Automated surfacing of rotationally symmetrical components
Everything from a single supply – it‘s greater than just a advertising promise! Over 50 drawings of varied components served as the premise for the automation answer developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one thing in frequent, they were all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM in their mission to develop a custom automation answer tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all round the world for transporting liquids utilizing centrifugal pumps. Their areas of software embody refineries, energy crops and nuclear vegetation, in the transport of liquefied pure gas (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The goal is to weld all pump safety valve parts automatically. These valves are linked on to the pumps and guarantee continuous operation of the pumps to forestall them running dry or being damaged by cavitation during minimal move circumstances. The pump protection valve is largely made up of the valve physique and the cone, which moves contained in the valve physique. The sealing surfaces between the valve physique and the cone have to be absolutely air and watertight. This is the only way to ensure correct functioning of the pump protection valve for many years to come back. Normally, these components are made using low-cost development steel DIN 1.0460. The sealing surfaces are reinforced with chrome steel DIN 1.4370. This process was beforehand performed manually, however, as a outcome of both the scarcity of fine welders and rising quality assurance necessities, automation of this step was crucial. The internal diameter of the valve our 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 the entire elements had one thing in widespread: they have been all rotationally symmetrical, making them perfect for an automatic course of. With this as a starting point, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly grew to become clear that only a robot system would fit the invoice when it got here to automating this specific course of. Having to cope with so many alternative part sizes was a cause for concern. Large elements require a big welding positioner. These, however, cannot provide the dynamics required for the smaller elements. 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 another elements. The height of the building 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 only approximately three metres excessive – extremely small for an industrial software. To assure accessibility while making certain extraction, both the extraction hood or the system benches were made to be cellular. The robot was fitted in an especially small sales space within the centre between the three stations. This booth additionally consists of each the power 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 safe wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations in any respect necessary positions is also ensured thanks to the acute arm length of two metres and optimised house inside the booths.
Special torch for excessive spaces
Each valve physique is supplied with a cone guide which is welded from above. With an inside diameter of simply 32 mm, entry is extremely difficult. For handbook welding, the welder is unable to see the weld seam and instead must rely on their experience. Even for automated welding, these spaces are very unusual. EWM was only capable of settle for this job because they manufacture the torches, emphasising the importance of the welding torch for this software. 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 application needed to be adapted to accommodate this unusual design: because dilution between the mother or father steel and the armouring must be as little as potential, solely somewhat energy is used. This ensures secure warmth dissipation regardless of the acute welding torch dimensions.
Secure welding outcomes via defined parameters
As the parts were rotationally symmetrical, it was easy to show the elements; teaching is all the time primarily based on the identical applications. Even new parts could be welded routinely quickly. Users simply should set the radius, variety of passes and the geometric dimensions of the surfaced components and the robotic management will care for the remaining. The desired welding result is all the time assured as a outcome of the welding procedure is outlined with all of its parameters. The quality can be confirmed retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was originally designed and meant for one specific utility, Schroeder is already considering of recent concepts and uses. Schroeder want 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 totally different kinds of surfaced components. Schroeder are additionally trying to increase and enhance the vary of welding tasks.
There are lots of of Schroeder Valves put in in plants in southern Africa defending assets at corporations like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore 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 phone 011 397 2833 or 0861 103 103 to be taught more.
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