Automated surfacing of rotationally symmetrical components
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of varied parts served as the premise for the automation resolution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one factor in common, they were all rotationally symmetrical. This was the begin line for welding machine manufacturer 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 all round the world for transporting liquids utilizing centrifugal pumps. Their areas of software embrace refineries, energy plants and nuclear plants, in the transport of liquefied pure gasoline (LNG), as properly as in offshore rigs. เกจวัดแรงดันถังลม are also used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The goal is to weld all pump safety valve parts mechanically. These valves are related on to the pumps and guarantee continuous operation of the pumps to prevent them operating dry or being damaged by cavitation during minimum flow conditions. The pump protection valve is largely made up of the valve physique and the cone, which strikes contained in the valve body. The sealing surfaces between the valve body and the cone should be absolutely air and watertight. This is the only method to make sure proper functioning of the pump safety valve for many years to return. Normally, these elements are made using low-cost development steel DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This course of was beforehand performed manually, however, due to each the shortage of excellent welders and rising high quality assurance necessities, automation of this step was crucial. The inner diameter of the valve bodies and the cone diameters have been between 32 mm and four hundred mm. The parts being moved additionally differed vastly in weight, ranging from a quantity of hundred grams to two and a half tonnes. But all of the parts had one thing in widespread: they had been all rotationally symmetrical, making them excellent for an automated process. With this as a starting point, EWM was capable of get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly grew to become clear that only a robot system would match the invoice when it got here to automating this specific course of. Having to cope with so many various part sizes was a cause for concern. Large elements require a big welding positioner. These, nonetheless, cannot present the dynamics required for the smaller components. This rapidly gave rise to the concept of three processing stations: one large L-positioner with tilting perform for the massive valve our bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a 3rd station with a system bench without positioners for another components. The peak of the constructing was also a particular challenge. The elements had to have the ability to be placed on the benches with the crane. The crane hook, nonetheless, was only roughly three metres excessive – extremely small for an industrial software. To guarantee accessibility whereas guaranteeing extraction, both the extraction hood or the system benches had been made to be cell. The robotic was fitted in an extremely small sales space within the centre between the three stations. This booth also contains each the power source 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 a hundred iD in all three stations at all necessary positions can be ensured because of the intense arm size of two metres and optimised area inside the cubicles.
Special torch for extreme areas
Each valve physique is provided 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 experience. Even for automated welding, these spaces are very unusual. EWM was only able to accept this job as a end result of they manufacture the torches, emphasising the significance of the welding torch for this application. The welding torch for Schroeder Valves is a particular development with a very small torch head and unconventionally lengthy torch neck. Of course, the particular utility had to be tailored to accommodate this uncommon design: because dilution between the mother or father steel and the armouring needs to be as little as potential, only somewhat power is used. This ensures secure warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding results by way of outlined parameters
As the elements had been rotationally symmetrical, it was easy to teach the elements; instructing is at all times primarily based on the same programs. Even new parts can be welded routinely shortly. Users merely need to set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot management will care for the rest. The desired welding result’s all the time assured as a result of the welding process is defined with all of its parameters. The high quality can additionally be proven retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was initially designed and supposed for one specific software, Schroeder is already pondering of recent concepts and makes use of. Schroeder want to try out some of the varied welding procedures which might be included in the Titan XQ welding machine as commonplace. This will permit to additional optimise completely different sorts of surfaced components. Schroeder are additionally seeking to broaden and enhance the vary of welding tasks.
There are lots of of Schroeder Valves put in in vegetation in southern Africa protecting belongings at corporations like Sasol, Eskom, Mondi and Sappi to name a couple of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning amenities can be found 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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