Automated surfacing of rotationally symmetrical components

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 resolution developed by EWM for pump safety 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 start line for welding machine producer EWM in their mission to develop a customized automation answer tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all round the world for transporting liquids utilizing centrifugal pumps. Their areas of software embrace refineries, power plants and nuclear crops, within the transport of liquefied pure fuel (LNG), in addition to in offshore rigs. They are additionally used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The aim is to weld all pump protection valve components mechanically. pressure gauge หลักการ ทํา งาน are linked directly to the pumps and ensure continuous operation of the pumps to forestall them operating dry or being broken by cavitation throughout minimal flow circumstances. The pump protection valve is largely made up of the valve body and the cone, which moves contained in the valve physique. The sealing surfaces between the valve physique and the cone have to be absolutely air and watertight. This is the one way to make sure correct functioning of the pump safety valve for many years to come. Normally, these components are made using low-cost construction steel DIN 1.0460. The sealing surfaces are bolstered with stainless-steel DIN 1.4370. This process was beforehand carried out manually, nonetheless, because of both the scarcity of good welders and rising quality assurance necessities, automation of this step was crucial. The internal diameter of the valve bodies and the cone diameters had been between 32 mm and 400 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 frequent: they were all rotationally symmetrical, making them perfect for an automated process. With this as a beginning point, EWM was in a place to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations

It soon turned clear that solely a robotic system would fit the invoice when it came to automating this particular process. Having to take care of so many different part sizes was a cause for concern. Large components require a large welding positioner. These, however, cannot present the dynamics required for the smaller parts. This quickly gave rise to the idea of three processing stations: one large L-positioner with tilting operate for the big valve bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a 3rd station with a system bench without positioners for another elements. The height of the building was also a selected problem. The parts had to be able to be placed on the benches with the crane. The crane hook, nonetheless, was only approximately three metres high – extraordinarily small for an industrial utility. To assure accessibility whereas guaranteeing extraction, either the extraction hood or the system benches were made to be mobile. The robot was fitted in an especially small booth in the centre between the three stations. This booth also consists of both the facility 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 safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations at all needed positions can also be ensured thanks to the acute arm size of two metres and optimised house inside the cubicles.
Special torch for excessive areas

Each valve body is supplied with a cone information which is welded from above. With an inside diameter of simply 32 mm, access is extraordinarily troublesome. For guide welding, the welder is unable to see the weld seam and as a substitute should rely on their expertise. Even for automated welding, these spaces are very unusual. EWM was solely able to settle for this job because they manufacture the torches, emphasising the significance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular construction with a very small torch head and unconventionally long torch neck. Of course, the special software needed to be adapted to accommodate this uncommon design: as a result of dilution between the mother or father metal and the armouring needs to be as low as potential, solely a little power is used. This ensures protected heat dissipation despite the extreme welding torch dimensions.
Secure welding results via outlined parameters

As the parts had been rotationally symmetrical, it was straightforward to teach the parts; instructing is always based on the identical programs. Even new components can be welded mechanically shortly. Users merely need to set the radius, variety of passes and the geometric dimensions of the surfaced elements and the robot management will care for the remaining. The desired welding result’s at all times guaranteed as a end result of the welding procedure is defined with all of its parameters. The high quality may also be proven retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was initially designed and meant for one specific utility, Schroeder is already thinking of new ideas and makes use of. Schroeder want to try out a variety of the varied welding procedures which may be included within the Titan XQ welding machine as standard. This will permit to further optimise totally different kinds of surfaced elements. Schroeder are additionally seeking to expand and improve the vary of welding duties.
There are hundreds of Schroeder Valves put in in plants in southern Africa protecting assets at corporations like Sasol, Eskom, Mondi and Sappi to call a quantity of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning facilities 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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