Automated surfacing of rotationally symmetrical components
Everything from a single supply – it‘s more than just a advertising promise! Over 50 drawings of various components served as the premise for the automation answer developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s components did have one thing in widespread, they were all rotationally symmetrical. This was the begin line for welding machine producer EWM of their mission to develop a custom automation resolution 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 software include refineries, energy crops and nuclear plants, in the transport of liquefied natural gasoline (LNG), in addition to in offshore rigs. weksler ea14 are additionally used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one software.
The goal is to weld all pump protection valve parts routinely. These valves are related directly to the pumps and guarantee continuous operation of the pumps to stop them working dry or being broken by cavitation throughout minimum move conditions. The pump protection valve is essentially made up of the valve body and the cone, which moves inside the valve physique. The sealing surfaces between the valve physique and the cone have to be absolutely air and watertight. This is the only way to make sure correct functioning of the pump protection valve for many years to come back. Normally, these components are made using low-cost building metal DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This course of was previously performed manually, nonetheless, because of each the scarcity of fine welders and growing high quality assurance necessities, automation of this step was essential. The inner diameter of the valve bodies and the cone diameters were between 32 mm and 400 mm. The elements being moved also differed vastly in weight, starting from a couple of hundred grams to 2 and a half tonnes. But all of the parts had one thing in frequent: they had been all rotationally symmetrical, making them excellent for an automated course of. With this as a beginning point, EWM was capable of get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon grew to become clear that only a robotic system would match the bill when it got here to automating this particular process. Having to cope with so many various half sizes was a cause for concern. Large components require a large welding positioner. These, nonetheless, can’t present 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 large valve our 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 any other parts. The peak of the constructing was also a selected challenge. The elements had to be able to be placed on the benches with the crane. The crane hook, nonetheless, was only approximately three metres excessive – extraordinarily small for an industrial software. To assure accessibility whereas making certain extraction, both the extraction hood or the system benches were made to be cellular. The robotic was fitted in an extremely small sales space within the centre between the three stations. This booth also includes both the ability source 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 100 iD in all three stations in any respect necessary positions can also be ensured thanks to the intense arm size of two metres and optimised area inside the cubicles.
Special torch for extreme spaces
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 difficult. For handbook welding, the welder is unable to see the weld seam and instead should depend on their expertise. Even for automated welding, these areas are very unusual. EWM was solely able to accept this job as a outcome of they manufacture the torches, emphasising the importance of the welding torch for this application. The welding torch for Schroeder Valves is a special building with a very small torch head and unconventionally long torch neck. Of course, the particular utility needed to be tailored to accommodate this uncommon design: because dilution between the father or mother metal and the armouring needs to be as low as possible, solely a little power is used. This ensures safe heat dissipation despite the extreme welding torch dimensions.
Secure welding outcomes by way of defined parameters
As the parts have been rotationally symmetrical, it was easy to teach the parts; educating is all the time based mostly on the identical packages. Even new components may be welded routinely shortly. Users simply need to set the radius, variety of passes and the geometric dimensions of the surfaced parts and the robot control will care for the remainder. The desired welding result’s at all times assured as a result of the welding process is outlined with all of its parameters. The quality may additionally be proven retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and supposed for one specific application, Schroeder is already pondering of new ideas and uses. Schroeder want to check out a number of the varied welding procedures that are included in the Titan XQ welding machine as standard. This will enable to further optimise totally different sorts of surfaced parts. Schroeder are additionally seeking to increase and enhance the range of welding tasks.
There are lots of of Schroeder Valves installed in vegetation in southern Africa protecting assets at companies like Sasol, Eskom, Mondi and Sappi to name a quantity of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning services can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or cellphone 011 397 2833 or 0861 103 103 to study more.
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