Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s greater than just a marketing promise! Over 50 drawings of various components served as the basis for the automation answer developed by EWM for pump safety 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 begin line for welding machine manufacturer EWM of their mission to develop a customized automation solution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move 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 plants, in the transport of liquefied pure fuel (LNG), in addition to in offshore rigs. They are additionally used throughout the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
เพรสเชอร์เกจคือ is to weld all pump protection valve components automatically. These valves are linked directly to the pumps and ensure continuous operation of the pumps to forestall them operating dry or being broken by cavitation during minimal move situations. The pump protection valve is largely made up of the valve body and the cone, which strikes contained in the valve physique. The sealing surfaces between the valve physique and the cone should 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 parts are made utilizing low-cost building steel DIN 1.0460. The sealing surfaces are reinforced with chrome steel DIN 1.4370. This course of was previously carried out manually, nonetheless, as a outcome of both the shortage of fine welders and rising high quality assurance requirements, automation of this step was crucial. The internal diameter of the valve bodies and the cone diameters were between 32 mm and four hundred mm. The elements being moved additionally differed vastly in weight, ranging from a few hundred grams to 2 and a half tonnes. But all of the elements had one thing in widespread: they have 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 turned clear that only a robot system would match the invoice when it got here to automating this particular process. Having to deal with so many different part sizes was a trigger for concern. Large parts require a big welding positioner. These, however, cannot present the dynamics required for the smaller parts. This quickly gave rise to the concept of three processing stations: one large L-positioner with tilting perform for the big 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 any other parts. The height of the building was additionally a particular challenge. The parts had to have the flexibility to be positioned on the benches with the crane. The crane hook, however, was only approximately three metres excessive – extraordinarily small for an industrial utility. To guarantee accessibility while ensuring extraction, either the extraction hood or the system benches have been made to be cell. The robotic was fitted in an especially small sales space within the centre between the three stations. This sales space additionally includes both the power 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 one hundred iD in all three stations at all essential positions can additionally be ensured thanks to the extreme arm length of two metres and optimised house contained in the cubicles.
Special torch for extreme spaces
Each valve body is equipped with a cone guide which is welded from above. With an inside diameter of simply 32 mm, entry is extraordinarily tough. For guide 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 uncommon. EWM was solely able to settle for this job as a end result of they manufacture the torches, emphasising the importance of the welding torch for this application. The welding torch for Schroeder Valves is a special building with a particularly small torch head and unconventionally lengthy torch neck. Of course, the particular utility needed to be tailored to accommodate this unusual design: because dilution between the mother or father metal and the armouring must be as low as attainable, only a little vitality is used. This ensures safe heat dissipation regardless of the extreme welding torch dimensions.
Secure welding results by way of defined parameters
As the components had been rotationally symmetrical, it was straightforward to teach the elements; educating is always primarily based on the same packages. Even new parts may be welded mechanically rapidly. Users merely 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 remaining. The desired welding result’s at all times guaranteed as a result of the welding process is defined with all of its parameters. The quality can additionally be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even though the system was originally designed and intended for one specific software, Schroeder is already thinking of new ideas and makes use of. Schroeder would like to check out some of the numerous welding procedures that are included within the Titan XQ welding machine as standard. This will allow to additional optimise completely different sorts of surfaced parts. Schroeder are also looking to increase and enhance the vary of welding tasks.
There are hundreds of Schroeder Valves put in in vegetation in southern Africa protecting assets at companies like Sasol, Eskom, Mondi and Sappi to call a number of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning services 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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