady operation of the pumps to prevent them working dry or being broken by cavitation throughout minimum move circumstances. The pump safety valve is largely made up of the valve body and the cone, which moves contained in 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 ensure proper functioning of the pump protection valve for many years to come. Normally, these components are made using low-cost building steel DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This course of was beforehand carried out manually, nonetheless, as a outcome of both the scarcity of excellent welders and growing high quality assurance requirements, automation of this step was essential. The inside diameter of the valve our bodies and the cone diameters have been between 32 mm and 400 mm. The parts being moved also differed vastly in weight, ranging from a number of hundred grams to two and a half tonnes. But all of the components had one factor in widespread: they have been all rotationally symmetrical, making them excellent for an automated 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 soon turned clear that only a robotic system would fit the bill when it got here to automating this particular process. Having to take care of so many various part sizes was a trigger for concern. Large elements require a large welding positioner. These, nevertheless, 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 operate for the large 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 without positioners for another elements. The top of the building was also a specific problem. The parts had to be able to be positioned on the benches with the crane. The crane hook, nevertheless, was solely roughly three metres excessive – extremely small for an industrial application. To guarantee accessibility while ensuring extraction, either the extraction hood or the system benches have been made to be cell. The robot was fitted in an especially small booth in the centre between the three stations. This sales space additionally includes both the power source 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 robotic arm ensures secure wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations at all necessary positions can also be ensured due to the acute arm length of two metres and optimised house contained in the cubicles.
Special torch for extreme areas
Each valve body is provided with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily difficult. For guide welding, the welder is unable to see the weld seam and as a substitute should rely on their experience. Even for automated welding, these spaces are very unusual. EWM was only in a place to accept this job because they manufacture the torches, emphasising the importance of the welding torch for this application. The welding torch for Schroeder Valves is a special development with a very small torch head and unconventionally long torch neck. Of course, the special application needed to be adapted to accommodate this unusual design: because dilution between the mother or father metal and the armouring needs to be as little as possible, solely slightly power is used. This ensures secure heat dissipation despite the extreme welding torch dimensions.
Hilarious welding results through defined parameters
As the elements were rotationally symmetrical, it was simple to teach the parts; educating is at all times primarily based on the identical packages. Even new elements may be welded automatically quickly. Users simply have to set the radius, number of passes and the geometric dimensions of the surfaced components and the robotic control will take care of the remainder. The desired welding result is all the time guaranteed as a end result of the welding procedure is outlined with all of its parameters. The high quality can additionally be proven retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was initially designed and supposed for one particular application, Schroeder is already thinking of recent ideas and uses. Schroeder want to try out a variety of the numerous welding procedures that are included within the Titan XQ welding machine as normal. This will permit to additional optimise different kinds of surfaced components. Schroeder are also trying to expand and enhance the range of welding duties.
There are tons of of Schroeder Valves put in in vegetation in southern Africa defending assets at firms like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning amenities are available 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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