Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of varied parts served as the idea for the automation solution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one thing in widespread, they were all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM of their mission to develop a customized automation solution tailor-made to this multifaceted problem.
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 include refineries, power vegetation and nuclear crops, in the transport of liquefied pure gasoline (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The goal is to weld all pump safety valve elements mechanically. These valves are linked on to the pumps and ensure continuous operation of the pumps to prevent them running dry or being broken by cavitation during minimum circulate conditions. The pump safety valve is essentially made up of the valve body and the cone, which strikes contained in the valve physique. The sealing surfaces between the valve physique and the cone have to be absolutely air and watertight. This is the only way to ensure proper functioning of the pump safety valve for decades to come back. Normally, these elements are made using low-cost building steel DIN 1.0460. The sealing surfaces are strengthened with stainless steel DIN 1.4370. This course of was previously performed manually, nonetheless, because of both the scarcity of fine welders and rising quality assurance requirements, automation of this step was essential. The inside diameter of the valve our bodies and the cone diameters have been between 32 mm and four hundred mm. The components being moved additionally differed vastly in weight, ranging from a number of hundred grams to 2 and a half tonnes. But all the parts had one thing in widespread: they had been all rotationally symmetrical, making them good for an automatic course of. With this as a place to begin, EWM was in a position to get the system planning ball rolling.
From Unsung to Big – Multiple Processing Stations
It quickly grew to become clear that only a robotic system would fit the invoice when it got here to automating this specific course of. Having to deal with so many alternative part sizes was a cause for concern. Large parts require a large welding positioner. These, nonetheless, cannot provide the dynamics required for the smaller parts. This rapidly gave rise to the thought of three processing stations: one massive L-positioner with tilting operate for the big valve bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a third station with a system bench without positioners for another elements. The peak of the building was also a particular challenge. The parts had to find a way to be positioned on the benches with the crane. The crane hook, nonetheless, was only approximately three metres high – extraordinarily small for an industrial utility. To assure accessibility while guaranteeing extraction, both the extraction hood or the system benches were made to be mobile. The robot was fitted in an extremely small booth in the centre between the three stations. This sales space additionally consists of both the power supply 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 robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations in any respect needed positions is also ensured thanks to the extreme arm size of two metres and optimised house contained in the cubicles.
Special torch for excessive spaces
Each valve body is supplied with a cone guide which is welded from above. With an inside diameter of simply 32 mm, access is extremely tough. For manual welding, the welder is unable to see the weld seam and as an alternative must depend on their expertise. Even for automated welding, these areas are very uncommon. EWM was solely capable of settle for this job because they manufacture the torches, emphasising the significance of the welding torch for this application. The welding torch for Schroeder Valves is a special construction with a particularly small torch head and unconventionally lengthy torch neck. Of course, the particular application had to be tailored to accommodate this uncommon design: as a outcome of dilution between the parent metal and the armouring needs to be as low as attainable, solely a little power is used. This ensures secure warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes through outlined parameters
As the components were rotationally symmetrical, it was straightforward to teach the elements; educating is all the time primarily based on the identical applications. Even new components may be welded routinely shortly. 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 remaining. The desired welding result is at all times guaranteed as a outcome of the welding process is outlined with all of its parameters. The quality can also be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was initially designed and intended for one specific utility, Schroeder is already pondering of new ideas and uses. Schroeder want to check out a number of the numerous welding procedures which might be included in the Titan XQ welding machine as commonplace. This will enable to further optimise different kinds of surfaced parts. Schroeder are also looking to broaden and enhance the range of welding tasks.
There are tons of of Schroeder Valves put in in crops in southern Africa protecting property at companies like Sasol, Eskom, Mondi and Sappi to name a couple of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore and reconditioning amenities can be found 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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