Automated surfacing of rotationally symmetrical elements
Everything from a single source – it‘s greater than just a advertising promise! Over 50 drawings of assorted elements served as the idea for the automation resolution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s components did have one thing in frequent, they have been all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM of their mission to develop a custom automation resolution tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of application embody refineries, energy crops and nuclear crops, in the transport of liquefied natural gas (LNG), as well as in offshore rigs. They are additionally used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one application.
The purpose is to weld all pump safety valve components mechanically. These valves are linked on to the pumps and ensure steady operation of the pumps to forestall them working dry or being damaged by cavitation throughout minimal move situations. The pump safety valve is largely made up of the valve physique and the cone, which strikes inside the valve body. The sealing surfaces between the valve body and the cone should be completely air and watertight. This is the only means to make sure correct functioning of the pump protection valve for many years to return. Normally, these parts are made using low-cost building steel DIN 1.0460. The sealing surfaces are strengthened with stainless-steel DIN 1.4370. This process was beforehand performed manually, nonetheless, due to both the scarcity of good welders and rising high quality assurance requirements, automation of this step was essential. The inside diameter of the valve our bodies and the cone diameters were between 32 mm and 400 mm. The components being moved additionally differed vastly in weight, starting from a number of hundred grams to 2 and a half tonnes. But all the components had one thing in widespread: they were all rotationally symmetrical, making them excellent 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 soon grew to become clear that solely a robotic system would match the invoice when it got here to automating this explicit course of. Having to deal with so many alternative part sizes was a trigger for concern. Large components require a big welding positioner. These, however, can not present the dynamics required for the smaller parts. This rapidly gave rise to the thought of three processing stations: one giant L-positioner with tilting perform 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 with out positioners for some other components. เพรสเชอร์เกจน้ำ of the building was also a selected problem. The elements had to be able to be positioned on the benches with the crane. The crane hook, nonetheless, was only approximately three metres high – extraordinarily small for an industrial software. To guarantee accessibility while guaranteeing extraction, either the extraction hood or the system benches had been made to be cellular. The robotic was fitted in a particularly small booth in the centre between the three stations. This booth additionally contains both the facility source and a Titan XQ. These are positioned behind the L-positioner on the large processing station. The Rob 5 drive 4X wire feeder mounted on the robotic arm ensures secure wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations in any respect necessary positions can also be ensured because of the intense arm size of two metres and optimised space contained in the booths.
Special torch for extreme areas
Each valve body is provided with a cone guide which is welded from above. With an inside diameter of simply 32 mm, entry is extremely tough. For manual welding, the welder is unable to see the weld seam and instead must rely on their expertise. Even for automated welding, these areas are very unusual. เกจแรงดันสูง was solely in a place to accept this job as a result of they manufacture the torches, emphasising the importance of the welding torch for this application. The welding torch for Schroeder Valves is a special development with a particularly small torch head and unconventionally long torch neck. Of course, the special utility had to be tailored to accommodate this uncommon design: as a result of dilution between the mother or father metal and the armouring must be as little as attainable, solely somewhat energy is used. This ensures secure warmth dissipation despite the intense welding torch dimensions.
Secure welding outcomes by way of outlined parameters
As the components had been rotationally symmetrical, it was easy to show the components; instructing is at all times primarily based on the same packages. Even new parts may be welded routinely shortly. Users merely should set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot management will deal with the rest. The desired welding result’s always assured as a end result of the welding procedure is outlined with all of its parameters. The quality may additionally be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and intended for one specific software, Schroeder is already thinking of recent concepts and uses. Schroeder want to check out a few of the various welding procedures that are included within the Titan XQ welding machine as standard. This will enable to further optimise completely different kinds of surfaced parts. Schroeder are also seeking to increase and improve the vary of welding duties.
There are lots of of Schroeder Valves put in in crops in southern Africa defending belongings at companies like Sasol, Eskom, Mondi and Sappi to call a couple 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 phone 011 397 2833 or 0861 103 103 to be taught more.
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