Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s more than just a advertising promise! Over 50 drawings of various parts served as the idea for the automation answer developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one factor in common, they had been all rotationally symmetrical. This was the starting point for welding machine manufacturer EWM of their mission to develop a customized automation answer tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all around the world for transporting liquids utilizing centrifugal pumps. Their areas of utility include refineries, energy crops and nuclear vegetation, in the transport of liquefied pure 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 application.
The purpose is to weld all pump protection valve components routinely. These valves are connected on to the pumps and guarantee steady operation of the pumps to prevent them operating dry or being broken by cavitation throughout minimal circulate circumstances. The pump protection valve is basically made up of the valve body and the cone, which strikes inside the valve body. The sealing surfaces between the valve physique and the cone must be absolutely air and watertight. This is the one method to make sure correct functioning of the pump protection valve for many years to return. Normally, these components are made using low-cost building steel DIN 1.0460. The sealing surfaces are reinforced with stainless steel DIN 1.4370. This course of was beforehand carried out manually, however, due to each the shortage of excellent welders and rising quality assurance necessities, automation of this step was essential. The inner diameter of the valve bodies and the cone diameters had been between 32 mm and four hundred mm. The parts being moved also differed vastly in weight, starting from a few hundred grams to two and a half tonnes. But all the components had one factor in common: they had been all rotationally symmetrical, making them perfect for an automated process. With this as a beginning point, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon grew to become clear that solely a robotic system would fit the bill when it came to automating this specific process. Having to cope with so many different half sizes was a cause for concern. Large components require a large welding positioner. These, however, can not present the dynamics required for the smaller elements. This shortly gave rise to the thought of three processing stations: one large L-positioner with tilting function for the big valve bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a third station with a system bench without positioners for any other parts. The top of the building was additionally a particular challenge. The elements had to have the power to be placed on the benches with the crane. The crane hook, nevertheless, was only roughly three metres high – extraordinarily small for an industrial application. To guarantee accessibility whereas ensuring extraction, either the extraction hood or the system benches were made to be cellular. The robotic was fitted in an especially small sales space in the centre between the three stations. เกจวัดแรงดันpressuregauge contains each the ability 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 secure wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations at all essential positions can additionally be ensured due to the intense arm size of two metres and optimised space contained in the booths.
Special torch for extreme spaces
Each valve body is equipped with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily troublesome. For handbook welding, the welder is unable to see the weld seam and instead should depend on their expertise. Even for automated welding, these areas are very uncommon. EWM was solely capable of settle for this job as a end result of they manufacture the torches, emphasising the significance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular development with a particularly small torch head and unconventionally lengthy torch neck. Of course, the particular utility had to be tailored to accommodate this uncommon design: as a result of dilution between the father or mother metallic and the armouring must be as low as attainable, solely somewhat vitality is used. This ensures secure warmth dissipation regardless of the acute welding torch dimensions.
Secure welding outcomes by way of outlined parameters
As the elements were rotationally symmetrical, it was easy to show the elements; educating is all the time based on the identical packages. Even new elements may be welded routinely shortly. Users merely have to set the radius, number of passes and the geometric dimensions of the surfaced components and the robotic control will care for the remainder. The desired welding result’s all the time guaranteed as a end result of the welding process is outlined with all of its parameters. The high quality may also be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even though the system was originally designed and meant for one particular software, Schroeder is already thinking of new ideas and makes use of. Schroeder want to check out a few of the various welding procedures which would possibly be included within the Titan XQ welding machine as commonplace. This will allow to additional optimise totally different sorts of surfaced elements. Schroeder are also looking to broaden and improve the vary of welding duties.
There are lots of of Schroeder Valves installed in plants in southern Africa protecting assets at firms like Sasol, Eskom, Mondi and Sappi to name a couple of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning facilities can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or phone 011 397 2833 or 0861 103 103 to study extra.
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