Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of assorted elements served as the basis for the automation resolution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s elements did have one factor in common, they have been all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM of their mission to develop a customized automation answer tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of application embrace refineries, energy vegetation and nuclear vegetation, in the transport of liquefied pure gas (LNG), as nicely as 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 purpose is to weld all pump safety valve parts mechanically. These valves are connected on to the pumps and guarantee steady operation of the pumps to stop them running dry or being damaged by cavitation during minimum circulate circumstances. The pump protection valve is basically made up of the valve physique and the cone, which strikes contained in the valve physique. The sealing surfaces between the valve body and the cone must be absolutely air and watertight. This is the only way to make sure proper functioning of the pump protection valve for decades to come back. Normally, these components are made using low-cost construction metal DIN 1.0460. The sealing surfaces are bolstered with chrome steel DIN 1.4370. This course of was beforehand carried out manually, nonetheless, because of both the scarcity of excellent welders and rising quality assurance requirements, automation of this step was essential. เกจวัดแรงดัน1บาร์ of the valve bodies and the cone diameters were between 32 mm and 400 mm. The parts being moved also differed vastly in weight, ranging from a couple of hundred grams to two and a half tonnes. But the entire elements had one thing in common: they were all rotationally symmetrical, making them excellent for an automated process. With this as a place to begin, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon became clear that solely a robotic system would fit the bill when it came to automating this explicit 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, can not provide the dynamics required for the smaller elements. This rapidly gave rise to the concept of three processing stations: one large L-positioner with tilting function for the big valve 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 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, nevertheless, was only approximately three metres high – extremely small for an industrial software. To assure accessibility while making certain extraction, both the extraction hood or the system benches have been made to be cell. The robotic was fitted in an especially small sales space in the centre between the three stations. This sales space additionally consists of each the ability supply and a Titan XQ. These are positioned behind the L-positioner on the large processing station. The Rob 5 drive 4X wire feeder mounted on the robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations in any respect needed positions can be ensured because of the intense arm size of two metres and optimised house inside the booths.
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 extremely difficult. For guide welding, the welder is unable to see the weld seam and as an alternative must rely on their expertise. Even for automated welding, these areas are very uncommon. EWM was solely capable of accept this job because they manufacture the torches, emphasising the importance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular building with a very small torch head and unconventionally long torch neck. Of course, the particular application had to be tailored to accommodate this unusual design: because dilution between the mother or father steel and the armouring must be as little as possible, only somewhat power is used. This ensures protected heat dissipation regardless of the acute welding torch dimensions.
Secure welding outcomes via outlined parameters
As the elements were rotationally symmetrical, it was simple to teach the elements; teaching is all the time based mostly on the identical packages. Even new parts could be welded mechanically rapidly. Users merely have to set the radius, number of passes and the geometric dimensions of the surfaced components and the robotic management will deal with the remaining. The desired welding result’s all the time guaranteed as a end result 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 application, Schroeder is already thinking of latest ideas and uses. Schroeder want to check out a few of the numerous welding procedures that are included within the Titan XQ welding machine as standard. This will enable to further optimise completely different kinds of surfaced elements. Schroeder are also looking to broaden and enhance the range of welding tasks.
There are lots of of Schroeder Valves put in in crops in southern Africa protecting assets at companies like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to protect their pumps. เกจวัดแก๊สlpg and reconditioning facilities can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or phone 011 397 2833 or 0861 103 103 to study extra.
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