Automated surfacing of rotationally symmetrical components
Everything from a single supply – it‘s greater than just a advertising promise! Over 50 drawings of various elements served as the basis for the automation solution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one thing in widespread, they were all rotationally symmetrical. This was the starting point for welding machine manufacturer EWM of their mission to develop a custom automation answer 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 application embody refineries, power crops and nuclear plants, in the transport of liquefied natural fuel (LNG), as nicely as in offshore rigs. They are additionally used throughout the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one software.
The goal is to weld all pump protection valve parts routinely. These valves are connected directly to the pumps and guarantee steady operation of the pumps to forestall them working dry or being broken by cavitation throughout minimal flow situations. The pump safety valve is essentially made up of the valve physique and the cone, which moves inside the valve physique. The sealing surfaces between the valve physique and the cone must be completely air and watertight. This is the one means to make sure correct functioning of the pump safety valve for many years to come back. Normally, these elements are made using low-cost construction metal DIN 1.0460. The sealing surfaces are reinforced with stainless steel DIN 1.4370. This course of was beforehand performed manually, however, as a outcome of each the scarcity of excellent welders and growing high 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 elements 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 widespread: they were all rotationally symmetrical, making them perfect for an automatic course of. With this as a starting point, EWM was in a position to 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 match the bill when it came to automating this explicit course of. Having to deal with so many alternative half sizes was a cause for concern. เกจวัดแรงดันดิจิตอล require a big welding positioner. These, nevertheless, cannot provide the dynamics required for the smaller parts. This shortly gave rise to the idea of three processing stations: one giant L-positioner with tilting function 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 parts. The peak of the building was additionally a particular challenge. The components had to have the ability to be placed on the benches with the crane. The crane hook, nevertheless, was only approximately three metres excessive – extremely small for an industrial software. To assure accessibility whereas guaranteeing extraction, both the extraction hood or the system benches had been made to be mobile. The robotic was fitted in an extremely small sales space within the centre between the three stations. This sales space also contains each the facility source and a Titan XQ. These are positioned behind the L-positioner at the large 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 necessary positions is also ensured due to the intense arm length of two metres and optimised house inside the booths.
Special torch for excessive areas
Each valve physique is supplied with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extremely tough. For handbook welding, the welder is unable to see the weld seam and as a substitute should depend on their expertise. Even for automated welding, these spaces are very unusual. EWM was solely in a position to settle for this job because they manufacture the torches, emphasising the importance of the welding torch for this utility. The welding torch for Schroeder Valves is a special development with a particularly small torch head and unconventionally long torch neck. Of course, the particular utility needed to be adapted to accommodate this uncommon design: because dilution between the father or mother metallic and the armouring must be as low as potential, solely somewhat vitality is used. This ensures secure heat dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes through outlined parameters
As the elements were rotationally symmetrical, it was easy to show the parts; educating is at all times based on the same applications. Even new parts may be welded routinely quickly. Users simply need to set the radius, variety of passes and the geometric dimensions of the surfaced parts and the robotic management will take care of the remainder. The desired welding result’s always assured because the welding process is outlined with all of its parameters. The quality can also be proven retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and meant for one particular software, Schroeder is already considering of new ideas and uses. Schroeder wish to check out some of the varied welding procedures which might be included within the Titan XQ welding machine as normal. This will enable to further optimise different sorts of surfaced elements. Schroeder are also looking to expand and enhance the vary of welding tasks.
There are hundreds of Schroeder Valves put in in crops in southern Africa defending assets at corporations like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning services 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 study extra.
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