Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s greater than just a advertising promise! Over 50 drawings of various elements served as the premise for the automation answer developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s elements did have one thing in common, they had been all rotationally symmetrical. This was the starting point for welding machine producer EWM of their mission to develop a custom automation solution 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 software embrace refineries, power plants and nuclear plants, in the transport of liquefied natural gas (LNG), in addition to in offshore rigs. They are additionally used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The goal is to weld all pump protection valve components routinely. These valves are connected on to the pumps and guarantee continuous operation of the pumps to prevent them running dry or being damaged by cavitation during minimal move situations. The pump safety valve is basically made up of the valve body and the cone, which moves inside the valve body. The sealing surfaces between the valve physique and the cone should be completely air and watertight. This is the only method to ensure correct functioning of the pump safety valve for many years to come. Normally, these elements are made using low-cost construction steel DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This process was beforehand performed manually, nevertheless, as a outcome of both the scarcity of good welders and rising quality assurance necessities, automation of this step was crucial. The internal diameter of the valve our bodies and the cone diameters had been between 32 mm and 400 mm. The elements being moved also differed vastly in weight, ranging from a few hundred grams to two and a half tonnes. But the entire parts had one factor in frequent: they were all rotationally symmetrical, making them perfect for an automated process. With this as a starting point, EWM was in a position to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon grew to become clear that only a robotic system would match the invoice when it came to automating this specific course of. Having to take care of so many alternative half sizes was a cause for concern. Large elements require a big welding positioner. These, however, cannot provide the dynamics required for the smaller parts. This shortly gave rise to the idea of three processing stations: one giant L-positioner with tilting operate for the massive valve our bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a 3rd station with a system bench without positioners for another parts. The top of the building was also a particular challenge. The components had to have the ability to be positioned on the benches with the crane. The crane hook, however, was solely approximately three metres high – 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 cell. The robot was fitted in an extremely small sales space in the centre between the three stations. This booth also contains both the power supply and a Titan XQ. These are positioned behind the L-positioner at the giant processing station. The Rob 5 drive 4X wire feeder mounted on the robotic arm ensures secure wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations at all essential positions can be ensured due to the extreme arm length of two metres and optimised house inside the booths.
Special torch for extreme areas
Each valve body is supplied 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 a substitute must depend on their experience. Even for automated welding, these spaces are very uncommon. EWM was only in a place to accept this job as a outcome of they manufacture the torches, emphasising the significance of the welding torch for this utility. The welding torch for Schroeder Valves is a special development with a particularly small torch head and unconventionally lengthy torch neck. Of course, the special utility needed to be tailored to accommodate this unusual design: as a result of dilution between the mother or father steel and the armouring needs to be as little as attainable, solely a little vitality is used. This ensures protected heat dissipation despite the acute welding torch dimensions.
Secure welding results through defined parameters
As the components had been rotationally symmetrical, it was easy to show the elements; teaching is always based on the identical applications. Even new parts may be welded mechanically rapidly. Users simply have to set the radius, number of passes and the geometric dimensions of the surfaced components and the robotic control will take care of the remaining. เกจวัดแรงดันราคา desired welding result is always guaranteed as a result of the welding procedure is outlined with all of its parameters. The quality can be confirmed retrospectively as all welding parameters are continuously monitored and recorded. Even although the system was initially designed and meant for one particular utility, Schroeder is already thinking of new concepts and uses. Schroeder want to try out a variety of the varied welding procedures that are included in the Titan XQ welding machine as normal. This will allow to further optimise totally different kinds of surfaced components. Schroeder are also looking to increase and improve the range of welding tasks.
There are hundreds of Schroeder Valves put in in plants in southern Africa protecting belongings at corporations like Sasol, Eskom, Mondi and Sappi to name a quantity of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning facilities can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please เกจวัดแรงดันลม10bar, or telephone 011 397 2833 or 0861 103 103 to study extra.
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