Automated surfacing of rotationally symmetrical elements

Everything from a single supply – it‘s greater than just a advertising promise! Over 50 drawings of varied components served as the basis for the automation answer developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s components did have one thing in frequent, they were all rotationally symmetrical. This was the beginning point for welding machine producer EWM in their mission to develop a customized automation resolution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all around the world for transporting liquids using centrifugal pumps. Their areas of utility embrace refineries, power plants and nuclear plants, within the transport of liquefied pure fuel (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one application.
The aim is to weld all pump safety valve elements mechanically. These valves are linked directly to the pumps and ensure steady operation of the pumps to stop them working dry or being broken by cavitation during minimal flow situations. The pump protection valve is essentially made up of the valve physique and the cone, which strikes contained in the valve body. The sealing surfaces between the valve body and the cone must be absolutely air and watertight. This is the one way to make sure correct functioning of the pump protection valve for decades to come back. Normally, these parts are made using low-cost construction steel DIN 1.0460. The sealing surfaces are bolstered with chrome steel DIN 1.4370. This process was previously performed manually, nevertheless, due to both the shortage of good welders and rising quality assurance necessities, automation of this step was essential. The internal diameter of the valve our bodies and the cone diameters have been between 32 mm and 400 mm. The elements being moved additionally differed vastly in weight, ranging from a couple of hundred grams to 2 and a half tonnes. But all of the parts had one factor in frequent: they had been all rotationally symmetrical, making them good for an automated course of. With this as a beginning point, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations

It quickly turned clear that solely a robotic system would match the invoice when it came to automating this particular course of. Having to deal with so many different half sizes was a trigger for concern. Large elements require a big welding positioner. These, nevertheless, can’t provide the dynamics required for the smaller parts. This quickly gave rise to the thought of three processing stations: one massive L-positioner with tilting perform for the massive valve our bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a 3rd station with a system bench with out positioners for any other parts. The top of the building was additionally a specific problem. The parts had to have the ability to be placed on the benches with the crane. The crane hook, nevertheless, was solely roughly three metres excessive – extremely small for an industrial utility. To assure accessibility whereas making certain extraction, both the extraction hood or the system benches have been made to be cellular. The robot was fitted in a particularly small booth in the centre between the three stations. This booth additionally contains each the facility source 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 robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations at all needed positions can also be ensured thanks to the acute arm length of two metres and optimised house inside the booths.
Special torch for excessive spaces

Each valve body is supplied with a cone information which is welded from above. With an inside diameter of simply 32 mm, access is extraordinarily difficult. For manual welding, the welder is unable to see the weld seam and instead should rely on their expertise. Even for automated welding, these areas are very unusual. EWM was only capable of settle for 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 construction with a particularly small torch head and unconventionally long torch neck. Of course, the particular utility needed to be tailored to accommodate this unusual design: as a result of dilution between the father or mother metal and the armouring needs to be as low as attainable, only slightly vitality is used. This ensures protected heat dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes by way of outlined parameters

As the elements had been rotationally symmetrical, it was straightforward to teach the elements; teaching is all the time based on the identical programs. Even new components may be welded mechanically shortly. Users simply need to set the radius, number of passes and the geometric dimensions of the surfaced components and the robotic control will deal with the rest. เกจแรงดัน desired welding result’s always guaranteed 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 constantly monitored and recorded. Even although the system was originally designed and intended for one specific utility, Schroeder is already thinking of latest ideas and makes use of. Schroeder would like to check out a number of the numerous welding procedures that are included within the Titan XQ welding machine as commonplace. This will enable to further optimise completely different kinds of surfaced elements. Schroeder are also looking to expand and improve the vary of welding duties.
There are lots of of Schroeder Valves put in in plants in southern Africa protecting assets at firms like Sasol, Eskom, Mondi and Sappi to call a quantity of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning facilities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or telephone 011 397 2833 or 0861 103 103 to learn more.
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