Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s more than just a marketing promise! Over 50 drawings of assorted components 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 components did have one factor in common, they have been all rotationally symmetrical. This was the begin line for welding machine producer EWM in their mission to develop a custom automation answer tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all over the world for transporting liquids using centrifugal pumps. Their areas of software include refineries, power crops and nuclear crops, within the transport of liquefied pure gas (LNG), in addition to in offshore rigs. They are also used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The purpose is to weld all pump protection valve components mechanically. These valves are connected directly to the pumps and guarantee continuous operation of the pumps to prevent them operating dry or being damaged by cavitation throughout minimum circulate situations. digital pressure gauge ราคา is essentially made up of the valve physique and the cone, which strikes inside the valve body. The sealing surfaces between the valve physique and the cone have to be absolutely air and watertight. This is the one method to make sure proper functioning of the pump safety valve for decades to return. Normally, these elements are made utilizing low-cost building steel DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This course of was previously carried out manually, however, due to each the scarcity of excellent welders and growing 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 four hundred mm. The parts being moved also differed vastly in weight, starting from a quantity of hundred grams to two and a half tonnes. But all of the elements had one factor in common: they were all rotationally symmetrical, making them excellent for an automated course of. 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 quickly turned clear that solely a robot system would match the invoice when it came to automating this specific course of. Having to deal with so many alternative part sizes was a cause for concern. Large parts require a big welding positioner. These, nevertheless, cannot present the dynamics required for the smaller elements. This quickly gave rise to the concept of three processing stations: one giant L-positioner with tilting perform for the large 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 constructing was additionally a particular problem. The parts had to have the ability to be positioned on the benches with the crane. The crane hook, however, was only roughly three metres high – extremely small for an industrial application. To assure accessibility whereas ensuring extraction, both the extraction hood or the system benches have been made to be cellular. The robot was fitted in an especially small sales space in the centre between the three stations. This sales space also contains each the facility 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 robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations in any respect needed positions is also ensured because of the intense arm size of two metres and optimised space inside the cubicles.
Special torch for extreme areas
Each valve body is equipped with a cone information which is welded from above. With an inside diameter of simply 32 mm, entry is extraordinarily troublesome. For guide welding, the welder is unable to see the weld seam and as a substitute must rely on their expertise. Even for automated welding, these areas are very uncommon. EWM was only capable of accept 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 particular development with a particularly small torch head and unconventionally lengthy torch neck. Of course, the particular utility had to be adapted to accommodate this unusual design: as a result of dilution between the mother or father steel and the armouring needs to be as low as potential, only slightly energy is used. This ensures secure warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding results by way of outlined parameters
As the components have been rotationally symmetrical, it was simple to teach the parts; educating is always primarily based on the identical programs. Even new elements could be welded routinely quickly. Users merely should set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot management will take care of the remaining. The desired welding result is all the time assured as a end result of the welding procedure is outlined with all of its parameters. The quality can be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even though the system was originally designed and supposed for one specific software, Schroeder is already thinking of new ideas and uses. Schroeder wish to check out a few of the various welding procedures which would possibly be included within the Titan XQ welding machine as commonplace. This will allow to further optimise totally different sorts of surfaced parts. Schroeder are also trying to increase and improve the vary of welding duties.
There are lots of of Schroeder Valves put in in vegetation in southern Africa protecting property at companies like Sasol, Eskom, Mondi and Sappi to call a few. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair 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 more.
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