Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of varied elements served as the premise for the automation resolution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. เกจวัดแรงดันแก๊สอาร์กอน of the main specialist’s components did have one thing in widespread, they have been all rotationally symmetrical. This was the place to begin for welding machine producer EWM in their mission to develop a custom automation answer tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all round the world for transporting liquids using centrifugal pumps. Their areas of utility include refineries, power crops and nuclear crops, in the transport of liquefied pure fuel (LNG), as well as in offshore rigs. They are also used all through the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one software.
The goal is to weld all pump safety valve parts automatically. These valves are connected directly to the pumps and guarantee steady operation of the pumps to prevent them running dry or being damaged by cavitation throughout minimal move conditions. The pump protection valve is basically made up of the valve body and the cone, which moves contained in the valve body. The sealing surfaces between the valve body and the cone should be completely air and watertight. This is the one method to make sure proper functioning of the pump protection valve for many years to return. Normally, these components are made utilizing low-cost development metal DIN 1.0460. The sealing surfaces are bolstered with stainless-steel DIN 1.4370. This course of was previously carried out manually, nonetheless, as a result of each the scarcity of excellent welders and growing high quality assurance requirements, automation of this step was crucial. The inside diameter of the valve our bodies and the cone diameters were between 32 mm and 400 mm. The elements being moved additionally differed vastly in weight, starting from a number of hundred grams to 2 and a half tonnes. But all the elements had one thing in widespread: they have been all rotationally symmetrical, making them good for an automated process. 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 turned clear that only a robot system would match the invoice when it got here to automating this specific process. Having to take care of so many different part sizes was a cause for concern. Large parts require a big welding positioner. These, nonetheless, can’t provide the dynamics required for the smaller parts. This shortly gave rise to the idea of three processing stations: one giant L-positioner with tilting function for the massive valve our bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a 3rd station with a system bench without positioners for some other components. The peak of the constructing was also a specific problem. The components had to be able to be positioned on the benches with the crane. The crane hook, however, was only roughly three metres excessive – extraordinarily small for an industrial software. To guarantee accessibility while making certain extraction, either the extraction hood or the system benches were made to be mobile. The robotic was fitted in an especially small booth within the centre between the three stations. This sales space also contains both the facility source and a Titan XQ. These are positioned behind the L-positioner at the massive processing station. The Rob 5 drive 4X wire feeder mounted on the robotic arm ensures secure wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations in any respect necessary positions can also be ensured due to the acute arm size of two metres and optimised house contained in the cubicles.
Special torch for excessive areas
Each valve body is supplied with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily troublesome. For manual welding, the welder is unable to see the weld seam and as an alternative should rely on their expertise. Even for automated welding, these spaces are very unusual. EWM was solely in a position to settle for this job because they manufacture the torches, emphasising the significance of the welding torch for this utility. 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 utility needed to be tailored to accommodate this uncommon design: because dilution between the parent steel and the armouring needs to be as little as attainable, only somewhat vitality is used. This ensures secure warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes by way of defined parameters
As the elements had been rotationally symmetrical, it was simple to show the parts; teaching is always primarily based on the same programs. Even new elements may be welded automatically rapidly. Users simply have to set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot control will deal with the remainder. The desired welding result is all the time assured as a outcome of the welding procedure is outlined with all of its parameters. The high quality may also be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was initially designed and supposed for one specific utility, Schroeder is already thinking of new concepts and makes use of. Schroeder would like to check out a few of the numerous welding procedures which are included in the Titan XQ welding machine as standard. This will permit to further optimise different kinds of surfaced components. Schroeder are also seeking to broaden and improve the range of welding tasks.
There are hundreds of Schroeder Valves installed in plants in southern Africa defending property at companies like Sasol, Eskom, Mondi and Sappi to call a few. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning facilities can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact sales@valve.co.za, www.valve.co.za or phone 011 397 2833 or 0861 103 103 to study more.
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