Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s greater than only a marketing promise! Over 50 drawings of assorted elements served as the premise for the automation answer developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s components did have one factor in common, they have been all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM in their mission to develop a custom automation resolution tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of software embody refineries, power crops and nuclear crops, in the transport of liquefied natural fuel (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one application.
The goal is to weld all pump safety valve elements routinely. 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 during minimal move circumstances. The pump protection valve is basically 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 should be completely air and watertight. This is the only way to ensure correct functioning of the pump protection valve for many years to come back. Normally, these components are made using low-cost development metal DIN 1.0460. The sealing surfaces are reinforced with chrome steel DIN 1.4370. This process was beforehand performed manually, nonetheless, due to both the shortage of good welders and rising quality assurance requirements, automation of this step was essential. The internal diameter of the valve bodies and the cone diameters were between 32 mm and four hundred mm. The parts being moved also differed vastly in weight, starting from a few hundred grams to two and a half tonnes. But all of the parts had one factor in common: they were all rotationally symmetrical, making them excellent for an automated course of. With this as a place to begin, EWM was in a position 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 got here to automating this explicit process. Having to cope with so many different half sizes was a cause for concern. Large parts require a big welding positioner. These, nonetheless, can’t provide the dynamics required for the smaller components. This shortly gave rise to the idea of three processing stations: one giant L-positioner with tilting operate 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 without positioners for another components. The top of the constructing was additionally a selected challenge. The elements had to find a way to be placed on the benches with the crane. The crane hook, nevertheless, was solely approximately three metres excessive – extraordinarily small for an industrial software. To assure accessibility whereas making certain extraction, both the extraction hood or the system benches were made to be cellular. The robot was fitted in a particularly small booth in the centre between the three stations. This sales space also consists of each the power 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 robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations in any respect essential positions can also be ensured due to the extreme arm length of two metres and optimised area contained in the cubicles.
Special torch for extreme areas
Each valve body is supplied with a cone information which is welded from above. With an inside diameter of simply 32 mm, entry is extremely difficult. For handbook welding, the welder is unable to see the weld seam and as a substitute should rely on their experience. Even for automated welding, these spaces are very unusual. EWM was solely in a position to 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 special building with a particularly small torch head and unconventionally long torch neck. Of course, the particular application had to be tailored to accommodate this uncommon design: because dilution between the mother or father steel and the armouring must be as low as potential, only slightly power is used. This ensures protected warmth dissipation regardless of the acute welding torch dimensions.
Secure welding outcomes through outlined parameters
As the elements had been rotationally symmetrical, it was simple to teach the parts; teaching is at all times primarily based on the identical packages. Even new components may be welded automatically shortly. Users simply need to set the radius, number of passes and the geometric dimensions of the surfaced components and the robot control will deal with the remaining. pressure gauge ราคา desired welding result’s at all times assured as a end result of the welding process is defined with all of its parameters. The high quality may also be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and meant for one specific application, Schroeder is already thinking of recent ideas and uses. Schroeder wish to check out a variety of the varied welding procedures which are included within the Titan XQ welding machine as normal. This will allow to further optimise completely different sorts of surfaced parts. Schroeder are additionally seeking to expand and enhance the vary of welding tasks.
There are lots of of Schroeder Valves put in in crops in southern Africa protecting belongings 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 facilities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or telephone 011 397 2833 or 0861 103 103 to be taught extra.

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