Automated surfacing of rotationally symmetrical elements

Everything from a single supply – it‘s more than only a advertising promise! Over 50 drawings of varied parts served as the basis for the automation answer developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one thing in frequent, they were all rotationally symmetrical. ราคาเกจวัดแรงดัน was the begin line for welding machine manufacturer EWM of their mission to develop a custom automation answer tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of utility include refineries, power plants and nuclear vegetation, within the transport of liquefied natural gas (LNG), in addition to in offshore rigs. They 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 purpose is to weld all pump safety valve components mechanically. These valves are linked directly to the pumps and ensure steady operation of the pumps to prevent them operating dry or being broken by cavitation throughout minimal circulate conditions. The pump protection valve is largely made up of the valve physique and the cone, which moves contained in the valve body. The sealing surfaces between the valve body and the cone have to be absolutely air and watertight. This is the only method to ensure correct functioning of the pump safety valve for many years to come back. Normally, these parts are made utilizing low-cost construction metal DIN 1.0460. The sealing surfaces are reinforced with chrome steel DIN 1.4370. This course of was previously performed manually, nonetheless, due to each the shortage of fine welders and growing high quality assurance necessities, automation of this step was essential. The internal diameter of the valve our bodies and the cone diameters had been between 32 mm and four hundred mm. The parts being moved additionally differed vastly in weight, starting from a few hundred grams to two and a half tonnes. But all the components had one thing in frequent: they had been all rotationally symmetrical, making them excellent for an automatic 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 solely a robotic system would match the bill when it got here to automating this particular process. Having to cope with so many different part sizes was a trigger for concern. Large parts require a large welding positioner. These, nevertheless, cannot present the dynamics required for the smaller components. This shortly gave rise to the concept of three processing stations: one giant L-positioner with tilting operate for the large valve our 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 components. The height of the constructing was additionally a specific challenge. The elements had to be able to be positioned on the benches with the crane. The crane hook, nevertheless, was only roughly three metres excessive – extremely small for an industrial application. To assure accessibility while guaranteeing extraction, either the extraction hood or the system benches were made to be cellular. The robot was fitted in an extremely small sales space within the centre between the three stations. This sales space additionally consists of each the ability 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 safe wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations at all needed positions can be ensured due to the extreme arm length of two metres and optimised area inside the cubicles.
Special torch for extreme spaces

Each valve physique is provided with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extremely tough. For manual welding, the welder is unable to see the weld seam and as a substitute should depend on their experience. Even for automated welding, these spaces are very uncommon. EWM was only able to settle for this job as a result of they manufacture the torches, emphasising the significance of the welding torch for this software. 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 application had to be tailored to accommodate this unusual design: as a end result of dilution between the father or mother steel and the armouring needs to be as little as attainable, only a little power is used. This ensures secure warmth dissipation regardless of the intense welding torch dimensions.
Secure welding outcomes via outlined parameters

As the parts have been rotationally symmetrical, it was easy to teach the components; teaching is always based mostly on the same applications. Even new elements can be welded automatically rapidly. Users merely have to set the radius, number of passes and the geometric dimensions of the surfaced components and the robotic management will care for the remaining. The desired welding result’s all the time guaranteed as a end result of the welding procedure is defined with all of its parameters. The quality can additionally be confirmed retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was initially designed and meant for one specific software, Schroeder is already pondering of recent ideas and uses. Schroeder wish to try out a variety of the various welding procedures which are included within the Titan XQ welding machine as normal. This will permit to additional optimise totally different kinds of surfaced elements. Schroeder are additionally seeking to broaden and improve the range of welding tasks.
There are hundreds of Schroeder Valves installed in plants in southern Africa protecting assets 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 phone 011 397 2833 or 0861 103 103 to learn more.
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