Automated surfacing of rotationally symmetrical components

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 answer developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one factor in common, they had been all rotationally symmetrical. This was the begin line for welding machine producer EWM of their mission to develop a custom automation answer tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used everywhere in the world for transporting liquids utilizing centrifugal pumps. Their areas of software embrace refineries, power crops and nuclear plants, within the transport of liquefied pure fuel (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The aim is to weld all pump protection valve components routinely. These valves are related directly to the pumps and ensure continuous operation of the pumps to prevent them working dry or being damaged by cavitation throughout minimum flow situations. The pump protection valve is basically made up of the valve physique and the cone, which strikes contained in the valve body. The sealing surfaces between the valve body and the cone should be absolutely air and watertight. This is the only means to ensure correct functioning of the pump protection valve for decades to come. Normally, these parts are made utilizing low-cost building metal DIN 1.0460. The sealing surfaces are reinforced with stainless steel DIN 1.4370. This course of was beforehand carried out manually, however, because of both the scarcity of fine welders and growing high quality assurance requirements, automation of this step was essential. The inner diameter of the valve 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 couple of hundred grams to two and a half tonnes. But all the components had one factor in common: they had been all rotationally symmetrical, making them perfect for an automated course of. With this as a starting point, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations

It soon grew to become clear that solely a robot system would match the invoice when it got here to automating this specific course of. Having to cope with so many different half sizes was a cause for concern. Large elements require a big welding positioner. These, however, can’t provide the dynamics required for the smaller elements. This rapidly gave rise to the thought 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 bodies, and a third station with a system bench with out positioners for some other components. The peak of the constructing was also a specific challenge. The components had to have the power to be placed on the benches with the crane. The crane hook, nevertheless, was only roughly three metres excessive – extraordinarily small for an industrial software. To guarantee accessibility while guaranteeing extraction, either the extraction hood or the system benches had been made to be cellular. 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 giant processing station. The Rob 5 drive 4X wire feeder mounted on the robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations at all needed positions can also be ensured due to the extreme arm length of two metres and optimised area inside the cubicles.
เกจ์วัดความดัน for excessive areas

Each valve physique is provided with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extremely difficult. For manual welding, the welder is unable to see the weld seam and as a substitute should 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 building with a very small torch head and unconventionally lengthy torch neck. Of course, the particular software had to be tailored to accommodate this unusual design: as a result of dilution between the parent metallic and the armouring must be as little as possible, only slightly power is used. This ensures protected warmth dissipation regardless of the intense welding torch dimensions.
Secure welding outcomes via defined parameters

As the components have been rotationally symmetrical, it was simple to teach the parts; instructing is at all times based on the identical applications. Even new components may be welded routinely rapidly. Users simply need to set the radius, number of passes and the geometric dimensions of the surfaced parts and the robot management will deal with the remaining. The desired welding result is all the time assured as a end result of the welding process is defined with all of its parameters. The high quality can be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was originally designed and meant for one specific software, Schroeder is already considering of latest concepts and makes use of. Schroeder wish to try out a variety of the various welding procedures which would possibly be included within the Titan XQ welding machine as standard. This will allow to additional optimise different kinds of surfaced elements. Schroeder are additionally looking to broaden and improve the vary of welding tasks.
There are hundreds of Schroeder Valves installed in crops in southern Africa protecting assets at corporations like Sasol, Eskom, Mondi and Sappi to name a quantity of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore 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 learn extra.
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