Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of varied parts served as the basis for the automation resolution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one thing in common, they had been all rotationally symmetrical. This was the place to begin for welding machine producer EWM in their mission to develop a custom automation solution tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used everywhere in the world for transporting liquids utilizing centrifugal pumps. Their areas of utility embody refineries, power vegetation and nuclear vegetation, within the transport of liquefied natural fuel (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The aim is to weld all pump protection valve parts automatically. These valves are linked directly to the pumps and guarantee steady operation of the pumps to prevent them working dry or being broken by cavitation throughout minimum flow circumstances. The pump safety valve is essentially made up of the valve physique and the cone, which strikes contained in the valve body. The sealing surfaces between the valve physique and the cone must be completely air and watertight. This is the only method to ensure proper functioning of the pump safety valve for decades to come. Normally, these elements are made utilizing low-cost construction metal DIN 1.0460. The sealing surfaces are bolstered with stainless-steel DIN 1.4370. This process was previously performed manually, nevertheless, because of both the shortage of fine welders and rising quality assurance necessities, automation of this step was crucial. The inner diameter of the valve our bodies and the cone diameters were between 32 mm and four hundred mm. The components being moved additionally differed vastly in weight, starting from a number of hundred grams to two and a half tonnes. But all of the elements had one thing in common: they have been all rotationally symmetrical, making them good for an automated course of. With this as a place to begin, EWM was capable of 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 bill when it got here to automating this explicit process. Having to cope with so many different half sizes was a trigger for concern. Large parts require a big welding positioner. These, nonetheless, can not provide the dynamics required for the smaller components. This quickly gave rise to the thought of three processing stations: one giant L-positioner with tilting perform for the massive valve bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a 3rd station with a system bench with out positioners for another parts. The peak of the constructing was additionally a selected problem. The parts had to find a way to be positioned on the benches with the crane. เกจวัดแรงดันลมราคา , nevertheless, was solely approximately three metres excessive – extraordinarily small for an industrial application. To assure accessibility whereas ensuring extraction, either the extraction hood or the system benches have been made to be cellular. The robotic was fitted in an extremely small booth within the centre between the three stations. This sales space additionally consists of each the facility supply 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 robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations at all essential positions can be ensured thanks to the extreme arm size of two metres and optimised area 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 just 32 mm, access is extraordinarily troublesome. For guide welding, the welder is unable to see the weld seam and instead should rely on their expertise. Even for automated welding, these spaces are very unusual. EWM was solely able to accept 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 particular construction with a particularly small torch head and unconventionally lengthy torch neck. Of course, the particular software needed to be tailored to accommodate this uncommon design: as a result of dilution between the father or mother metal and the armouring must be as low as possible, solely a little vitality is used. This ensures secure heat dissipation despite the extreme welding torch dimensions.
Secure welding outcomes via defined parameters
As the elements have been rotationally symmetrical, it was simple to teach the elements; instructing is all the time primarily based on the identical programs. Even new elements may be welded automatically quickly. Users simply have to set the radius, variety of passes and the geometric dimensions of the surfaced elements and the robot management will deal with the remainder. The desired welding result’s all the time assured because the welding procedure is defined with all of its parameters. The high quality can be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even though the system was originally designed and intended for one particular software, Schroeder is already considering of recent ideas and makes use of. Schroeder want to check out a variety of the numerous welding procedures which might be included in the Titan XQ welding machine as standard. This will enable to further optimise different sorts of surfaced parts. Schroeder are additionally looking to broaden and enhance the vary of welding tasks.
There are tons of of Schroeder Valves put in in vegetation in southern Africa protecting assets at firms like Sasol, Eskom, Mondi and Sappi to call a few. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning amenities are available 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 study more.
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