Automated surfacing of rotationally symmetrical components
Everything from a single source – it‘s more than only a marketing promise! Over 50 drawings of various elements served as the premise for the automation resolution developed by EWM for pump safety valve producer, Schroeder Valves GmbH in Germany. เพรสเชอร์เกจน้ำ of the leading specialist’s parts did have one factor in frequent, they had been all rotationally symmetrical. This was the beginning point for welding machine producer EWM of their mission to develop a customized automation answer tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used all over the world for transporting liquids using centrifugal pumps. Their areas of application embody refineries, power crops and nuclear plants, within the transport of liquefied natural gas (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 utility.
The purpose is to weld all pump safety valve elements mechanically. These valves are connected on to the pumps and guarantee steady operation of the pumps to forestall them running dry or being broken by cavitation during minimum flow circumstances. The pump safety valve is basically 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 have to be completely air and watertight. This is the one means to ensure correct functioning of the pump protection valve for many years to return. Normally, these elements are made using low-cost development metal DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This process was previously performed manually, however, due to each the shortage of good welders and rising quality assurance requirements, automation of this step was crucial. 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 also differed vastly in weight, starting from a couple of hundred grams to two and a half tonnes. But all of the components had one thing in frequent: they were 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 grew to become clear that solely a robot system would match the bill when it got here to automating this particular course of. Having to deal with so many different half sizes was a trigger for concern. Large components require a large welding positioner. เกจวัดแรงดันดิจิตอล , however, can’t provide the dynamics required for the smaller parts. This shortly gave rise to the concept of three processing stations: one large 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 3rd station with a system bench without positioners for some other parts. The height of the building was additionally a selected challenge. The components had to have the ability to be placed on the benches with the crane. The crane hook, however, was only approximately three metres excessive – extraordinarily small for an industrial software. To assure accessibility while guaranteeing extraction, both the extraction hood or the system benches had been made to be cell. The robot was fitted in a particularly small booth in the centre between the three stations. This sales space additionally consists of each the power source and a Titan XQ. These are positioned behind the L-positioner at the massive processing station. The Rob 5 drive 4X wire feeder mounted on the robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations in any respect essential positions can be ensured due to the intense arm length of two metres and optimised area inside the cubicles.
Special torch for excessive areas
Each valve body is supplied with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extremely troublesome. For guide welding, the welder is unable to see the weld seam and as a substitute must rely on their expertise. Even for automated welding, these spaces 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 development with a particularly small torch head and unconventionally lengthy torch neck. Of course, the special software had to be tailored to accommodate this unusual design: because dilution between the mother or father metal and the armouring needs to be as little as possible, only slightly vitality is used. This ensures secure warmth dissipation despite the acute welding torch dimensions.
Secure welding outcomes via outlined parameters
As the elements were rotationally symmetrical, it was easy to show the components; instructing is all the time based mostly on the identical programs. Even new elements may be welded routinely shortly. Users merely need to set the radius, number of passes and the geometric dimensions of the surfaced components and the robot management will deal with the remaining. The desired welding result is all the time guaranteed because the welding procedure is defined with all of its parameters. The high quality can additionally be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and supposed for one particular software, Schroeder is already thinking of latest concepts and makes use of. Schroeder would like to check out some of the numerous welding procedures that are included within the Titan XQ welding machine as normal. This will enable to further optimise different sorts of surfaced elements. Schroeder are additionally seeking to increase and enhance the vary of welding tasks.
There are lots of of Schroeder Valves put in in crops in southern Africa defending assets at companies like Sasol, Eskom, Mondi and Sappi to name a number of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning amenities 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 extra.
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