Automated surfacing of rotationally symmetrical elements

Everything from a single supply – it‘s greater than only a marketing promise! Over 50 drawings of assorted components served as the idea for the automation solution developed by EWM for pump safety valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s components did have one factor in widespread, they have been all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM in their mission to develop a custom automation solution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all over the world for transporting liquids using centrifugal pumps. Their areas of software embody refineries, power plants and nuclear plants, in the transport of liquefied pure fuel (LNG), as well as in offshore rigs. They are additionally used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one application.
The purpose is to weld all pump protection valve parts automatically. These valves are related on to the pumps and ensure continuous operation of the pumps to stop them operating dry or being broken by cavitation during minimum move situations. The pump safety valve is largely made up of the valve body and the cone, which strikes 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 method to make sure proper functioning of the pump safety valve for many years to come back. Normally, these components are made utilizing low-cost development metal DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This process was previously performed manually, nevertheless, due to both the scarcity of fine welders and growing quality assurance requirements, automation of this step was essential. The inside diameter of the valve bodies and the cone diameters had been between 32 mm and four hundred mm. The elements being moved additionally differed vastly in weight, ranging from a quantity of hundred grams to 2 and a half tonnes. But all the elements had one factor in widespread: they had been all rotationally symmetrical, making them good for an automated course of. With this as a place to begin, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations

It quickly became clear that only a robot system would fit the invoice when it came to automating this particular process. Having to deal with so many different half sizes was a trigger for concern. Large parts require a large welding positioner. เพรสเชอร์เกจ , however, can’t provide the dynamics required for the smaller components. This quickly gave rise to the thought of three processing stations: one giant L-positioner with tilting function 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 with out positioners for some other elements. The top of the constructing was additionally a particular challenge. The elements had to have the flexibility to be positioned on the benches with the crane. The crane hook, nevertheless, was only approximately three metres excessive – extremely small for an industrial software. To guarantee accessibility while ensuring extraction, both 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 contains each the power supply and a Titan XQ. These are positioned behind the L-positioner at the giant 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 in any respect necessary positions can be ensured thanks to the acute arm length of two metres and optimised area inside the cubicles.
Special torch for excessive spaces

Each valve physique is equipped with a cone guide which is welded from above. With an inside diameter of simply 32 mm, access is extremely difficult. For manual welding, the welder is unable to see the weld seam and as a substitute should depend on their experience. Even for automated welding, these areas are very uncommon. EWM was only in a position to accept this job as a result of they manufacture the torches, emphasising the importance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular development with a very small torch head and unconventionally long torch neck. Of course, the special application needed to be tailored to accommodate this unusual design: as a result of dilution between the parent steel and the armouring must be as little as attainable, solely slightly vitality is used. This ensures protected heat dissipation regardless of the acute welding torch dimensions.
Secure welding outcomes by way of defined parameters

As the parts had been rotationally symmetrical, it was simple to teach the elements; teaching is all the time based on the identical programs. Even new components could be welded automatically rapidly. Users merely need to set the radius, number of passes and the geometric dimensions of the surfaced components and the robot management will take care of the remaining. The desired welding result’s always assured as a end result of the welding process is outlined with all of its parameters. The high quality may additionally be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was originally designed and intended for one particular application, Schroeder is already thinking of latest concepts and makes use of. Schroeder want to check out a number of the varied welding procedures that are included within the Titan XQ welding machine as commonplace. This will allow to additional optimise different kinds of surfaced elements. Schroeder are also trying to increase and enhance the vary of welding duties.
There are hundreds of Schroeder Valves installed in vegetation in southern Africa protecting belongings at companies like Sasol, Eskom, Mondi and Sappi to call a few. Sulzer & KSB routinely use Schroeder valves to guard 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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