Automated surfacing of rotationally symmetrical elements
Everything from a single source – it‘s greater than just a marketing promise! Over 50 drawings of varied components served as the idea for the automation answer developed by EWM for pump safety valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s components did have one thing in widespread, they had been all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM in their mission to develop a customized automation resolution tailored 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 software embrace refineries, power vegetation and nuclear plants, in the transport of liquefied pure gasoline (LNG), as well as in offshore rigs. They are additionally used all through the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one application.
The purpose is to weld all pump safety valve elements automatically. These valves are linked directly to the pumps and ensure continuous operation of the pumps to prevent them working dry or being damaged by cavitation throughout minimum circulate conditions. 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 have to be absolutely air and watertight. This is the only way to make sure proper functioning of the pump protection valve for many years to return. Normally, these elements are made utilizing low-cost development metal DIN 1.0460. The sealing surfaces are strengthened with stainless steel DIN 1.4370. This process was beforehand carried out manually, however, due to both the shortage of fine welders and growing high quality assurance necessities, automation of this step was essential. The inner diameter of the valve bodies and the cone diameters were between 32 mm and four hundred mm. เกจวัดแรงดันลม being moved also differed vastly in weight, starting from a few hundred grams to 2 and a half tonnes. But all of the elements had one thing in widespread: they had been all rotationally symmetrical, making them good for an automatic course of. With this as a place to begin, EWM was in a place to 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 invoice when it came to automating this particular process. Having to take care of so many various half sizes was a trigger for concern. Large parts require a big welding positioner. These, however, can not provide 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 big valve our 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 some other parts. The peak of the building was additionally a selected challenge. The elements had to have the flexibility to be placed on the benches with the crane. The crane hook, nevertheless, was only approximately three metres excessive – extraordinarily small for an industrial software. To ส่วนประกอบpressuregauge whereas guaranteeing extraction, both the extraction hood or the system benches were made to be cell. The robotic was fitted in an extremely small booth within the centre between the three stations. This sales space also includes 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 secure wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations in any respect needed positions is also ensured because of the extreme arm size of two metres and optimised house inside the booths.
Special torch for excessive areas
Each valve physique is equipped with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extremely troublesome. For handbook welding, the welder is unable to see the weld seam and as a substitute must rely on their expertise. Even for automated welding, these areas are very uncommon. EWM was only able to settle for this job because they manufacture the torches, emphasising the significance of the welding torch for this software. The welding torch for Schroeder Valves is a special construction with a particularly small torch head and unconventionally long torch neck. Of course, the special software had to be tailored to accommodate this uncommon design: because dilution between the father or mother steel and the armouring needs to be as little as attainable, solely a little power is used. This ensures secure heat dissipation regardless of the extreme welding torch dimensions.
Secure welding results via outlined parameters
As the components had been rotationally symmetrical, it was simple to teach the elements; instructing is at all times based on the same applications. Even new parts could be welded mechanically quickly. Users simply should set the radius, variety of passes and the geometric dimensions of the surfaced components and the robotic control will care for the remaining. The desired welding result’s all the time assured because the welding process is defined with all of its parameters. The high quality can be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even though the system was initially designed and meant for one specific software, Schroeder is already pondering of recent concepts and makes use of. Schroeder wish to check out a few of the numerous welding procedures which are included within the Titan XQ welding machine as normal. This will enable to additional optimise totally different sorts of surfaced parts. Schroeder are additionally trying to increase and enhance the range of welding tasks.
There are hundreds of Schroeder Valves put in in vegetation in southern Africa defending property at corporations like Sasol, Eskom, Mondi and Sappi to call a few. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning facilities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or cellphone 011 397 2833 or 0861 103 103 to be taught extra.
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