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Automated surfacing of rotationally symmetrical elements

Everything from a single supply – it‘s greater than only a marketing promise! Over 50 drawings of assorted components served as the basis for the automation solution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one factor in widespread, they had been all rotationally symmetrical. This was the begin line for welding machine producer EWM in their mission to develop a custom automation resolution tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all around the world for transporting liquids using centrifugal pumps. Their areas of utility include refineries, energy plants and nuclear plants, within the transport of liquefied natural gasoline (LNG), in addition to in offshore rigs. They are also used throughout the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The aim is to weld all pump protection valve elements routinely. These valves are related directly to the pumps and ensure steady operation of the pumps to prevent them running dry or being damaged by cavitation during minimal move conditions. The pump protection valve is essentially made up of the valve physique and the cone, which strikes contained in the valve physique. The sealing surfaces between the valve physique and the cone should be absolutely air and watertight. This is the one way to ensure correct functioning of the pump protection valve for decades to return. Normally, these elements are made using low-cost construction steel DIN 1.0460. The sealing surfaces are reinforced with stainless-steel DIN 1.4370. This course of was previously performed manually, however, as a outcome of both the shortage of fine welders and rising quality assurance necessities, automation of this step was essential. The inside diameter of the valve our bodies and the cone diameters had been between 32 mm and four hundred mm. The elements being moved additionally differed vastly in weight, ranging from a couple of hundred grams to two and a half tonnes. But the entire parts had one factor in common: they were all rotationally symmetrical, making them perfect for an automatic process. With this as a beginning point, EWM was in a position to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations

It soon turned clear that only a robotic system would fit the invoice when it came to automating this explicit process. Having to deal with so many alternative part sizes was a cause for concern. Large elements require a large welding positioner. These, nevertheless, can’t present the dynamics required for the smaller components. This rapidly gave rise to the concept of three processing stations: one massive L-positioner with tilting function 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 with out positioners for another components. เพรสเชอร์เกจ of the building was additionally a specific problem. The elements had to find a way to be placed on the benches with the crane. The crane hook, however, was solely roughly three metres high – extremely small for an industrial application. To guarantee accessibility whereas guaranteeing extraction, either the extraction hood or the system benches were made to be cell. The robotic was fitted in an especially small sales space in the centre between the three stations. This booth additionally consists of both the power 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 safe wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations at all necessary positions can be ensured because of the acute arm size of two metres and optimised area inside the booths.
Special torch for excessive spaces

Each valve physique is equipped with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extremely tough. For manual welding, the welder is unable to see the weld seam and instead should depend on their expertise. Even for automated welding, these spaces are very unusual. EWM was only capable of accept this job as a result of they manufacture the torches, emphasising the significance of the welding torch for this software. The welding torch for Schroeder Valves is a special construction with a particularly small torch head and unconventionally lengthy torch neck. Of course, the special software needed to be adapted to accommodate this unusual design: as a end result of dilution between the mother or father metal and the armouring must be as little as possible, only somewhat vitality is used. This ensures safe warmth dissipation regardless of the extreme welding torch dimensions.
diaphragm seal welding outcomes through outlined parameters

As the elements had been rotationally symmetrical, it was easy to show the components; educating is always primarily based on the identical programs. Even new elements could be welded automatically shortly. Users merely need to set the radius, variety of passes and the geometric dimensions of the surfaced components and the robot management will take care of the remaining. The desired welding result is always assured as a outcome of the welding process is defined with all of its parameters. The high quality can be proven retrospectively as all welding parameters are continuously monitored and recorded. Even although the system was initially designed and supposed for one specific utility, Schroeder is already considering of recent ideas and uses. Schroeder wish to try out some of the various welding procedures which might be included in the Titan XQ welding machine as standard. This will enable to additional optimise different sorts of surfaced components. Schroeder are additionally looking to broaden and improve the range of welding duties.
There are lots of of Schroeder Valves installed in vegetation in southern Africa protecting property at firms like Sasol, Eskom, Mondi and Sappi to name a couple of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning facilities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or telephone 011 397 2833 or 0861 103 103 to learn more.
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