Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s more than only a marketing promise! Over 50 drawings of varied components served as the basis for the automation resolution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one factor in frequent, they have been all rotationally symmetrical. This was the starting point for welding machine producer EWM in 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 all over the world for transporting liquids using centrifugal pumps. Their areas of utility include refineries, power vegetation and nuclear plants, within the transport of liquefied natural gasoline (LNG), in addition to in offshore rigs. They are additionally used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in 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 running dry or being broken by cavitation throughout minimal move situations. The pump safety valve is essentially made up of the valve physique and the cone, which moves contained in the valve physique. The sealing surfaces between the valve physique and the cone have to be completely air and watertight. This is the one means to ensure 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 strengthened with stainless steel DIN 1.4370. This process was previously carried out manually, nevertheless, because of both the shortage of good welders and growing high quality assurance requirements, automation of this step was crucial. The internal diameter of the valve our bodies and the cone diameters were between 32 mm and four hundred mm. The elements being moved also differed vastly in weight, ranging from a quantity of hundred grams to two and a half tonnes. But all the elements had one thing in frequent: they had been all rotationally symmetrical, making them perfect for an automated process. With this as a place to begin, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon became clear that solely a robot system would fit the invoice when it came to automating this particular process. Having to take care of so many different half sizes was a trigger for concern. Large elements require a large welding positioner. These, however, cannot present the dynamics required for the smaller components. This rapidly gave rise to the idea of three processing stations: one giant L-positioner with tilting operate for the massive 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 with out positioners for another parts. The peak of the constructing was also a selected problem. The components had to find a way to be positioned on the benches with the crane. Censored , nevertheless, was solely approximately three metres excessive – extraordinarily small for an industrial utility. To assure accessibility while making certain extraction, both the extraction hood or the system benches have been made to be cellular. The robotic was fitted in an especially small sales space within the centre between the three stations. This booth additionally includes both the power source and a Titan XQ. These are positioned behind the L-positioner on the massive 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 necessary positions is also ensured thanks to the acute arm size of two metres and optimised house contained in the booths.
Special torch for excessive areas
Each valve physique is provided with a cone information which is welded from above. With an inside diameter of just 32 mm, access is extraordinarily difficult. For guide welding, the welder is unable to see the weld seam and as an alternative should depend on their experience. Even for automated welding, these spaces are very uncommon. EWM was only capable of accept this job as a end result of they manufacture the torches, emphasising the significance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular building with a very small torch head and unconventionally long torch neck. Of course, the particular software had to be tailored to accommodate this uncommon design: as a outcome of dilution between the mother or father steel and the armouring must be as little as possible, only a little energy is used. This ensures secure heat dissipation despite the intense welding torch dimensions.
Secure welding outcomes via outlined parameters
As the elements had been rotationally symmetrical, it was straightforward to show the components; instructing is always primarily based on the same programs. Even new parts can be welded mechanically rapidly. Users merely have to set the radius, number of passes and the geometric dimensions of the surfaced parts and the robotic control will care for the remainder. The desired welding result’s at all times assured as a 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 although the system was originally designed and meant for one specific software, Schroeder is already considering of recent concepts and uses. Schroeder want to try out a number of the numerous welding procedures which would possibly be included within the Titan XQ welding machine as normal. This will allow to further optimise different kinds of surfaced parts. Schroeder are also seeking to increase and enhance the range of welding tasks.
There are tons of of Schroeder Valves installed in crops in southern Africa defending assets at firms like Sasol, Eskom, Mondi and Sappi to call 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, or telephone 011 397 2833 or 0861 103 103 to study more.
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