Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s more than only a advertising promise! Over 50 drawings of various components served as the idea for the automation answer developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one factor in widespread, they were all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM of their mission to develop a customized automation answer tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of application embody refineries, power crops and nuclear vegetation, within the transport of liquefied pure gasoline (LNG), in addition to in offshore rigs. They are also used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one software.
The purpose is to weld all pump protection valve elements automatically. These valves are connected on to the pumps and ensure continuous operation of the pumps to prevent them running dry or being damaged by cavitation throughout minimum circulate situations. เครื่องมือที่ใช้ในการวัดความดัน is essentially made up of the valve physique and the cone, which moves contained in the valve body. The sealing surfaces between the valve physique and the cone should be absolutely air and watertight. This is the only way to make sure correct functioning of the pump safety valve for decades to return. Normally, these components are made using low-cost construction steel DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This process was beforehand carried out manually, however, because of both the shortage of good welders and growing quality assurance necessities, automation of this step was essential. The inside diameter of the valve our bodies and the cone diameters have been between 32 mm and four hundred mm. The elements being moved additionally differed vastly in weight, starting from a number of hundred grams to 2 and a half tonnes. But the entire elements had one factor in common: they have been all rotationally symmetrical, making them excellent for an automatic course of. With this as a place to begin, EWM was capable of get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly became clear that only a robot system would match the invoice when it came to automating this specific process. Having to cope with so many different half sizes was a cause for concern. Large components require a large welding positioner. These, nevertheless, cannot provide the dynamics required for the smaller components. This quickly gave rise to the concept of three processing stations: one large L-positioner with tilting function for the massive valve bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a 3rd station with a system bench without positioners for some other parts. The top of the constructing was also a particular challenge. The elements had to have the flexibility to be positioned on the benches with the crane. The crane hook, nevertheless, was solely roughly three metres excessive – extremely small for an industrial software. To assure accessibility whereas ensuring extraction, either the extraction hood or the system benches were made to be mobile. The robot was fitted in a particularly small booth in the centre between the three stations. This sales space additionally consists of both the power 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 robotic arm ensures secure wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations at all essential positions can also be ensured because of the extreme arm length of two metres and optimised house inside the booths.
Special torch for extreme areas
Each valve body is provided with a cone information which is welded from above. With an inside diameter of just 32 mm, access is extraordinarily tough. For handbook welding, the welder is unable to see the weld seam and as a substitute must rely on their expertise. Even for automated welding, these areas are very unusual. EWM was only capable of accept this job as a outcome of they manufacture the torches, emphasising the significance of the welding torch for this application. The welding torch for Schroeder Valves is a particular development with a particularly small torch head and unconventionally lengthy torch neck. Of course, the special application had to be tailored to accommodate this unusual design: because dilution between the father or mother metal and the armouring needs to be as little as potential, only a little power is used. This ensures safe heat dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes through outlined parameters
As the elements had been rotationally symmetrical, it was easy to show the parts; instructing is at all times primarily based on the identical packages. Even new components can be welded mechanically quickly. Users merely 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’s all the time assured as a end result of the welding procedure is outlined with all of its parameters. The high quality can additionally be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even although เกจวัดแรงดันอาร์กอน was originally designed and supposed for one particular utility, Schroeder is already considering of recent ideas and uses. Schroeder would like to try out a variety of the varied welding procedures which might be included in the Titan XQ welding machine as standard. This will allow to further optimise different kinds of surfaced parts. Schroeder are also trying to broaden and enhance the range of welding tasks.
There are lots of of Schroeder Valves put in in plants in southern Africa protecting property at corporations like Sasol, Eskom, Mondi and Sappi to call a quantity of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning facilities can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact sales@valve.co.za, www.valve.co.za or telephone 011 397 2833 or 0861 103 103 to learn more.
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