Automated surfacing of rotationally symmetrical components
Everything from a single source – it‘s more than only a advertising promise! Over Unauthorized of assorted elements served as the idea for the automation resolution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one thing in widespread, they were all rotationally symmetrical. This was the beginning point for welding machine manufacturer EWM of their mission to develop a custom automation solution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of application embrace refineries, power plants and nuclear vegetation, in the transport of liquefied natural fuel (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Psycho – one software.
The purpose is to weld all pump safety valve elements automatically. These valves are related on to the pumps and guarantee steady operation of the pumps to prevent them operating dry or being damaged by cavitation throughout minimal circulate circumstances. The pump safety valve is essentially made up of the valve body and the cone, which strikes inside the valve physique. The sealing surfaces between the valve body and the cone should be absolutely air and watertight. This is the one means to ensure correct functioning of the pump safety valve for many years to come. Normally, these components are made using low-cost development steel DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This course of was previously performed manually, nevertheless, as a end result of both the shortage of excellent welders and growing high quality assurance necessities, automation of this step was essential. The inner diameter of the valve bodies and the cone diameters had been between 32 mm and four hundred mm. The parts being moved additionally differed vastly in weight, ranging from a few hundred grams to two and a half tonnes. But all of the components had one factor in frequent: they have been all rotationally symmetrical, making them perfect for an automated course of. With this as a starting point, EWM was capable of get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly became clear that solely a robotic system would fit the invoice when it got here to automating this specific course of. Having to cope with so many different part sizes was a trigger for concern. Large components require a large welding positioner. These, nevertheless, can’t provide the dynamics required for the smaller components. This quickly gave rise to the idea 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 with out positioners for another elements. The peak of the building was also a selected problem. The components had to have the power to be placed on the benches with the crane. The crane hook, however, was only approximately three metres excessive – extraordinarily small for an industrial application. To assure accessibility whereas ensuring extraction, both the extraction hood or the system benches have been made to be mobile. The robot was fitted in an especially small booth in the centre between the three stations. This sales space also consists of each 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 a hundred iD in all three stations at all essential positions can also be ensured because of the acute arm size of two metres and optimised space contained in the cubicles.
Special torch for excessive areas
Each valve physique is supplied with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extremely troublesome. For manual welding, the welder is unable to see the weld seam and as an alternative should rely on their experience. Even for automated welding, these areas are very uncommon. EWM was solely able to settle for this job as a outcome of they manufacture the torches, emphasising the importance of the welding torch for this software. The welding torch for Schroeder Valves is a special construction with a very small torch head and unconventionally long torch neck. Of course, the particular application needed to be adapted to accommodate this unusual design: because dilution between the father or mother metallic and the armouring must be as low as potential, only somewhat vitality is used. This ensures protected warmth dissipation despite the acute welding torch dimensions.
Secure welding results through outlined parameters
As the components were rotationally symmetrical, it was straightforward to show the parts; instructing is always based on the same programs. Even new elements may be welded automatically quickly. Users simply have to set the radius, number of passes and the geometric dimensions of the surfaced elements and the robotic control will take care of the rest. The desired welding result’s all the time guaranteed because the welding process is outlined with all of its parameters. The quality may also be proven retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was originally designed and intended for one particular software, Schroeder is already considering of recent ideas and uses. Schroeder wish to check out a few of the numerous welding procedures that are included in the Titan XQ welding machine as normal. This will enable to further optimise different kinds of surfaced components. Schroeder are additionally trying to increase and enhance the vary of welding tasks.
There are hundreds of Schroeder Valves put in in plants in southern Africa protecting property at firms like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning services 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 more.
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