Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of assorted components served as the premise for the automation solution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s elements did have one thing in common, they had been all rotationally symmetrical. This was the starting point for welding machine producer 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 software embrace refineries, power plants and nuclear crops, in the transport of liquefied pure fuel (LNG), as nicely as in offshore rigs. They are additionally used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one application.
The goal is to weld all pump protection valve parts automatically. These valves are linked on to the pumps and ensure steady operation of the pumps to stop them operating dry or being broken by cavitation throughout minimum circulate situations. The pump protection valve is basically made up of the valve body and the cone, which moves inside the valve physique. The sealing surfaces between the valve body and the cone must be completely air and watertight. This is the one method to ensure proper functioning of the pump safety valve for decades to return. Normally, these parts are made using low-cost development metal DIN 1.0460. The sealing surfaces are strengthened with stainless steel DIN 1.4370. This course of was beforehand performed manually, however, due to each the scarcity of fine welders and rising high quality assurance requirements, automation of this step was essential. The inside diameter of the valve bodies and the cone diameters were between 32 mm and four hundred mm. The elements being moved also differed vastly in weight, starting from a number of hundred grams to 2 and a half tonnes. But all the components had one thing in widespread: they had been all rotationally symmetrical, making them excellent for an automated process. With this as a beginning point, EWM was in a place to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon became clear that only a robotic system would fit the bill when it got here to automating this specific course of. Having to take care of so many different half sizes was a cause for concern. Large components require a large welding positioner. These, nonetheless, cannot provide the dynamics required for the smaller components. This rapidly gave rise to the concept of three processing stations: one giant L-positioner with tilting operate for the massive valve our bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a 3rd station with a system bench with out positioners for another components. The top of the constructing was also a selected problem. The elements had to find a way to be placed on the benches with the crane. The crane hook, nevertheless, was only approximately three metres excessive – extraordinarily small for an industrial utility. To assure accessibility whereas guaranteeing extraction, either the extraction hood or the system benches were made to be cell. The robotic was fitted in an especially small booth in the centre between the three stations. This sales space additionally consists of both 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 robotic arm ensures safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations in any respect essential positions can additionally be ensured due to the intense arm length of two metres and optimised house inside the cubicles.
Special torch for extreme areas
Each valve physique is equipped with a cone guide which is welded from above. With an inside diameter of simply 32 mm, entry is extremely troublesome. For Clear , the welder is unable to see the weld seam and instead must depend on their experience. Even for automated welding, these areas are very uncommon. EWM was only capable of settle for 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 special building with a particularly small torch head and unconventionally long torch neck. Of course, the particular utility had to be tailored to accommodate this uncommon design: as a end result of dilution between the father or mother metallic and the armouring needs to be as low as attainable, only slightly power is used. This ensures safe heat dissipation despite the extreme welding torch dimensions.
Secure welding outcomes by way of defined parameters
As the elements were rotationally symmetrical, it was simple to teach the components; teaching is all the time based mostly on the same applications. Even new components could be welded routinely shortly. Users merely need to set the radius, variety of passes and the geometric dimensions of the surfaced components and the robotic management will deal with the rest. The desired welding result is always 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 continuously monitored and recorded. Even although the system was originally designed and meant for one particular utility, Schroeder is already thinking of recent concepts and uses. Schroeder would like to try out some of the various welding procedures which would possibly be included in the Titan XQ welding machine as commonplace. This will permit to further optimise totally different sorts of surfaced elements. Schroeder are also seeking to broaden and improve the vary of welding tasks.
There are hundreds of Schroeder Valves put in in vegetation in southern Africa defending property at corporations 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 are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or telephone 011 397 2833 or 0861 103 103 to study extra.
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