Automated surfacing of rotationally symmetrical elements

Everything from a single source – it‘s more than just a advertising promise! Over 50 drawings of assorted parts 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 parts did have one thing 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 solution tailored to this multifaceted problem.
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 embody refineries, energy plants and nuclear crops, in the transport of liquefied natural fuel (LNG), in addition to in offshore rigs. They 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 linked directly to the pumps and ensure steady operation of the pumps to forestall them operating dry or being broken by cavitation throughout minimal move situations. The pump protection valve is basically made up of the valve body and the cone, which strikes inside the valve body. The sealing surfaces between the valve physique and the cone must be absolutely air and watertight. This is the only means to ensure proper functioning of the pump safety valve for many years to come back. Normally, these components are made using low-cost development metal DIN 1.0460. The sealing surfaces are reinforced with chrome steel DIN 1.4370. This process was previously carried out manually, nevertheless, because of each the shortage of fine welders and rising quality assurance necessities, automation of this step was essential. เกจวัดแก๊สหุงต้ม of the valve our bodies and the cone diameters have been between 32 mm and 400 mm. The elements being moved also differed vastly in weight, starting from a quantity of hundred grams to two and a half tonnes. But the entire parts had one thing in widespread: they had been all rotationally symmetrical, making them excellent for an automatic course of. With this as a starting point, EWM was in a place to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations

It soon turned clear that solely a robotic system would fit the bill when it came to automating this explicit course of. Having to take care of so many various half sizes was a cause for concern. Large elements require a big welding positioner. These, nevertheless, cannot provide the dynamics required for the smaller components. This rapidly gave rise to the idea of three processing stations: one massive L-positioner with tilting function 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 another elements. The top of the constructing was additionally a selected challenge. The parts had to have the flexibility to be positioned on the benches with the crane. The crane hook, nonetheless, was only approximately three metres high – extremely small for an industrial software. To guarantee accessibility whereas making certain extraction, either the extraction hood or the system benches were made to be mobile. The robot was fitted in an especially small booth within the centre between the three stations. This sales space also contains each the ability supply and a Titan XQ. These are positioned behind the L-positioner on the massive processing station. The Rob 5 drive 4X wire feeder mounted on the robotic arm ensures secure wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations in any respect necessary positions can also be ensured due to the acute arm size of two metres and optimised space contained in the booths.
Special torch for extreme spaces

Each valve physique is supplied with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extremely tough. For guide welding, the welder is unable to see the weld seam and instead must depend on their expertise. Even for automated welding, these areas are very uncommon. EWM was only in a place to accept this job as a end result of they manufacture the torches, emphasising the significance of the welding torch for this utility. The welding torch for Schroeder Valves is a special construction with a very small torch head and unconventionally long torch neck. Of course, the special software had to be adapted to accommodate this unusual design: as a end result of dilution between the mother or father metallic and the armouring needs to be as low as potential, only slightly power is used. This ensures secure heat dissipation despite the intense welding torch dimensions.
Secure welding outcomes via outlined parameters

As the parts were rotationally symmetrical, it was easy to teach the parts; educating is at all times primarily based on the same applications. Even new parts can be welded routinely shortly. Users merely should set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot control will take care of the rest. The desired welding result is always guaranteed because the welding process is defined with all of its parameters. The high quality can be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was initially designed and meant for one specific software, Schroeder is already pondering of new concepts and uses. Schroeder want to check out a few of the numerous welding procedures which are included within the Titan XQ welding machine as standard. This will enable to further optimise different kinds of surfaced parts. Schroeder are additionally looking to increase and enhance the vary of welding duties.
There are lots of of Schroeder Valves installed in plants 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 amenities 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 learn more.
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