Automated surfacing of rotationally symmetrical components
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of various parts served as the idea for the automation resolution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one factor in frequent, they have been all rotationally symmetrical. This was the start line for welding machine manufacturer EWM of their mission to develop a custom automation answer tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all over the world for transporting liquids utilizing centrifugal pumps. เกจวัดแรงดันสูญญากาศ of software embrace refineries, energy plants and nuclear crops, in the transport of liquefied natural gas (LNG), as properly as in offshore rigs. They are also used throughout the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one software.
The purpose is to weld all pump protection valve components routinely. These valves are linked on to the pumps and ensure steady operation of the pumps to prevent them operating dry or being broken by cavitation during minimum circulate situations. The pump protection valve is essentially made up of the valve physique and the cone, which strikes inside the valve body. The sealing surfaces between the valve physique and the cone must be absolutely air and watertight. This is the one means to ensure proper functioning of the pump protection valve for decades to come back. Normally, these components are made utilizing low-cost building steel DIN 1.0460. The sealing surfaces are strengthened with stainless-steel DIN 1.4370. This course of was previously performed manually, however, as a end result of both the shortage of excellent welders and rising quality assurance requirements, automation of this step was crucial. The internal diameter of the valve our bodies and the cone diameters had been between 32 mm and 400 mm. The parts being moved also differed vastly in weight, ranging from a number of hundred grams to two and a half tonnes. But all of the elements had one factor in common: they were all rotationally symmetrical, making them excellent for an automated process. With this as a starting 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 robot system would match the bill when it got here to automating this particular course of. Having to take care of so many alternative part sizes was a trigger for concern. Large elements require a big welding positioner. These, however, cannot present the dynamics required for the smaller elements. This shortly gave rise to the concept of three processing stations: one giant L-positioner with tilting function for the big valve 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 height of the building was additionally a selected problem. The elements had to have the ability to be positioned on the benches with the crane. The crane hook, nevertheless, was only approximately three metres high – extraordinarily small for an industrial software. To assure accessibility whereas ensuring extraction, both the extraction hood or the system benches have been made to be cellular. The robot was fitted in a particularly small sales space within the centre between the three stations. This sales space also contains both the ability supply and a Titan XQ. These are positioned behind the L-positioner on the giant 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 necessary positions can also be ensured thanks to the intense arm size of two metres and optimised space inside the booths.
Special torch for extreme spaces
Each valve physique is supplied with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extraordinarily tough. For manual welding, the welder is unable to see the weld seam and as a substitute must depend on their expertise. Even for automated welding, these spaces are very unusual. EWM was solely capable of settle for this job as a outcome of they manufacture the torches, emphasising the importance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular construction with a particularly small torch head and unconventionally long torch neck. Of course, the special software had to be adapted to accommodate this uncommon design: as a end result of dilution between the father or mother steel and the armouring must be as low as potential, solely slightly energy is used. This ensures safe warmth dissipation regardless of the acute welding torch dimensions.
Secure welding outcomes by way of outlined parameters
As the elements have been rotationally symmetrical, it was easy to teach the components; teaching is at all times based mostly on the same packages. Even new elements may be welded mechanically quickly. Users simply have to set the radius, variety of passes and the geometric dimensions of the surfaced parts and the robot management will deal with the remaining. The desired welding result is always guaranteed as a outcome of the welding procedure is defined with all of its parameters. The high quality can be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was initially designed and meant for one particular application, Schroeder is already thinking of recent ideas and uses. Schroeder want to try out a few of the various welding procedures which may be included within the Titan XQ welding machine as commonplace. This will enable to further optimise totally different kinds of surfaced parts. Schroeder are also looking to broaden and improve the vary of welding tasks.
There are lots of of Schroeder Valves put in in plants in southern Africa protecting assets at firms like Sasol, Eskom, Mondi and Sappi to call a quantity of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore and reconditioning amenities 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 be taught more.
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