Automated surfacing of rotationally symmetrical components
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of assorted parts served as the premise for the automation answer developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one thing in widespread, 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 challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all over the world for transporting liquids utilizing centrifugal pumps. เกจวัดแรงดันถังออกซิเจน of software embody refineries, energy crops and nuclear vegetation, in the transport of liquefied natural fuel (LNG), in addition to in offshore rigs. They are also used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one software.
The purpose is to weld all pump protection valve components routinely. These valves are related directly to the pumps and ensure steady operation of the pumps to prevent them running dry or being broken by cavitation during minimal move conditions. The pump safety valve is essentially 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 must be completely air and watertight. This is the one means to ensure proper functioning of the pump safety valve for decades to come. Normally, these parts are made using low-cost development steel DIN 1.0460. The sealing surfaces are bolstered with chrome steel DIN 1.4370. This course of was beforehand carried out manually, however, 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 elements being moved additionally differed vastly in weight, ranging from a quantity of hundred grams to 2 and a half tonnes. But all of the parts had one thing in common: they had been all rotationally symmetrical, making them excellent for an automatic process. With this as a beginning point, EWM was capable of get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon became clear that only a robot system would match the invoice when it got here to automating this explicit course of. Having to cope with so many different half sizes was a cause for concern. Large components require a big welding positioner. These, nonetheless, cannot present the dynamics required for the smaller components. This quickly gave rise to the thought of three processing stations: one massive L-positioner with tilting operate for the massive 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 with out positioners for another parts. The peak of the constructing was also a specific problem. The components had to have the flexibility to be positioned on the benches with the crane. The crane hook, nonetheless, was only approximately three metres excessive – extraordinarily small for an industrial utility. To guarantee accessibility whereas ensuring extraction, either the extraction hood or the system benches have been made to be cellular. The robot was fitted in a particularly small sales space in the centre between the three stations. This booth also consists of both the ability 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 robotic arm ensures safe wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations at all necessary positions is also ensured thanks to the acute arm size of two metres and optimised space inside the booths.
Special torch for extreme spaces
Each valve body is supplied with a cone information which is welded from above. With an inside diameter of simply 32 mm, access is extremely troublesome. For guide welding, the welder is unable to see the weld seam and as a substitute must rely on their expertise. Even for automated welding, these areas are very uncommon. EWM was only in a place to settle for this job as a end result of they manufacture the torches, emphasising the importance of the welding torch for this application. The welding torch for Schroeder Valves is a particular development with a very small torch head and unconventionally long torch neck. Of course, the particular software needed to be tailored to accommodate this unusual design: as a result of dilution between the parent steel and the armouring needs to be as low as potential, only a little vitality is used. This ensures safe heat dissipation regardless of the intense welding torch dimensions.
Secure welding results by way of defined parameters
As the elements have been rotationally symmetrical, it was straightforward to teach the parts; educating is always based mostly on the identical packages. Even new elements could be welded automatically shortly. Users simply should set the radius, variety of passes and the geometric dimensions of the surfaced components and the robot control will deal with the remaining. The desired welding result is at all times assured as a end result of the welding procedure is defined with all of its parameters. The quality may also be confirmed 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 pondering of latest ideas and uses. Schroeder would like to check out some of the varied welding procedures that are included within the Titan XQ welding machine as commonplace. This will enable to further optimise different kinds of surfaced parts. Schroeder are additionally trying to expand and enhance the range of welding tasks.
There are tons of of Schroeder Valves installed in vegetation in southern Africa defending assets at firms like Sasol, Eskom, Mondi and Sappi to call a quantity of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore and reconditioning amenities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or phone 011 397 2833 or 0861 103 103 to be taught more.
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