Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s more than only a advertising promise! Over 50 drawings of assorted parts served as the premise for the automation solution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one factor in frequent, they were all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM of their mission to develop a custom automation resolution tailored to this multifaceted challenge.
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 embrace refineries, energy crops and nuclear vegetation, within the transport of liquefied pure fuel (LNG), in addition to in offshore rigs. They are additionally used throughout the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The purpose is to weld all pump safety valve components mechanically. These valves are linked on to the pumps and guarantee steady operation of the pumps to stop them running dry or being damaged by cavitation during minimum flow circumstances. The pump safety valve is largely made up of the valve physique and the cone, which strikes contained in the valve body. The sealing surfaces between the valve physique and the cone should be absolutely air and watertight. This is the only method to ensure proper functioning of the pump protection valve for decades to come. Normally, these elements are made utilizing low-cost building steel DIN 1.0460. The sealing surfaces are reinforced with stainless-steel DIN 1.4370. This process was previously carried out manually, nonetheless, because of each the scarcity of fine welders and rising high 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 few hundred grams to two and a half tonnes. But all the parts had one factor in common: they have been all rotationally symmetrical, making them excellent for an automated process. With this as a place to begin, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon grew to become clear that only a robot system would match the bill when it got here to automating this explicit process. Having to deal with so many various half sizes was a trigger for concern. Large elements require a large welding positioner. These, nevertheless, can’t provide the dynamics required for the smaller elements. This shortly gave rise to the concept of three processing stations: one giant L-positioner with tilting perform 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 with out positioners for another components. The peak of the constructing was additionally a selected problem. The elements had to have the ability to be placed on the benches with the crane. The crane hook, however, was only approximately three metres high – extraordinarily small for an industrial utility. To guarantee accessibility whereas guaranteeing extraction, both the extraction hood or the system benches had been made to be cellular. The robot was fitted in an extremely small booth in the centre between the three stations. This booth also includes both the facility supply 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 robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations in any respect essential positions is also ensured because of the extreme arm length of two metres and optimised space inside the booths.
Special torch for extreme areas
Each valve physique is provided with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily troublesome. For handbook welding, the welder is unable to see the weld seam and as a substitute should depend on their expertise. Even for automated welding, these areas are very unusual. EWM was only capable of accept this job as a result of they manufacture the torches, emphasising the importance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular building with a very small torch head and unconventionally lengthy torch neck. Of course, the particular utility had to be tailored to accommodate this unusual design: as a result of dilution between the parent metallic and the armouring must be as little as potential, solely somewhat power is used. This ensures safe heat dissipation regardless of the acute welding torch dimensions.
เกจไนโตรเจนsumo welding results through outlined parameters
As the parts have been rotationally symmetrical, it was straightforward to show the components; educating is always primarily based on the identical packages. Even new components may be welded automatically rapidly. Users simply have to set the radius, variety of passes and the geometric dimensions of the surfaced components and the robot management will care for the rest. The desired welding result is always guaranteed because the welding process is outlined with all of its parameters. The quality can be proven retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and meant for one particular application, Schroeder is already thinking of recent ideas and makes use of. Schroeder want to check out a few of the varied welding procedures that are included in the Titan XQ welding machine as commonplace. This will enable to additional optimise totally different kinds of surfaced parts. Schroeder are additionally looking to broaden and enhance the range of welding duties.
There are tons of of Schroeder Valves put in in vegetation in southern Africa protecting property at companies like Sasol, Eskom, Mondi and Sappi to call a couple of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair 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 cellphone 011 397 2833 or 0861 103 103 to be taught more.
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