Automated surfacing of rotationally symmetrical elements
Everything from a single source – it‘s greater than just a advertising promise! Over 50 drawings of varied components served as the premise for the automation resolution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one factor in common, they had been all rotationally symmetrical. This was the starting point for welding machine producer EWM in their mission to develop a customized automation resolution tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all over the world for transporting liquids utilizing centrifugal pumps. Their areas of software embody refineries, power crops and nuclear crops, in the transport of liquefied pure gasoline (LNG), as well as in offshore rigs. เกจวัดแรงดันดิจิตอล are additionally used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one application.
The purpose is to weld all pump safety valve components mechanically. These valves are connected on to the pumps and guarantee steady operation of the pumps to forestall them operating dry or being broken by cavitation during minimal move conditions. The pump safety valve is basically made up of the valve body and the cone, which moves contained in the valve body. The sealing surfaces between the valve physique and the cone must be absolutely air and watertight. This is the one way to ensure correct functioning of the pump safety valve for many years to come. Normally, these parts are made using low-cost construction metal DIN 1.0460. The sealing surfaces are strengthened with stainless steel DIN 1.4370. This process was previously performed manually, nonetheless, due to each the scarcity of excellent welders and rising high quality assurance requirements, automation of this step was essential. The inner diameter of the valve our 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 the parts had one thing in frequent: they have been all rotationally symmetrical, making them perfect for an automatic course of. With this as a beginning 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 robotic system would fit the invoice when it came to automating this specific course of. Having to deal with so many different part sizes was a cause for concern. Large components require a large welding positioner. These, nonetheless, can’t provide 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 big valve bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a third station with a system bench with out positioners for another components. The top of the building was additionally a specific challenge. The components had to be able to be placed on the benches with the crane. The crane hook, nonetheless, was only roughly three metres high – extraordinarily small for an industrial software. To assure accessibility while ensuring 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 sales space additionally consists of each the ability 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 robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations at all essential positions can also be ensured because of the intense arm size of two metres and optimised house inside the cubicles.
Special torch for excessive areas
Each valve physique is supplied with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily tough. For handbook welding, the welder is unable to see the weld seam and instead should depend on their expertise. Even for automated welding, these spaces are very uncommon. EWM was only in a position 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 development with a particularly small torch head and unconventionally long torch neck. Of course, the special software had to be tailored to accommodate this unusual design: as a result of dilution between the father or mother steel and the armouring must be as low as possible, solely slightly energy is used. This ensures protected warmth dissipation regardless of the intense welding torch dimensions.
Secure welding outcomes through defined parameters
As the parts had been rotationally symmetrical, it was straightforward to teach the components; teaching is all the time based on the identical packages. Even new components could be welded automatically shortly. Users merely need to set the radius, number of passes and the geometric dimensions of the surfaced components and the robotic control will deal with the remaining. The desired welding result is always assured as a outcome of the welding procedure is defined with all of its parameters. The quality can additionally be proven retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was initially designed and intended for one particular software, Schroeder is already considering of latest ideas and makes use of. Schroeder would like to check out a few of the numerous welding procedures that are included within the Titan XQ welding machine as commonplace. This will enable to further optimise completely different sorts of surfaced elements. Schroeder are additionally seeking to broaden and improve the range of welding duties.
There are lots of of Schroeder Valves put in in crops in southern Africa defending property at corporations like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning services can be found 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 extra.
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