Automated surfacing of rotationally symmetrical components
Everything from a single source – it‘s more than only a advertising promise! Over 50 drawings of various parts served as the idea for the automation answer developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one factor in widespread, they were all rotationally symmetrical. This was the place to begin for welding machine producer EWM of their mission to develop a customized automation resolution tailored 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, power crops and nuclear crops, in the transport of liquefied pure fuel (LNG), as well as in offshore rigs. They are also used throughout the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one application.
The aim 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 forestall them operating dry or being broken by cavitation during minimal flow situations. The pump safety valve is largely made up of the valve body and the cone, which strikes contained in the valve body. The sealing surfaces between the valve physique and the cone have to be completely air and watertight. This is the one way to ensure proper functioning of the pump safety valve for many years to come back. Normally, these elements are made utilizing low-cost building metal DIN 1.0460. The sealing surfaces are bolstered with stainless-steel DIN 1.4370. This process was beforehand carried out manually, however, due to both the shortage of excellent welders and growing quality assurance necessities, automation of this step was crucial. The inside 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, starting from a quantity of hundred grams to two and a half tonnes. But all the parts had one thing in widespread: they have been all rotationally symmetrical, making them perfect for an automated process. With this as a starting point, EWM was in a place to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly turned clear that only a robotic system would fit the bill when it got here to automating this particular process. Having to cope with so many different part sizes was a cause for concern. Large parts require a big welding positioner. These, however, cannot present the dynamics required for the smaller parts. This shortly gave rise to the idea of three processing stations: one large L-positioner with tilting perform 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 top of the building was also a specific problem. The components had to be able to be positioned on the benches with the crane. The crane hook, however, was solely approximately three metres excessive – extraordinarily small for an industrial software. To assure accessibility while making certain extraction, either the extraction hood or the system benches had been made to be cell. The robot was fitted in an especially small sales space in the centre between the three stations. This sales space also includes both the power 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 robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations in any respect essential positions is also ensured thanks to the intense arm size of two metres and optimised space inside the booths.
Special torch for excessive areas
Each valve body is provided with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extremely difficult. For handbook welding, the welder is unable to see the weld seam and as an alternative should depend on their expertise. Even for automated welding, these spaces are very uncommon. EWM was solely in a position to settle for this job as a end result of they manufacture the torches, emphasising the significance of the welding torch for this application. The welding torch for Schroeder Valves is a special development with a particularly small torch head and unconventionally lengthy torch neck. Of course, the particular application needed to be adapted to accommodate this uncommon design: as a outcome of dilution between the parent metal and the armouring must be as low as attainable, solely a little vitality is used. This ensures protected heat dissipation regardless of the intense welding torch dimensions.
Secure welding outcomes through defined parameters
As the parts have been rotationally symmetrical, it was easy to show the parts; educating is always based mostly on the same applications. Even new components could be welded automatically shortly. 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 remainder. The desired welding result is all the time guaranteed because the welding procedure is defined with all of its parameters. The quality can be proven retrospectively as all welding parameters are constantly monitored and recorded. Even though the system was initially designed and intended for one specific utility, Schroeder is already pondering of new ideas and makes use of. Schroeder want to try out some of the various welding procedures which are included in the Titan XQ welding machine as standard. This will permit to additional optimise completely different kinds of surfaced components. Schroeder are additionally seeking to broaden and enhance the vary of welding duties.
There are lots of of Schroeder Valves put in in plants in southern Africa protecting belongings at companies like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning amenities 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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