SCHROEDER – NEW WELDING ROBOT FOR PUMP PROTECTION VALVES

Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s more than only a advertising promise! Over 50 drawings of varied components 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 widespread, they have been all rotationally symmetrical. This was the beginning point for welding machine producer EWM of their mission to develop a customized automation solution tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of utility embrace refineries, energy crops and nuclear vegetation, in the transport of liquefied natural gas (LNG), as nicely as 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 utility.
The purpose is to weld all pump safety valve elements automatically. These valves are related directly to the pumps and guarantee continuous operation of the pumps to prevent them running dry or being broken by cavitation throughout minimal circulate conditions. The pump safety valve is largely made up of the valve body and the cone, which moves inside the valve physique. The sealing surfaces between the valve body and the cone should be completely air and watertight. This is the only method to make sure proper functioning of the pump safety valve for decades 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 beforehand carried out manually, nonetheless, because of both the scarcity of excellent welders and growing quality assurance necessities, automation of this step was essential. The inner diameter of the valve bodies and the cone diameters had been between 32 mm and four hundred mm. The components being moved also differed vastly in weight, starting from a couple of hundred grams to 2 and a half tonnes. But all of the components had one thing in widespread: they had been all rotationally symmetrical, making them excellent for an automatic 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 became clear that only a robot system would match the invoice when it came to automating this particular process. Having to deal with so many different half sizes was a cause for concern. Large elements require a big welding positioner. These, nevertheless, can not provide the dynamics required for the smaller components. This quickly gave rise to the concept of three processing stations: one giant L-positioner with tilting perform for the large valve our bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a third station with a system bench with out positioners for any other elements. The peak of the building was also a selected challenge. The components had to have the ability to be placed on the benches with the crane. The crane hook, nevertheless, was solely approximately three metres excessive – extraordinarily small for an industrial utility. To assure accessibility whereas guaranteeing 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 includes 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 robotic arm ensures safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations at all necessary positions is also ensured thanks to the intense arm size of two metres and optimised space inside the booths.
Special torch for extreme areas
Each valve physique is provided with a cone guide which is welded from above. With an inside diameter of simply 32 mm, entry is extraordinarily troublesome. For manual welding, the welder is unable to see the weld seam and instead must depend on their experience. Even for automated welding, these areas are very unusual. EWM was only capable of accept this job as a outcome of they manufacture the torches, emphasising the significance of the welding torch for this software. The welding torch for Schroeder Valves is a particular development with a very small torch head and unconventionally lengthy torch neck. Of course, the special utility needed to be adapted to accommodate this uncommon design: as a end result of dilution between the parent metallic and the armouring needs to be as little as potential, only a little power is used. This ensures secure heat dissipation despite the intense welding torch dimensions.
Secure welding results by way of defined parameters
As the parts had been rotationally symmetrical, it was easy to teach the parts; educating is at all times primarily based on the identical packages. Even new components could be welded mechanically quickly. Users merely need to set the radius, variety of passes and the geometric dimensions of the surfaced parts and the robotic management will deal with the remainder. The desired welding result’s all the time assured as a end result of the welding procedure is defined with all of its parameters. The high quality can additionally be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was originally designed and supposed for one particular application, Schroeder is already pondering of latest concepts and makes use of. Schroeder wish to try out some of the numerous welding procedures which would possibly be included in the Titan XQ welding machine as normal. This will enable to further optimise totally different sorts of surfaced parts. Schroeder are also trying to increase and improve the vary of welding duties.
There are lots of of Schroeder Valves installed in vegetation in southern Africa protecting assets at firms like Sasol, Eskom, Mondi and Sappi to name a quantity of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. เกจแรงดัน and reconditioning services 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 learn more.
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