Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s greater than just a advertising promise! Over 50 drawings of assorted elements 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 components did have one thing in common, they were all rotationally symmetrical. This was the place to begin for welding machine producer EWM of their mission to develop a customized automation resolution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of utility embody refineries, energy plants and nuclear plants, within the transport of liquefied pure gasoline (LNG), in addition to in offshore rigs. They are additionally used all through the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one application.
The purpose is to weld all pump safety valve components mechanically. These valves are linked on to the pumps and guarantee continuous operation of the pumps to prevent them operating dry or being broken by cavitation during minimal flow conditions. The pump protection valve is basically made up of the valve body and the cone, which strikes inside the valve body. The sealing surfaces between the valve physique and the cone must be absolutely air and watertight. This is the only way to ensure proper functioning of the pump protection valve for many years to come. Normally, these parts are made utilizing low-cost construction steel DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This course of was previously carried out manually, nevertheless, due to each the scarcity of good welders and growing quality assurance necessities, automation of this step was essential. The internal diameter of the valve our bodies and the cone diameters were between 32 mm and four hundred mm. The components being moved also differed vastly in weight, ranging from a couple of hundred grams to 2 and a half tonnes. But the entire components had one factor in widespread: they had been all rotationally symmetrical, making them excellent for an automatic course of. With this as a place to begin, EWM was in a place 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 bill when it got here to automating this specific process. Having to cope with so many different 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 parts. This shortly gave rise to the concept of three processing stations: one massive L-positioner with tilting perform for the big valve bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a third station with a system bench without positioners for another elements. The height of the constructing was also a specific problem. The elements had to have the flexibility to be placed on the benches with the crane. The crane hook, nevertheless, was only approximately three metres excessive – extraordinarily small for an industrial software. To assure accessibility while ensuring extraction, both the extraction hood or the system benches have been made to be cell. The robot was fitted in a particularly small booth within the centre between the three stations. เกจวัดแรงดันเบนซิน includes both the power 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 100 iD in all three stations at all necessary positions is also ensured due to the acute arm length of two metres and optimised space contained in the cubicles.
Special torch for excessive areas
Each valve physique is equipped with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extraordinarily tough. For manual welding, the welder is unable to see the weld seam and as an alternative should depend on their expertise. Even for automated welding, these spaces are very unusual. EWM was only capable of accept this job because they manufacture the torches, emphasising the significance of the welding torch for this software. The welding torch for Schroeder Valves is a particular construction with a particularly small torch head and unconventionally long torch neck. Of course, the particular utility needed to be tailored to accommodate this unusual design: as a result of dilution between the parent metal and the armouring needs to be as little as possible, only a little power is used. This ensures safe heat dissipation despite the extreme welding torch dimensions.
Secure welding results through defined parameters
As the components were rotationally symmetrical, it was simple to teach the elements; educating is at all times primarily based on the identical programs. Even new elements may be welded routinely shortly. Users merely should set the radius, number of passes and the geometric dimensions of the surfaced parts and the robotic management will care for the remaining. The desired welding result is at all times assured as a result of the welding process is outlined with all of its parameters. The high quality may also be proven retrospectively as all welding parameters are continuously monitored and recorded. Even although the system was originally designed and intended for one specific software, Schroeder is already considering of recent ideas and makes use of. Schroeder would like to check out a few of the varied welding procedures which are included in the Titan XQ welding machine as commonplace. This will allow to additional optimise totally different sorts of surfaced components. Schroeder are also seeking to broaden and improve the range of welding duties.
There are tons of of Schroeder Valves put in in crops in southern Africa defending assets at firms like Sasol, Eskom, Mondi and Sappi to name a number of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning amenities 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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