Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s more than only a advertising promise! Over 50 drawings of various elements served as the basis for the automation resolution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one factor in common, they have been all rotationally symmetrical. This was the begin line for welding machine manufacturer EWM of their mission to develop a customized automation answer 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 application embody refineries, energy crops and nuclear plants, in the transport of liquefied pure fuel (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 application.
The goal is to weld all pump safety valve elements automatically. These valves are connected on to the pumps and guarantee steady operation of the pumps to forestall them working dry or being damaged by cavitation during minimal move conditions. The pump safety valve is largely made up of the valve body and the cone, which moves 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 means to make sure proper functioning of the pump protection valve for many years to come back. Normally, these components are made using low-cost building metal DIN 1.0460. The sealing surfaces are bolstered with chrome steel DIN 1.4370. This course of was previously performed manually, nevertheless, as a end result of each the scarcity of fine welders and rising quality assurance requirements, automation of this step was crucial. The internal diameter of the valve bodies and the cone diameters have been between 32 mm and 400 mm. The parts being moved additionally differed vastly in weight, starting from a few hundred grams to two and a half tonnes. But all the parts had one thing in widespread: they have been all rotationally symmetrical, making them good for an automatic course of. With this as a beginning point, 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 solely a robotic system would fit the invoice when it got here to automating this specific process. Having to take care of so many different part sizes was a trigger for concern. เกจ์ออกซิเจนsumo require a big welding positioner. These, nonetheless, can’t present the dynamics required for the smaller components. This shortly gave rise to the thought of three processing stations: one massive L-positioner with tilting perform for the big 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 without positioners for another components. The height of the building was additionally a specific challenge. The parts had to have the flexibility to be positioned on the benches with the crane. The crane hook, nevertheless, was only approximately three metres high – extraordinarily small for an industrial utility. To guarantee accessibility while ensuring extraction, either the extraction hood or the system benches had been made to be cell. The robotic was fitted in an extremely small sales space in the centre between the three stations. This sales space additionally consists of each the facility 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 100 iD in all three stations at all necessary positions can be ensured thanks to the acute arm length of two metres and optimised area inside the booths.
Special torch for excessive areas
Each valve body is supplied with a cone guide which is welded from above. With an inside diameter of simply 32 mm, access is extraordinarily difficult. 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. EWM was solely capable of accept this job because they manufacture the torches, emphasising the significance of the welding torch for this application. The welding torch for Schroeder Valves is a particular construction with a particularly small torch head and unconventionally lengthy torch neck. Of course, the particular utility had to be adapted to accommodate this uncommon design: as a end result of dilution between the parent steel and the armouring must be as little as attainable, only a little vitality is used. This ensures secure warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding results through outlined parameters
As the elements were rotationally symmetrical, it was simple to teach the parts; educating is always based on the same programs. Even new parts can be welded mechanically shortly. Users simply should set the radius, number of passes and the geometric dimensions of the surfaced components and the robot management will deal with the remaining. The desired welding result’s all the time guaranteed as a outcome of the welding process is outlined with all of its parameters. The high quality can additionally be proven retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was initially designed and intended for one particular application, Schroeder is already thinking of recent ideas and uses. Schroeder wish to check out a number of the varied welding procedures that are included within the Titan XQ welding machine as normal. This will enable to further optimise different kinds of surfaced components. Schroeder are also trying to expand and enhance the vary of welding tasks.
There are hundreds of Schroeder Valves installed in plants in southern Africa defending belongings at corporations like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning services are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact sales@valve.co.za, www.valve.co.za or telephone 011 397 2833 or 0861 103 103 to learn more.
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